EXAIR keeps a library of Case Studies for your reference. The library is also organized by product, so you can easily find the information and product you are interested in. These case studies summarize how our customers have purchased, used, and benefited from our products and their implementation. These studies focus on our products and our customers’ projects. We keep our customers anonymous and only use photos, details and data that are approved to be shared.
Here is an example of my latest case study!
APPLICATION GOAL: A frozen chicken wing manufacturer was having issues with a drilled and slotted tube blowoff not evenly removing excess sauce from the wings and belt prior to it going into a spiral freezer. They also had concerns about the volume of air the pipe was consuming and how loud it was, so they wanted to reduce both of these features.
BEFORE EXAIR: A new sauce applicator had been installed at the customer’s plant. A drilled and slotted tube was provided with the equipment. This tube ran approximately 14 hours per day at a pressure of 16 PSIG to remove excess sauce on chicken wings. Due to the lack of performance, they temporally installed another drilled and slotted tube to remove excess sauce. The header pressure on these knives was 60 PSIG, but due to the large volume of air they were consuming, they were only able to run them at 16 PSIG. And at 16 PSIG they produced a sound level well over 90 dBA.
AFTER EXAIR: The customer installed a 110030SS-316PKI 30’’ 316 Stainless Steel Super Air Knife on the sauce applicator and a 110024SS-316PKI 24’’ 316 Stainless Steel Super Air Knife on the Spiral Freezer. (Both with plumbing kits installed) They reduced the noise to 65 dBA. The old drilled and slotted tubes consumed 484.2 SCFM each at the 16 PSIG. For a total consumption of 968.4 SCFM with both tubes. The Super air knives combined consume 124.2 SCFM at 60 PSIG. And the Super Air Knives laminar flow provided better sauce removal, over the turbulent nature of the drilled and slotted tube.
SUMMARY: The sauce removal process performance increased dramatically, reducing the rejected product. Sound levels dropped from over 90 dBA to 65 dBA, a reduction of 25 dBA. Air consumption went from 968.4 SCFM to 124.2 SCFM. When you factor in the 14 hours these knives are running, that is 709,128 SCF of air per day saved. Based on a compressed air cost of $0.25 per 1000 SCF of air, that calculates out to over $177.28 in compressed air cost saved every day. ($46,092.80 saved per year, 260 working days) The ROI on these two knives is just under 30 days.
EXAIR appreciates a good success story. We encourage you to share your successes in using one or more of our products in your application. EXAIR believes in case studies so much, we incentivize our customers’ participation. We will offer a discount to any company who will provide enough information to produce a case study. If you are interested in creating a case study (and saving money) on your next project, please contact one of our Application Engineers. We would be happy to explain the details of working through this process with you.
Jordan Shouse, Application Engineer
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