Application Database: Compressed Air Use in the Food & Beverage Industry

EXAIR uses many different methods to connect with our customers.  We have our website, social media, blogs, publications etc. We like to share solutions for some of the most common pneumatic problems in the industry.  EXAIR generated a large collection of application information where EXAIR products have already solved problems and improved processes.  We organized them by Application and by Industry.  In this blog, I will show you how to use the Application database; specifically, for the Food and Beverage Industry.

Compressed Air Systems are considered to be a fourth utility within industries because they use a large amount of energy.  Whether an air compressor uses fuel for portable units or electricity, it is important to use this system as efficiently as possible.  This would apply to the Food and Beverage industry.  EXAIR has a library of different processes in which we already improved these areas safely and efficiently.  If you are in the Food and Beverage industry, it would benefit you to take a peek at the implementations where we already improved, establish OSHA safety, and saved money.

Here is how you can find this library.  First, you will have to sign into EXAIR.  Click here: Log In.  Once you fill in the proper information, you can then retrieve a great amount of resources about EXAIR products that we manufacture.   The Application Database is under the Knowledge Base tab.  (Reference photo below).

At the Application Search Library, we have over one thousand application that we reference.  In the left selection pane, we organized then in alphabetical order under two categories, Applications and Industry.   (Reference photo below).

Scroll down in the selection pane until you come to the sub-category: Industry.  Under this Sub-category, you will find three selections that are related to this blog: Food and Beverage, Food Packaging, and Food Processing.  We have other applications that may relate to your process like; Beverage Bottling and Beverage.  You will find many applications that EXAIR has already helped to improve and it is documented.

Why is this important?  If you are a plant manager or owner, the value of the Application Database can improve your current processes with pre-qualified results.  Within the Food and Beverage industry, simple solutions can be found to address those “nagging” issues that you see every day.  For crisis situations and shutdowns, EXAIR categorized these applications in a way to reference quickly and easily.  And since EXAIR has a high volume of stocked quality items, we can get the parts to you very fast; minimizing downtime.

In today’s market, companies are always looking for ways to cut cost, increase productivity, and improve safety.  EXAIR can offer engineered products to do exactly that.  With the “been there and done that” solutions already described in the Application Database; you can have confidence in finding a way in solving pneumatic issues.  If you do not sign up at www.EXAIR.com and take advantage of these offerings, you will be missing out on a great tool in optimizing your compressed air system.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

 

 

Ion Air Jets Make Beekeeper’s Operation As Sweet As Honey

A honey producer sells their product in specialty glass jars. They pay a premium for these jars, as they enhance the appearance of their product, so the “visual” is obviously very important to them. So much so, that they’re willing to go to great lengths to make sure that the jars are sparkly clean and pristine before filling them with honey.

It’s a given that the inside needs to be clean…it’s a food product, so, of course, there’s a thorough cleaning process for that. The outsides of the jars, though, would sometimes have a little dust or debris left over in the ‘nooks and crannies’ which took away from the crystal clear appearance of the rest of the jar.

They got a Model 8494 GEN4 Ion Air Jet Kit, which they use to remove all of this dust & debris from the outside of the bottle, and then they got another Model 8194 GEN4 Ion Air Jet (which uses the same Power Supply, Filter Separator, and Pressure Regulator from the 8494 Kit) to blow an “insurance” blast of ionized air inside the bottle…just in case. “You can’t be too careful” is a popular mantra for folks who make food products, it seems!

Compact, convenient, easy to use: EXAIR Model 8194 GEN4 Ion Air Jet creates a focused blast of ionized air for static dissipation and cleaning.

Ionized air is extremely effective for ensuring the cleanliness of glass surfaces. Window makers love our Super Ion Air Knives. Some big name sunglasses manufacturers use our Ion Air Jets to ensure the highest quality and consistency of their products. Ion Air Jets and Ion Air Cannons are commonly used to keep optics clean & clear in critical vision inspection systems. If you’d like to find out more about improving “visuals” with ionized air, give me a call.

Two Birds With One Stone (and A Shim)

Blowing off bottles is such a popular application for the EXAIR Super Air Knife, it’s been featured on the cover of our Catalog…several times…and is the “banner” pictures on the Super Air Knives page on our website:

This always makes me thirsty for orange soda.

I had the pleasure of helping a caller from a bottling plant recently with just such an application.  Thing is, they run a couple of different size bottles, and it’s not a very big facility…they didn’t want to, or have room to, install different lengths of Air Knives, and also didn’t want to waste air flow when they were running the shorter bottles.

9″ Air Knives were required for the taller bottles, but their shorter bottles were a little under 6″ tall.  They had considered buying both 6″ and 9″ Air Knives, but called me to see if there was a less expensive, and possibly, easier way.  (There is!)

