Tag: compressed air flow control

Optimize Your Performance

Published on by jasonkirbyLeave a comment

Compressed air leaks and ineffective blow-offs can result in significant electricity wastage annually, impacting your organization’s production expenses and overall profitability. In numerous facilities, leakage can represent as much as 30% of the total system capacity costs associated with compressed air.

Turning air off when it’s not needed adds up, even if it’s just for a few seconds at a time.

Since 1983, we have been dedicated to offering products that are efficient, safe, and effective. Our ambition extended beyond mere manufacturing; we aimed to enhance our customers’ compressed air systems as well. This vision led to the creation of our Optimization product line. These products serve a dual purpose: they emphasize the significance of conserving compressed air, enhancing safety, and streamlining processes, while also optimizing the performance of your compressed air system to maximize its potential.

EFC: The EFC is engineered to conserve compressed air. In instances where a blowing or cooling process is intermittent, it is advisable to deactivate the compressed air supply when not needed. This compact, timed PLC employs a photoelectric sensor to facilitate this action with a compressed air supply. By reducing the consumption of compressed air, significant cost savings is achieved.

Digital Flowmeter: Measuring flow enables numerous optimization opportunities. The Digital Flowmeter effectively displays and logs the flow rate within your compressed air system. Additionally, it assists in leak detection, troubleshooting pneumatic issues, and utilizing the collected data for preventive maintenance. When comparing EXAIR products to open pipes or competing solutions, the air savings become apparent, allowing for a straightforward calculation of the payback period, typically within weeks. EXAIR also provides various recording options, including wireless, serial, or USB Datalogger types, facilitating continuous 24/7 monitoring of your compressed air system.

In contrast to the 98dBA sound level produced by this array of nozzles, the sound pressure level produced by an EXAIR Super Air Knife is only 69dBA.

Digital Sound Level Meter: This instrument is utilized for assessing sound levels. To ensure safety, OSHA established time-based decibel limits for workplace environments. The Digital Sound Level Meter is calibrated according to NIST standards to provide precise noise measurements. Inadequate nozzles on air guns or exposed pipes for blow-offs may lead to non-compliance with OSHA standard 29CFR 1910.95(a), potentially incurring fines. EXAIR products are engineered to comply with this regulation.

Ultrasonic Leak Detector: Numerous compressed air systems experience leaks, which, if undetected, can significantly diminish the system’s overall capacity and lead to substantial financial losses. Such leaks may represent up to one-third of the total compressed air output. The ULD is capable of identifying these leaks, thereby enhancing system efficiency and promoting the optimal functioning of your compressor.

If you would like to discuss our Optimization products, or any of our EXAIR products, please do not hesitate to contact an Application Engineer. We are always happy to help!

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

Fixing Leaks and Saving Money

Published on by Al WooffittLeave a comment

Compressed air is an incredibly useful resource, that comes with many advantages over non-pneumatic alternatives. You will find compressed air being used in a variety of industries and applications. It is so widely used that it often called the 4th utility. And as with any utility, it is important to be mindful of the cost, and how to make the most of it.

One simple way to save compressed air is to find and fix leaks in your compressed air system. According to the Compressed Air and Gas Institute, leaks should not exceed 5-10% of your systems air supply (we would obviously want 0%, but realistically this is unachievable). However, it is not uncommon to see leaks account for over 30% of many facilities compressed air supply being lost through leakage.

We think leak detection, and correction, is so important, that it is step 2 of our six simple steps to optimize your compressed air system. We have written many blogs on these six steps. To put some context around it, leaks the size of 1/16″, 1/8″ and 1/4″ holes will cost the following:
 

Knowing the cost of leaks is one thing, but finding them is another challenge altogether. Many leaks are undetectable to the human ear. That’s where EXAIR’s Ultrasonic Leak Detector comes in. Our Model 9207 can detect these high-frequency sounds, allowing you to pinpoint where they are. With the two attachments included; the parabola to locate leaks up to 20 feet away, and the tube attachment to define the exact location, our simple-to-use instrument will save you money, as well as a lot of headaches.

