EXAIR’s Knowledge Base is THE Place for Compressed Air Related Content

At EXAIR, we want to ensure our customers have access to as much technical data and information as possible. This helps to assist in identifying solutions to common industrial problems and provide you with the resources necessary to make an informed purchase. A big part of that effort is displayed here on the EXAIR Blog. But, did you know that our website is home to a wealth of information ranging from Case Studies, Videos, Webinars, Installation Guides, Catalog Sections, CAD Models and much, much more?

Once you’ve registered for an account on the website, you’re able to access the content housed in our Knowledge Base. Have a question on a particular product? Check out the FAQ section, created by our Application Engineers, the FAQ section contains a variety of commonly asked questions from customers.

Misplaced your installation sheet? No problem! All installation and maintenance guides, in addition to product catalog sections, can be found in .pdf format for download under “PDF Library”.

With 15 different product lines, EXAIR has products capable of addressing a wide range of industrial process issues. Not sure where in your facility you may have an opportunity to improve? EXAIR’s Application Search Library allows you to narrow down your search. Categorized both by specific process or by industry, we’ve highlighted a variety of different specific applications that our products can serve.

EXAIR hosts a yearly Free Webinar covering a variety of topics related to industry and compressed air. After the webinar has been sent out to all registrants, we include a recorded video of the webinar as well:

It doesn’t just stop there. The Knowledge Base also contains calculators and general compressed air related data in addition to PowerPoint presentations for each product line. Click here to register for the website and begin accessing all of this valuable content!

Tyler Daniel

Application Engineer

E-mail: TylerDaniel@EXAIR.com

Twitter: @EXAIR_TD

Nozzles for Cleaning Inside Hose, Tube, Pipe and More

Some applications such as blowing chips or debris out of a pipe or blind hole, it may not be possible to blow forward. The pipe may be too long, making it impossible to push the debris all the way down the pipe or the other end of the pipe may not be open. In either of these scenarios, the Back Blow Nozzle is the right tool for the job. An array of holes around the diameter of the Back Blow Nozzles provides a powerful 360° airflow pattern that will clear out any leftover coolant or chips from the machining process.

EXAIR has three different size Back Blow Nozzles; the 1004SS (M4 x .5), the 1006SS (1/4 NPT), and the 1008SS (1” NPT). The 1004SS is recommended for use on pipes as small as ¼” and up to 1”. The 1006SS can be used for a wide range of pipe sizes, from 7/8” up to 4”. The 1008SS nozzle offers the greatest overall force for stubborn or sticky materials stuck to the inside diameter of the pipe. This nozzle is suitable for use in pipes ranging from 2”-16”. As the Back Blow Nozzle will be blowing chips and debris back out of the pipe towards the operator, it is always recommended that a Chip Shield is used. The strong polycarbonate Chip Shield will keep them safe from flying debris and keep you in compliance with OSHA directive 1910.242(b).

Various Views of the Model 1006SS Back Blow Nozzle

All of EXAIR’s Back Blow Nozzles are available with extensions. For the 1004SS we have extensions from 6”-36”, and from 12”-72” for the 1006SS and 1008SS. The Back Blow Nozzle can also be installed on our VariBlast, Soft Grip, Heavy Duty, and Super Blast Safety Air Guns. With such a wide range of available sizes and configurations, we can tackle just about any internal pipe cleaning application. If you have a process in your facility that may benefit from the use of one of these nozzles, give us a call and get one on order today!

Jordan Shouse
Application Engineer

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Optimizing Compressed Air Systems in Six Easy Steps

Knowing your compressed air needs and understanding the limitations of your equipment is essential when optimizing your compressed air system. Everything about compressed air systems are interrelated. Items putting demand on your system can and will effect how the equipment supplying the demand will operate. Taking a holistic approach when optimizing your compressed air system will not only give you a better understanding of your supply and demand requirements but will also serve as the most efficient means to optimize your process. Now lets look at the six steps to optimizing.

  1. Measure: the air consumption You must create a baseline to understand your demand requirements. How can you measure your improvements if you do not understand your total demand or baseline? Installing an EXAIR Flow Meter to your main air lines will help identify the amount of compressed air demand you have and help identify areas of concern.
  2. Find and fix leaks in the system: The repair of compressed air leaks is one of easiest ways to gain energy savings. In most cases all you need is a keen sense of hearing to locate a leak. Once a you have confirmed a leak then the make the necessary repairs. Harder to find leaks may require tools such as EXAIR’s Ultrasonic Leak Detector. This is a hand held high quality instrument that can be used to locate costly air leaks.
  3. Upgrade your blow off, cooling and drying operations: Updating your compressed air process tooling can save you energy and help you comply with OSHA noise and safety regulations. An example would be to replace old blow off or open pipe systems with EXAIR Safety Air Nozzles. Replacing open copper tubes or pipes can amount up to 80% air savings. You achieve lower sound levels and significant energy savings.
  4. Turn off the compressed air when it isn’t in use: It sounds obvious but how many times has an operator left for a break or lunch and doesn’t shut off the compressed air for his/her station? The minutes add up to a significant amount of time annually meaning there is opportunity for energy savings. The use of solenoid valves will help but EXAIR’s Electronic Flow Control (EFC) will dramatically reduce compressed air costs with the use of a photoelectric sensor and timing control.
  5. Use intermediate storage of compressed air near the point of use: The use of storage receivers can improve your overall system efficiency in a number of ways. For example, using a main air receiver at the compressor room can make load/unload compressor control more efficient. Localizing receiver tanks such as EXAIR’s 9500-60 sixty gallon receiver tank by the point of use for a high demand process will stabilize the demand fluctuations allowing a more fluid operation.
  6. Control the air pressure at the point of use to minimize air consumption: The use of pressure regulators will resolve this issue. Using regulators you can control the amount of air being processed at each point of use. EXAIR offers different sized pressure regulators depending upon your air line and process requirements. Regulating the compressed air to the minimum amount required and will reduce your overall demand resulting in annual savings and a payback schedule.

Compressed air optimization can definitely be implemented using low cost and manual procedures but sometimes you will need a higher level means to achieve your goal. EXAIR has many optimization products to support your efforts. You can review our catalog, blogs and videos at www.EXAIR.com or by calling 800.903.9247 and any of our qualified Application Engineers will assist you.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK

EXAIR Celebrates Manufacturing Day With A Win For A Manufacturer

In 2012, the National Association of Manufacturers organized an effort to proclaim the first Friday in October (hey, that’s today!) as Manufacturing Day.  According to the Advanced Manufacturing National Program Office (a division of NIST, the National Institute of Standards & Testing,) the purpose of MFG Day is “to raise awareness among students, parents, educators and the general public about modern manufacturing and the rewarding careers available.”

Today is kind of a big deal around here.  Not only is EXAIR Corporation a manufacturer, but many of the companies that use our products are as well.  A lot of us have a rich story, woven into the cloth of the history of American manufacturing (which, in turn, is woven into the larger cloth of American history.)  Have you heard the one about the motivated inventor with an idea to make innovative products who started an operation out of his home that, with inspired direction & vision, became a worldwide leader in their industry?

Yeah; that’s us.  Today, we’re honoring Roy Sweeney’s legacy (he founded the company in October 1983,) and celebrating MFG Day, by publishing a new Case Study, proving out the benefits of the use of EXAIR Intelligent Compressed Air Products in regard to the monetary savings associated with the reduction in compressed air use, and the noise level reduction from the implementation of our engineered products.

You can download the complete Case Study here, but while we’re on the subject, here’s a basic rundown:

  • A roll forming operation used to blow off their product with a combination of loud and inefficient devices: copper tubing and modular flexible hose which is designed primarily for machine tool coolant, but often misapplied for use with compressed air.
  • It worked just fine, but an engineering study noted it as a potential wasteful use of compressed air.  That’s when they called us.
  • By replacing those blow offs with Model 1100 Super Air Nozzles and Model 1122 2″ Flat Super Air Nozzles, their noise levels dropped from 107 dBA to 83.8 dBA.  To put that in perspective, it went from the approximate sound level of a rock concert to that of a leaf blower. (ref: Centers for Disease Control & Prevention: What Causes Hearing Loss?)
  • Compressed air consumption dropped by more than half, from 190 SCFM to 86.8 SCFM…an annual savings of over $3,200.00.  All for an investment of $654.00 (2020 pricing) for those engineered Air Nozzles, Stay Set Hoses, and Magnetic Bases.  That means they’ll have paid for themselves in just under two months.
  • In addition to that, for participation in this Case Study, we’re giving them a generous credit on their order.  Happy Manufacturing Day!

And frankly, I think the engineered products just look better too.

Last but certainly not least, this reduction in compressed air usage decreases the load on their air compressors, reducing the electrical power consumed.  Product impact, along with our own consumption of resources and waste recycling, is a key component of EXAIR Corporation’s Sustainability Plan.  We’re making the world a better place, by making products that make the world a better place, using methods that make the world a better place.  I can’t think of a better way to celebrate Manufacturing Day.  If you want to get in on it, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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MFG Day logo courtesy of nist.gov