EXAIR makes, and stocks, every product in our 208 page catalog right here in this building in Cincinnati, Ohio.  We also make custom parts when the need arises…and custom Air Knife shims were the solution to this customer’s application.

By installing two Model 110009 9″ Aluminum Super Air Knives, one on either side of the conveyor (just like the photo above,) they’re able to blow off the taller bottles.  When they run the shorter bottles, they change out the shims for ones that limit the flow to a 6″ curtain.

So…for a little under $50.00 (2017 cost for those custom shims,) they’re going to save almost $550.00 per year in compressed air costs – AND make sure that their compressed air system is optimized & available for other loads throughout the plant.

EXAIR offers the Super Air Knife in lengths from 3″ to 108″, with a 0.002″ shim installed.  They’re ideal for most industrial and commercial blow off applications, right out of the package.  If your application calls for something a little “outside the box,” you may only be a shim away from success.  If you have such an application, give me a call.

Russ Bowman
Application Engineer
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Super Air Knives Make Beer Bottle Labels Stick; EFC Optimizes Efficiency

The Super Air Knife has been featured as the cover photo of every EXAIR Compressed Air Products catalog since I got here in 2011…except for Catalog #26 in 2013, which featured the Super Ion Air Knife. BIG difference, right there.

The highlighted application photos may change from catalog to catalog, but one that always remains is the iconic (I think, anyway) image of the Super Air Knives blowing off the orange soda bottles:

This is a darn-near ‘textbook’ application for the Super Air Knives…the even, laminar flow wraps around the bottles, stripping moisture away. Among other reason why this is important, it improves the next step in the process – the labels stick better.

One of the many simple and effective ways an EXAIR Super Air Knife is commonly used.

In my younger, intemperate days, I’d join my friends at a popular watering hole to celebrate special occasions like…well, Tuesday, for example. Sometimes, there’d be a ballgame on the TV, or lively conversation, to entertain us. Other times, we’d make a game out of trying to separate the labels from the beer bottles, in one piece.

Some years later, I tried to teach my young sons this game…except with root beer bottles. It didn’t work near as well, because these labels adhered much tighter to the root beer bottles in my dining room than the ones on the beer bottles at the bar.

Some years after that (those boys are teenagers now,) I became an Application Engineer at EXAIR, and found out that this drying-the-bottles-to-make-the-labels-stick-better thing was for real, because I got to talk to folks in the bottling business who told me that the Super Air Knives had made all the difference in the world for their operation.

Just the other day, I had the pleasure of helping a caller who operates a micro-brewery, and had just installed a set of 110009 9″ Aluminum Super Air Knives for the express purpose of (you guessed it, I hope…) making their labels stick better. The only thing that could make it better, according to them, was if they could use less compressed air, and they were interested in what the EFC Electronic Flow Control could do for them.

Click here to calculate how much you can save with an EXAIR EFC Electronic Flow Control.

As a micro-brewery, their production lines don’t run near as fast…nor do they want them to…as some of the Big Names in the business. As such, there’s some space between the bottles on the filling lines, and they thought that turning the air off, if even for a fraction of a second, so they weren’t blowing air into those empty spaces, would make a difference. And they’re right…it’s a simple matter of math:

Two 9″ Super Air Knives, supplied at 80psig, will consume 26.1 SCFM each (52.2 SCFM total). This microbrew was running two 8 hour shifts, 5 days per week. That equates to:

52.2 SCFM X 60 minutes/hour X 16 hours/day X 5 days/week X 52 weeks/yr = 13,029,120 standard cubic feet of compressed air, annually.  Using a Department of Energy thumbrule which estimates compressed air cost at $0.25 per 1,000 SCF, that’s an annual cost of $3257.00*

Let’s say, though, that the micro-brewery finds that it takes one second to blow off the bottle, and there’s 1/2 second between the bottles.  The EFC is actually adjustable to 1/10th of a second, so it can be quite precisely set.  But, using these relatively round numbers of 1 second on/0.5 seconds off, that’s going to save 1/3 of the air usage…and the cost…which brings the annual cost down to $2171.00*

*As a friendly reminder that the deadline to file our USA income tax returns is closing fast, I’ve rounded down to the nearest dollar.  You’re welcome.

That means that the Model 9055 EFC Electronic Flow Control (1/4 NPT Solenoid Valve; 40 SCFM) with a current 2017 List Price of $1,078.00 (that’s exact, so you know) will have paid for itself just short of one year. After that, it’s all savings in their pocket.

If you’d like to find out how much you can save with EXAIR Intelligent Compressed Air Products, give me a call.

Russ Bowman
Application Engineer
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