Tag: calculate savings

EXAIR Knowledge Base: A great and powerful tool

Published on by johnball2014Leave a comment

Knowledge is Power.  At EXAIR, we’re committed to providing our customers with the tools necessary to fix problems and train staff members with a selection of many different types of offerings.  We call this the “Knowledge Base”.  We have them segregated into different criteria to give you that “been there, done that” solutions.  There’s a ton of valuable information, and best of all, it’s all FREE!

Within our Knowledge Base, you’ll find case studies that highlight examples of applications where we’ve helped customers improve their processes, save money by reducing compressed air consumption, and improve worker safety. There’s a list of FAQs categorized by product line, a library of calculators to help estimate the savings you’ll experience, and a list of application examples.

In addition, we also have a library of previously recorded webinars that are free to view at your convenience.  We cover topics like inefficient vs. engineered nozzles, static generation, and finding and fixing leaks, to name a few.  In addition, we have videos that include product functions, informal videos, and tips and tricks for using our products.  We also include Application Assistance and an Efficiency Lab which will allow recommendations and performance comparisons. 

Don’t let these free resources go to waste.  You will have to sign in to EXAIR’s website, which is easy to do.  To find this wealth of information, just click on “Resources” in the top banner (as shown in the photo below).  It is a “one-stop” spot that gives available solutions with our Intelligent Compressed Air® Products.  

If you have pneumatic issues with blow-offs, cooling, cleaning, conveying, coating, or needing to conserve compressed air, we may have already solved this for you.  Don’t feel like we’re leaving you to figure everything out on your own. In addition to all the resources available to you within the Knowledge Base, EXAIR has a team of highly-trained Application Engineers with experience in a wide variety of industries and processes. There’s a good chance one of us has dealt with a similar application, and we’ll be happy to help point you in the right direction.

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

Photo: Question mark pile by qimono.  Pixabay license. 

Customer Saves Nearly $7000 by Installing Super Air Knives on Converting Machine

Published on by Tyler DanielLeave a comment

EXAIR proves often that we’re able to work with you to create a customized solution that best serves your application. Recently I had the pleasure of working with a customer who wanted a better solution on their tissue paper converting machine. What they currently had was too loud, too inefficient, and they knew there was a better way.

The machine was an old rewinder used to convert webs of tissue paper ranging from 99-115” in width. Installed on the old machine was a 115” drilled pipe with 1/16” drilled holes spaced out every ½” along the length of the pipe. This was using a substantial amount of compressed air and was significantly louder than they would’ve liked. They purchased a new machine that had an EXAIR Super Air Knife already installed and working great, so they reached out to us for some help.

The customer conducted some time studies to determine exactly how much air this application required. The air blast ran for 500 seconds per hour, equating to 8.3min/hr of air usage. The operation runs 24/7, but with time spent doing changeovers the actual run time is closer to 20hrs.

20hrs x 8.2min = 166 min/day of air usage

166min x 365 = 60,590 min per year

A 1/16” unpolished, drilled hole will consume 2.58 SCFM at a pressure of 60 PSIG. With a total of 228 holes across the full pipe, this is quite a bit of compressed air.

2.58 SCFM x 228 = 588 SCFM of compressed air

588 x 60,590 min = 35,626,920 SCF

Considering the lightweight nature of the material, we recommended that the customer use our .001” shim to cut the flow from our stock Super Air Knives to their minimum. We recommended our Model 110054-.001 and Model 110060-.001. At 60 PSIG, a Super Air Knife with .001 shim installed will consume 1.15 SCFM/inch of knife length.

114 x 1.15 SCFM = 131 SCFM of compressed air

131 x 60,590 min = 7,937,290 SCF

Installing the Super Air Knives with .001” shim reduced their air consumption by 77% for a total air savings of 27,689,630 SCF each year. But, what does this mean in terms of money? To determine the cost of compressed air, we use the approximate value of $0.25/1000 SCF.

27,689,630 SCF x $0.25/1000 = $6,922.41

In just one year, on this one single machine, this customer was able to save almost $7k per year. These knives quickly pay for themselves, then begin to contribute to your bottom line. All of this in addition to lowering the sound level and providing a safer working environment for their operators.

If you have areas in your facility that are using air inefficiently, contact an EXAIR Application Engineer today.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD