Process Improvement, ROI and Safety from One Air Nozzle

Process improvement projects can be detailed, complex, expensive, and take a long time to prove their worth.  Today, I want to tell you about one that WAS NOT ANYTHING like that.

A metal stamping company used compressed air to blow their products from their dies.  They did what many do – they ran some copper tubing, and aimed it at the platen so it would properly eject the parts as they were stamped.  They KNEW it was loud, and they suspected it was inefficient as well.

After discussing the setup and seeing a picture of it (the one on the left, below,) I recommended installing a few engineered Super Air Nozzles to lower the noise levels considerably.  Boy, was I wrong.  About “a few” nozzles, that is…turns out, they only needed one Model 1122-9212 2″ Flat Super Air Nozzle with 12″ Stay Set Hose.  The copper tubes come from a manifold that already had 1/4 NPT ports – installation took a matter of minutes.  Nothing detailed, complex, or expensive about it:

This loud & inefficient copper tubing blowoff was just a compression fitting (and a Model 1122 2″ Flat Super Air Nozzle) away from being quiet and efficient.

It didn’t take much longer than that to prove its worth either: as soon as they noticed how much the noise level went down on THIS press, they ordered them for the other eighteen presses in their facility as well.

The 1/4″ copper tubes blew continuously from a pressure regulator set @60psig…the three of them theoretically consumed a total of ~80 SCFM.  The Model 1122, at 60psig supply, consumes only 17.2 SCFM.  Simple return on investment was as follows:

  • 80 SCFM was costing them $48.00 a week
    • 80 SCFM X 60 min/hr X 8 hr/day X 5 days/week X $0.25/1,000 CFM = $48.00
  • 17.2 SCFM, using the same formula, only costs $10.32 a week (I’ll let you do the math; it’s good practice.)
  • They saved $37.68 a week.  The Model 1122-9212 costs $116.00 (2020 pricing) – that means that each of them paid for themselves in just a hair over three weeks.
  • $37.68 x 50 work weeks per year = $1884.00 saved annually per nozzle
  • $1884 x 18 (the number of presses) = $33,912 saved annually 

Considering they also didn’t have to listen to those very loud open ended copper tube blowoffs, I think you’ll have to agree it made for a very good investment.  They did. The new nozzle runs at 77 decibels, a comfortable level and well below the OSHA standard [29 CFR – 1910.95(a)] for allowable noise exposure.

If you’d like to find out how EXAIR Intelligent Compressed Air Products can save you money on compressed air – and save everyone’s hearing – give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Video Blog: Filter/Separator and Pressure Regulator Mounting and Coupling Kit Installation

Using EXAIR mounting and coupling kits you can assemble EXAIR Filters and Regulators into one plug and play assembly. Follow along with the video posted below to complete this task!

If you need a deeper understanding about how EXAIR’s products can be applied and help your process or product, feel free to contact us and we will do our best to give you a clear understanding of the benefits when using our engineered compressed air products. We can also explain proper implementation of accessory items such as compressed air filters and regulators.

Jordan Shouse
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

Henri Coanda: Founder of The Coanda Effect (1886-1972)

EXAIR uses the Coanda effect in many of our products. Henri Coanda is an important figure in the world of fluid dynamics and aerodynamics.

Henri Coanda was a prominent Romanian Inventor and aerodynamics pioneer is known for the creation of the Coanda-1910 experimental plane as well as discovering the Coanda effect. On June 7, 1886 Henri was born in Bucharest Romania to General Constantin Coanda and Aida Danet. In 1899 Henri’s father who desired him to have a military career had him transfer to a Military High School for additional years of schooling, where he graduated with the rank of Sergeant Major. Continuing his studies, he went on to technical school back in Bucharest for Artillery, Military, and Naval Engineering. In 1904 he was sent to an artillery regiment in Germany where he would enroll in Technische Hochshule. Henri did not give up on studying and in 1907 went to Montefiore Institute in Liege, Belgium, where he met Gianni Caproni.

In 1910 Henri and Gianni began a partnership to construct an experimental aircraft which was later called the Coanda-1910. The Coanda-1910 was unlike any other aircraft of its time as it had no propeller; instead it sported an oddly shaped front end with built-in rotary blades arranged in a swirl pattern. These blades were driven by an internal turbine screw that would suck air in through the turbine while exhausting the gases out of the rear, propelling the plane forward. This initial jet engine was quite impressive for the time, but sadly nobody believed it would ever fly and is believed that it never did achieve flight. Coanda is not credited with the invention of the jet engine, but his technology spurred the future of aviation into the future.

During World War 2 Henri spent his time developing the turbo-propeller drive system from his 1910 Biplane. After World War 2 had ended Henri began furthering his research on the Coanda Effect which would become the basis for several investigations into entrained and augmented flow of fluids. Later on in 1969 Henri would spend the last of his days in Romania serving as Director of the Institute for Scientific and Technical Creation. Coanda died on November 25, 1972 in his home town of Bucharest.

Here at EXAIR we have taken Henri Coanda’s, Coanda Effect and applied it to a number of our products to help amplify total airflow and save on compressed air.  The most notable product lines are our Air Amplifiers, Air Nozzles, and Air Knives – which are some of the most efficient products of their kind. These products can help lower your compressed air demand. 

If you have any questions about compressed air systems or want more information on any of EXAIR’s products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

EXAIR’s Return on Investment For One Engineered Air Nozzle is Amazing!

Return on Investment (ROI) is a measure of the gain (preferably) or loss generated relative to the amount of money that was invested.  ROI is typically expressed as a percentage and is generally used for financial decisions, examining the profitability of a company, or comparing different investments.  It can also be used to evaluate a project or process improvement to decide whether spending money on a project makes sense.  The formula is shown below-

ROI
ROI Calculation
  • A negative ROI says the project would result in an overall loss of money
  • An ROI at zero is neither a loss or gain scenario
  • A positive ROI is a beneficial result, and the larger the value the greater the gain
1100group
Our catalog publishes most products’ performance and specification data for a compressed air supply pressure of 80psig.

Example – installing a Super Air Nozzles (14 SCFM compressed air consumption) in place of 1/4″ open pipe (33 SCFM of air consumption consumption) .  Using the Cost Savings Calculator on the EXAIR website, model 1100 nozzle will save $1,710 in energy costs. The model 1100 nozzle costs $42, assuming a $5 compression fitting and $45 in labor to install, the result is a Cost of Investment of $92.00. The ROI calculation for Year one is-

ROI2

ROI = 1,759% – a very large and positive value.  Payback time is only 13 working days!

If you have questions regarding ROI and need help in determining the gain and cost from invest values for a project that includes an EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

Save Compressed Air Energy with Pressure Regulators

Why should you consider a Pressure Regulator when designing your compressed air system? As many know, our products and those of other  product manufacturers have a certain set of specifications regarding performance at stated input pressures. But what if your application doesn’t require that “full, rated performance”? Maybe instead of needing two pounds of force, you only need one pound? Sometimes more force does not produce the desired result for an application. By that, I mean you cause damage to the target or other surrounding items in the application. Or, perhaps blowing too hard (or vacuuming too hard in the case of a Line Vac or E-vac) might cause the vessel or the material you are picking up to collapse or deform (due to too much power).

Regulators catalog
EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

There is also the concern about using more energy than one really needs to in order to achieve the desired effect in an application. In other words, if you can achieve your goals with only 40 PSIG, then why would you ever use 80 PSIG to accomplish the goal? By reducing your compressed air from 80 down to 40 PSIG, you can easily reduce the air consumption of the “engineered” solution by another 40% or more.  Once you have installed engineered air nozzles to reduce compressed air on blow off applications, a pressure regulator can fine tune the pressure to save even more energy.

Regulator Internal
Regulator Internals

Then there is the issue of taking advantage of the pressure differential (from 80 down to 40 PSIG) that creates a little bit more air volume capacity. At 80 PSIG, your compressed air to free air volume ratio is 6.4:1. At 40 PSIG, it is only 3.7:1. The net effect is you effectively have an overall larger volume of air you can use for other applications in your facility. By reducing compressed air pressure of your demand applications, you may be able to reduce over all compressor discharge pressure. Reducing compressor discharge pressure by 2 PSIG also reduces required input power by 1 percent – so keep your pressure as low as possible!

Regulating pressure is definitely warranted given the benefits that compliment the operation of the core EXAIR products.

If you need a deeper understanding about how EXAIR’s products can help your application, feel free to contact us and we will do our best to give you a clear understanding of all the benefits that can be had by our products’ use as well as proper implementation of accessory items such as compressed air filters and regulators.

Jordan Shouse
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

50 Years of Earth Day – Happy Earth Day!

Today marks the 50th anniversary of Earth Day and it will be observed in over 190 countries. For EXAIR, this year marks our 37th year helping compressed air users save compressed air energy and electrical resources. And the 37th year for improving our own efficiencies and processes in order to reduce waste. Because your volunteer opportunities may not be available this year, Earthday.org has gone digital for 2020 and is providing ways to participate via your computer.

EXAIR remains committed to a minimal footprint and continues to focus on manufacturing our products with little impact and doing our part to help protect our planet. We are proud to manufacture efficient products, implement processes and programs throughout our facility to help use our resources wisely and recycle everything we possibly can.

We manufacture and sell Intelligent Compressed Air Products that are specifically designed to reduce the use of compressed air throughout facilities.  On top of that, when you purchase an EXAIR product it will arrive in fully recyclable packaging and, in most cases, is made from a material that will be recyclable should it reach a point it is no longer useful.

Over the past years we continually look for improvement opportunities within our systems and processes. Recently we have…

  • Over the past year, EXAIR recycled 1300 yards of paper and cardboard.
  • Recycled 100% of our cardboard and mixed paper products. Of the waste we place into our trash dumpsters – 80% is recycled and 20% is sent to the landfill.
  • Recycled 100% of the metal scrap from our machining processes. Improvements in these processes has reduced scrap rates, which equates to 5.5 tons of recycled metal.
  • Used our very own Chip Trapper Systems in our manufacturing areas to extend the water-soluble coolant life from 6 weeks per changeover to 6 months per changeover. Keeping our coolant clean allows us to minimize the total amount of wastewater we recycle each year.
  • Further reduced our wastewater for reclamation by another 25% compared to last year.
  • Minimized our own compressed air use by 1 million cubic feet per year
  • Made improvements to the efficiency of our computers and computer servers which require fewer Kilowatt hours (KWH) per day

Another waste reducing factor that has proven to work out well for EXAIR is asking every customer if they accept digital invoices rather than requiring them to be printed and mailed.  We have been able to eliminate over 91% of all printed and mailed invoices. This helps to reduce our resources used as well as the amount of materials that are possibly turned into solid wastes at customer facilities. This also prevents the gas and vehicles necessary to deliver all of these invoices by mail.

Adding to the efforts above, we continue to maintain RoHS compliance on all electronic products, as well as actively track our supply chains to ensure no Conflict Minerals are being sourced and used in our products.

If you have any questions on how we can help your facility reduce their volume of compressed air or why we continue to reduce our wastes and increase our recycling efforts, contact us.

Happy Earth Day from EXAIR!

 

 

Image Credit: NASA/NOAA/GSFC/Suomi NPP/VIIRS/Norman Kuring

Sanitizing Applications Using Atomizing Spray Nozzles

As our journeys through the COVID-19 pandemic began, EXAIR was deemed an essential business due to our relationships with critical businesses who are also helping to fight the pandemic and keep our lives as normal as possible. Within our customer base, we are proud to include medical, food, pharmaceutical, and nearly every industry listed by the Department of Homeland Security as critical industries.

EXAIR has seen an increase in assisting end-user customers who have in house sanitizing needs and OEMs (original equipment manufacturers) who are producing sanitizing systems or “showers” for their processes and products as demanded by our pandemic circumstances.

Our Atomizing Spray Nozzles, designed to atomize fluids in a wide range of different spray patterns, utilize a small amount of compressed air that mixes with the liquid supply to create a fine mist of atomized liquid. This makes them very effective in applications that utilize expensive paints, oils, or other liquids. Rather than wasting the expensive materials, the nozzle can be set to precisely dispense only what is necessary to achieve a successful application. They are made from type 303 stainless steel.

No Drip Atomizing Nozzle

Atomizing spray nozzles have been critical for customer’s decontamination and sanitizing needs. Most recently we learned they are being used to build an N95 mask sanitizing systems, when the customer needed to replenish their rapidly dwindling supply of atomizing spray nozzles. Don’t forget, we have them in STOCK and ready to ship!

Internal Mix Atomizing Spray Nozzles

Another customer utilizes the Model EF1010SS to perform a dry fogging process inside of residential and commercial rooms to eliminate mold, odors, and pathogens. For them this is a common process, but due to the concerns related to COVID-19 they’ve seen a dramatic increase in business related to pathogen removal. Using a two-step dry fogging process, the solution fills the entire volume of the space to remove any contaminants and prevent against microbial growth in the future. The nozzle provides a fine atomized mist that fills the entire space in a short amount of time. After a physical wipe down of all surfaces, a second solution is applied that prevents future microbial growth.

And yet another customer manufactures decontamination booths for personnel. They’re also noticing an increase in inquiries as companies look to decontaminate their employees upon entering the building. Utilizing (3) of EXAIR’s SF2020SS Atomizing Spray Nozzles, they’re able to spray a decontaminating solution to aid removal of pathogens from their clothing before it has an opportunity to spread around the office.

We are here to help. Let us know if we may help you.

Stay safe,
The EXAIR Team