Communication Is Key

Effective communication is a key interpersonal skill and learning how each of us can improve our communication is beneficial to all. Communication is a two way process, so improving communication involves both how we deliver and listen to the message. To best service our customers, EXAIR has many ways to share and receive information.

There are the standard methods, of course, that have been around for years.  Phone and fax are still very useful, and everyone has noticed that fax is slowly becoming less utilized. As dreaded as it may be, email is certainly a valuable way to communicate, especially as it allows ‘attachments’ such as photos, which as the saying goes, are definitely worth a thousand words. If video or 3D models are exchanged I am certain the number of words increases.

The newest technology for communication is via ‘chat’ which can be accessed from the EXAIR website. Here, you can chat with an Application Engineer and do something as simple as confirming a part number to something more involved like sizing a Cabinet Cooler System.

chat

Chat Live with an Engineer ‘Button’

The US Postal System is still a valuable communication tool, as we send out the EXAIR Catalog (currently volume No. 30) and the EXAIR-Mail (Number 109/Fall 2016 issue just went out), and some Purchase Orders still are dropped off by the Postman.

Another method of communication is face to face.  We have what we call the ‘Demo Room’ here at the factory in Cincinnati, OH.  In this room, we have every type of our Intelligent Compressed Air Products, in just about every size offered, ready for demonstration and testing to your application.  We’ve had visitors from all over the world come in and share face to face their applications and collaborate with us and test out the EXAIR solution.

exair_facility

There is also the EXAIR website, where we provide a plethora of information regarding the EXAIR product lines, CAD and PDF librariesCase StudiesPresentations, and the Video Library just to name a few.  Also, here is where you can Request a Catalog, Sign up for E-News, and Check List Pricing.

Lastly, and since you are reading this you already are familiar with the EXAIR Blog – a great way for us to share with you our musings and thoughts, in a way that makes it a personal take on the EXAIR products and our interactions with our customers.

blog

Effective communication is very important to us and what we do here every day.  Feel free to utilize one or more of the Contact Us tools to communicate with us and we’ll be in touch!

Brian Bergmann
Application Engineer

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Energy Rebates and EXAIR Products

In case it goes unnoticed, EXAIR focuses on engineered compressed air point of use products to ensure that our customers are utilizing their costly utility as efficiently as possible.  The main benefits to purchasing EXAIR products are the support you receive from us at EXAIR, the quality of the product, the savings in compressed air, and the increase in safety.  Another added benefit is a large number of utility companies are offering rebates on the purchase of engineered nozzles, just like the Super Air Nozzles that EXAIR offers.

Many energy providers offer these energy rebates for commercial or industrial users.  Here in the Cincinnati area, Duke Energy offers rebates on items such as lighting, air compressors, engineered air nozzles, heaters / dryers for extrusion machines, energy management systems, variable frequency drives, data center equipment, even food service equipment, custom incentives, and many other items.

Duke Energy Rebate

Example of our local energy rebate offering for Engineered Nozzles

For each engineered compressed air nozzle that is installed, in order to meet the rebate requirements they must flow less than or equal to given flow rates in SCFM at 80 psig inlet pressure. The pipe sizes, flow rates, and EXAIR equivalents are shown below.

EXAIR Engineered Air Nozzle Part Number EXAIR Flow Rate @ 80 psig
#1102/#1103 – 1/8 NPT 10 SCFM
#1100/#1101 – 1/4 NPT 14 SCFM
#1108SS-NPT/#1109SS-NPT/#1110SS-NPT
All are 1/8 NPT
2.5, 4.9, 8.3 SCFM
respectively
#1003 – 3/8 NPT 18 SCFM

By just replacing the nozzles the customer saved 2.7 SCFM per nozzle.If we take an example such as the EXAIR Case Study  shown below for 1/4″ copper tube that was being used as an open ended blow off.  The copper tubes were consuming 19.6 SCFM at 100 psig inlet pressure, there were 10 machines with one line per machine operating 40 hours, 52 weeks per year.   The customer retrofitted the open pipes with a model 1100 Super air nozzle and was able to reduce the air consumption by 2.7 SCFM per nozzle.  If they were to purchase these nozzles this year, current list price for a model 1100 Super Air Nozzle is $36.00 USD, then apply for the energy rebate offered by Duke Energy and receive $20.00 per nozzle replaced.  The total savings and return on investment is shown below.

Case Study 1561

EXAIR Model 1100 Super Air Nozzle Replaces Open Copper Pipe Blow Off

10 nozzles x 2.7 SCFM = 27 SCFM  x 60 minutes per hour x 8 hours per day x 5 days per week x 52 weeks per year = 3,369,600 SCF of compressed air saved per year.

3,369,600 / 1,000 SCF x $.25 = $842.40 USD savings in compressed air per year.

Cost Savings per week = $16.20 USD

Total purchase cost is  $36.00 x 10 nozzles = $360.00 USD

Energy Rebate = @20.00 per nozzle x 10 nozzles  = $200.00 USD in rebates.

$360.00 USD purchase price – $200.00 USD energy rebate = $160.00 USD final purchase cost.

Return on investment at a savings of  $16.20 USD per week is

$160.00 / $16.20 = Less than 10 weeks pay back!

By applying for the energy rebate this customer could reduce the ROI of this air savings project from just over 22 weeks (which is still very good) to less than 10 weeks.

If you would like to learn more about whether there are Industrial energy rebates available in your area, contact an Application Engineer and let us know where you are located and who your energy provider is.

We will help you determine the correct engineered solution to save your compressed air as well as help you to apply for eligible energy rebates in your area.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

Dealing With The Unexpected

Last year about this time, I used the bully pulpit of my weekly blog to update you on the success of our ninth annual Father’s Day Weekend Campout. If you hadn’t guessed, I’m about to fill you in on how awesome the tenth was, but first:

A fellow Boy Scout leader is fond of saying that, when you camp, the weather is always perfect. It may be perfectly sunny or perfectly rainy. Perfectly warm or perfectly cold. Perfectly wet or perfectly frozen. Regardless, it’s always perfect. Yeah; we don’t always like him.

If we’ve learned one thing, it’s to expect the unexpected. This year, it rained. Well, not the whole time. Friday evening was beautiful…we got the campsite set up and dinner cooked well in advance of sundown. My friend & his son had recently waterproofed their tent, and me & my boys had recently purchased a new tent. Both were successfully, and extensively, leak tested Friday night. And all day Saturday. ALL DAY.

This, of course, put a damper on our plans to zipline, which didn’t exactly bother me. I’m sure it’s a temporary reprieve; I mean, I know darn well what I’m doing next year for Father’s Day Weekend, and it CAN’T rain forever. It also, however, put an unexpected damper on our plans to kayak on Sunday. The weather was gorgeous…and fitting for the first day of summer. It was hot enough to make some horseplay in the river sound downright inviting…but the constant rain over the past week had swelled the river banks, and none of the docks were accessible. So we broke camp and returned home to dry our gear. And to look forward to next year.

As Application Engineers, it’s a big part of our jobs to not just expect, but eliminate the unexpected. At EXAIR, we have an impressive arsenal of tools at hand to do just that. Our Efficiency Lab is fully stocked and outfitted to test any of our products…or yours…for performance and effectiveness. We’ve got a wealth of data in our constantly growing Case Study Library. Our Application Database has over 1,000 instances of what will work in certain situations, and our notes on product returns from our 30 Day Unconditional Guarantee give us information on what WON’T work.

If you’d like to find out how our products…and their capabilities…can work for you, give us a call. I look forward to seeing how we can help.

Russ Bowman
Application Engineer
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Shocking Credit Cards Costs … In Manufacturing

Winter’s weather comes with a variety of problems. I hope that folks in the Northeast get a break from all this snow soon. In Cincinnati we have not had to deal with much precipitation this year, but it has been cold and gloomy for too long. Personally, I am ready for spring to come and to the see the flowers pop up. I’m also tired of the getting shocked every time I pet my dog. Also, his hair that generally falls everywhere is now stuck to the side of couch.

On a more serious note, the dry air of winter can have a significant impact on manufacturing processes. The same static that attracts dog hair to a couch will also attract dust on to a non-conductive substrate like plastic or glass. I was working with a customer this week who manufactures credit cards and gift cards with custom logos. They fell prey to the dry, statically charged air of winter which caused a quality issue during these winter months. To create the promotional cards, the company would first digitally print the logo on a PVC substrate. This substrate is then stacked to await lamination. As they pulled each sheet from the stack, a charge would build up on the surface which would attract any dust in the area. The dust needed to be removed before the last clear layer was applied or it showed up as ugly bumps on the card surface. This dust was nearly impossible to clean off and still maintain a good finish on the PVC substrate. They tried to wipe the material off with soft fabric, but the rubbing only increased the static while moving the dust around, not off the laminate.

1559 before

Laminating station two stacks of PVC substrate in the plastic bins

1559-photo

Laminating Station with the 110036″ Super Ion Air Knife installed

Using an EXAIR Static Meter, part number 7905, the customer measured 19.5 kV/inch on the PVC sheets before lamination. Because of this charge the customer installed a 36″ Super Ion Air Knife, part number 111036, above the lamination station. The operator would pull a sheet from the stack and pass it under the Super Ion Air Knife. After passing under the Super Ion Air Knife the charge on the sheet read 1.3 kV/Inch, and the dust was removed by the air blowing from the Super Air Knife. This dust removal drastically reduced their scrap levels. In the 3 months of winter, it was accepted that they would loss approximately 15% of all the cards they created do to blemishes on the cards. After installing the Air Knives, they only scrapped 3% of the cards they created. This scrap rate was even better than there summer production. The air knives will now be used year round.  The Super Ion Air Knife reduced scrap by 80%! Also, operators no longer tried to clean the dust with cloth, which allowed them to increase their production.

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com

EXAIR’s Case Study Library: Where is it? What is it? How Do I Use It?

Case Study (505x640)

EXAIR Case Study Example

Above you will see pictured a Case Study that we have published for Cold Gun. The Case Study documents are arranged in a Library situated on the main EXAIR web site at the following link from the home page: Case Study Library.  There are far more Case Studies that are posted and arranged by Application Type and also by Product category so you can look up application details for specific situations where EXAIR products have proven successful.

Applications are what help our customers better understand our product and how it works. This library is designed to assist you in learning about the common ways in which our products can provide you with a positive outcome to specific application problems.

The Case Studies are arranged in the following format for easy to understand discussion about the application:

  1. Application Goal: States simply what the customer wants to achieve.
  2. Before EXAIR: States the problem that the customer was having prior to installing EXAIR solution.
  3. After EXAIR: Gives the details about how EXAIR’s product was able to save time, save money, save energy, improve the process, speed up the process, etc.
  4. Each Case Study will also include photos of the application to also show the unit in the application.

The EXAIR Case Studies are a great learning tool to determine how EXAIR products can help you with your application.

The more confidence that you have that EXAIR has the right solution for you by reading about how we have helped other customers solve their similar application problems, the more quickly you can get to that solution for your own application problem.

Neal Raker, International Sales Manager
nealraker@exair.com

Never Think Your Idea Will Not Be Heard

The above title proved very true in a work experience of my father’s. After working in the mill for several years, he drew up a new piece of process equipment which would eventually turn in to something that they put in place on the production line.   This was all done from his idea that he was able to place on a scrap piece of paper as a drawing.   While he wasn’t the decision maker in the process, he was the person who saw what kind of impact this device could have and knew the people he had to get the information to.

That brings me to the topic of this blog, don’t ever think an idea is too small to warrant a reward.  This can ring true throughout any type of application, including compressed air.  There have been instances where a maintenance worker, or even a new operator, have called in to speak to me here asking what can they do to lower the noise in the work area when they are using the hand held blow gun the company supplies.   After talking to them about what they are trying to achieve with the blow gun and how much air they are currently using, we generally find that they can save a good amount of compressed air, lower the noise level, and become OSHA compliant, all by changing this one simple tool.   Once they have all the benefits that their company will see from implementing our engineered solution, they can then propose this to the decision makers.

For the most part, companies will at the very least entertain ideas like this.  When you back that idea up with some relevant data on how much money the company will save, or the fact that is will make the work environment safer and more enjoyable, then you will more than likely get a little more attention.  The main point is to ensure that you are getting that information to the correct person and that you have the correct information.   That is one of the many reasons that EXAIR has a full team of Application Engineers who can help you identify how much air you might be using, what products will fit the need, and what kind of benefits your company will see.   On top of all the information that we have available for free, we even offer the chance to get compensation for sharing application data with us.

EXAIR Efficiency Lab

EXAIR’s Efficiency Lab will test your product for force, flow, and noise.

That’s right, we will compensate you for sharing your cost savings, sound level reductions or application improvements, with us.  This is all possible through our Case Study program.  All you have to do to find out more is contact any Application Engineer.  We simply need some photographs of the application and some quantitative data for the benefits you have gained.  Don’t know what your current device is using, take advantage of our EXAIR Efficiency Lab, that will give us a good amount of information we need to then, help you solve a problem as well as produce a Case Study.

If you would like to discuss your compressed air systems or how we can help you, please contact us.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

Durable, Efficient, and Quiet: EXAIR Heavy Duty Safety Air Guns

I had the pleasure, recently, to help the maintenance supervisor of a large, well known bakery with the selection of replacement air guns for their facility. He agreed to participate in a Case Study, quantitatively demonstrating the improvements realized by using EXAIR Safety Air Guns in place of their current ones. Their main complaint was the durability of the ones they were using: the trigger mechanisms routinely failed, and despite repeated contacts with the manufacturer, were unable to get the problem satisfactorily addressed.

In order to get accurate air flow, force, and sound level data, I asked them to send one of these air guns in for testing in our Efficiency Lab. Frankly, I was expecting to see an inexpensive commercial grade offering from a discount tool wholesaler. Instead, it was a heavily advertised product from one of the “key players” in our market. Not only did their product use more air than ours, it was louder than ours, and the trigger BROKE WHILE I WAS TESTING IT. I saw what our customer meant about the durability.

They’ve been using our Model 1310 Heavy Duty Safety Air Guns, with a variety of Extension Pipe lengths, for almost five months now. They called the other day to order some more, and express their satisfaction with our products. This made me think of two things:

*Unlike our competitor in this situation, we WANT to know if you’re not getting the most out of our products. I’m one of the most highly trained Application Engineers in this business, and I share an office with the others. We’ve got an unparalleled track record of successfully solving compressed air applications. Try us.

*It sure is nice to hear from someone you’ve made a positive impact on. If you’ve experienced this lately, you know what I mean. And if someone’s done something like that for you, you should go tell them. You’ll both be better off for it.

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Web: http://www.exair.com
Blog: https://blog.exair.com/
Twitter: twitter.com/exair_rb
Facebook: http://www.facebook.com/exair

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