If you would like to discuss how EXAIR’s Ultrasonic Leak Detector can save you money, don’t hesitate to give us a call!

Al Wooffitt
Application Engineer

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Take the Steps: Installing Intermediate Storage

Published on by jasonkirbyLeave a comment

Air compressors depend on electricity to generate compressed air, making it essential to enhance the efficiency of your compressed air system. EXAIR offers six straightforward steps that can assist in lowering electrical expenses, minimizing overhead, and boosting profitability. This blog will focus on the fifth step, which involves the intermediate storage of compressed air close to the point of use.

Intermediate storage plays a vital role in managing pressure variations that can arise during production processes. When materials are transferred from one stage to another, sudden changes in pressure can negatively affect the quality of the product. By incorporating intermediate storage, manufacturers can create a buffer that helps stabilize pressure fluctuations. This stabilization ensures that the materials remain consistent before they move on to the next stage, thereby preserving their quality and integrity. Ultimately, this careful handling supports better overall outcomes in the final product, leading to higher customer satisfaction.

In some cases when only one or a few applications need air sporadically, using a properly sized storage receiver can be very helpful. Placing this storage receiver near the point where air is needed most can improve efficiency. It is essential to include a check valve and metering valve with the storage receiver. The check valve ensures that air does not flow back, while the metering valve controls the rate of refilling which is another strategy for reducing overall load on a compressor.

Receiver tanks play an important role in providing compressed air for tasks that require a lot of air for a short time. By placing these tanks in the right locations, users can ensure a steady supply of air without always depending on the compressor. This setup allows for more efficient operations during peak demand periods. Properly sizing the tanks is crucial, as it ensures they can deliver the right amount of air when needed. Overall, receiver tanks enhance the performance of compressed air systems and help meet varying demands effectively, and with a more consistent result.

Step Five of our Six Steps To Optimizing Your Compressed Air System: Use intermediate storage near the point of use.

EXAIR provides a 60-gallon receiver tank that is ready for immediate use. This tank is designed for applications that require a lot of air for short periods. The model 9500-60 can be placed close to where you need extra compressed air. By having this tank nearby, you can ensure that there is enough air supply when demand increases. This setup helps maintain efficiency and performance in your operations.

If you have any questions about intermediate storage, or you need assistance with any of EXAIR‘s products, please do not hesitate to reach out.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

CE Compliance Explained

Published on by jasonkirbyLeave a comment

At EXAIR, we guarantee that our products meet the highest of standards, and adhere to all product requirements and regulations. UL certification is optional in the United States, whereas CE certification is required for products marketed within the European Economic Area (EEA). The CE marking, derived from the French term “Conformité Européenne,” indicates that a product complies with European Union health, safety, and environmental standards, thereby ensuring the safety of consumers.

CE marking is required for over 20 categories of products, such as construction materials, gas appliances, toys, measuring devices, mobile phones, and elevators. A comprehensive list of these product types, subject to mandatory CE marking, can be found on the European Commission’s website.

What the CE mark says about your product:

  • It complies with all relevant product directives and regulations in the European Union.
  • You have checked and identified all the laws that apply to it.
  • It conforms to all the applicable health, safety, and environmental laws.
  • It is legally compliant enough to sell anywhere in the European Union.
  • It meets the laws’ essential requirements, and you can prove it with documentation.
  • You can provide the EU Authorities at their request with a legally correct and complete Technical File that demonstrates conformity.
  • You have given legal assurance, and you take full legal responsibility for any failings and their consequences.

The CE markings on a product guarantee its eligibility for sale in any EU member state, irrespective of its country of origin. This certification has also gained recognition as a standard in various other regions globally, although it primarily holds significance within Europe. When you observe the small ‘CE’ symbol on our products, it signifies their high quality and adherence to stringent standards. This assurance means that your investment is well justified.

If you have any questions about how our products meet CE or other specifications, or you need assistance with any of EXAIR‘s products, please do not hesitate to reach out.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk