Blowoff Systems Makes it Easy to Clean Extrusions

A metal cutting facility would cut pieces of aluminum extrusions, bars and cylinders to specific lengths as requested by their customers.  They used a variety of different types of cutting equipment depending on the size and profile, but every cutting machine would use coolant. At the end of the cutting process, they would run the parts through a washing system to remove any coolant and then through an inkjet marking system.  They would print the corresponding tag information on the top of each product.

The surface had to be dry or the ink would run and become illegible.  To try and speed up the drying process, they attached four soft copper tubes to blow compressed air along the top of the parts.  They flattened the ends slightly to give a wider blowing area as well as to direct the air into the T-slots of the extrusions.  The customer liked the flexibility of the copper tubes as they would need to change the position often to fit the appropriate size and profile.

The problem that they had with their setup was that the blowing was too loud and it used a large amount of compressed air.  They found EXAIR which looked to have a better solution to blow off the water from the product.

Blow Off Application

The customer gave some additional details on their process.  They could cut a wide range of diameters from 2 inches (51 mm) to 12 inches (305 mm) within their bar and cylinder stock.  They also would cut square and rectangular extrusions that had a variety of profiles and dimensions.  They requested a flexible product that could conform to the different sizes and types and also be adjusted manually for optimum blowing positions.

1122-9412 Blowoff Kit

EXAIR offers a great product line that would fit their requirements for this application, the Blowoff Systems.  With their requested specifications, the flat blowing pattern and flexibility, it directed me to the model 1122-9412 Blowoff Kit.  This kit comes with a Magnetic Base, Flat Super Air Nozzles, and flexible Stay Set Hoses.  The model 1122-9412 has two 2” Flat Super Air Nozzles which will give a wide blowing area.

The Magnetic Base contains two outlets with shut off valves on each port to allow for an easy way to turn off a nozzle when not needed for the smaller products.  Between the Magnetic Base and the 2” Flat Super Air Nozzle, a 12” (305mm) long Stay Set Hoses connects them together which will allow for precise blowing and maneuverability.

By installing two pieces of the model 1122-9412 to his system, the customer was able to remove the four pieces of the copper tubing which were loud and inefficient.  The noise level dropped to 77 dBA with the 2” Flat Super Air Nozzles which was a relief, and they realized that the air compressor was working less.  By adding the Blowoff Kits to their system, they now had a flexible, efficient and effective way in drying the products prior to printing.

With the customer above, they saw much improvement in blowing off the water which kept the ink jet printing process from running or smearing.  If you need flexibility in your blowing application, EXAIR offers a variety of kits with different types of nozzles to accommodate the best blowing feature for your application.  If you would like to discuss these options, you can contact an EXAIR Application Engineer, and they will be happy to help.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

The Case For The EXAIR Super Air Wipe

If you’ve ever used an air gun to blow something off, you’re familiar with the cleaning ability of compressed air.  If you can get the whole object blown off from where you’re standing, there really is no substitute…but what if you need to get to the other side…or sides?

Even if your product is not on fire, you probably wouldn’t want to “limbo” under it with an air gun…

This is where the EXAIR Super Air Wipe comes in…they allow you to blow a continuous, uniform 360° air stream, all around your product.  Consider their benefits:

*Sizes: the Super Air Wipe’s compact ring design means it won’t take up a lot of room; you just need a few inches, in any direction, to install one.  We stock them in eleven sizes, from 11″, all the way down to our brand-new 3/8″ diameter.

*Durability:  All EXAIR Super Air Wipes are assembled with stainless steel shims and hardware.  Models up to 4″ come with a rugged, stainless steel wire braided hose, connecting the two halves for compressed air supply.

The aluminum Super Air Wipe is available in 11 sizes; the stainless steel Super Air Wipe comes in 5 sizes…all from stock.

*Ease of installation:  Smaller sizes can be supported by the compressed air supply line, if a pipe is used and threaded into the connector hose’s 1/4 NPT port.  Larger sizes can likewise be adequately supported with pipe to both halves. All models have a bolt circle of 1/4″-20 tapped holes for more permanent and rigid mounting.  The split ring design is another key feature:

Simply open the two halves, and clamp them around your product…no threading!

*Corrosion resistance: Depending on the environment in which the Super Air Wipe will be installed, we offer them with aluminum (3/8″ – 11″ sizes) or stainless steel (3/8″ – 4″ sizes) bodies.

*Temperature rating: Aluminum Super Air Wipes are good to 400°F (204°C) and stainless steel models are good to 800°F (427°C.)

*Range of operation: We install a 0.002″ thick shim in all stock Super Air Wipes; this is suitable for a wide range of typical industrial/commercial blow off applications…a Pressure Regulator can then be used to “dial in” the air flow precisely to meet specific needs.  If a job calls for higher force & flow, additional 0.002″ shims can be installed.  Shim Sets come with the Super Air Wipe Kits, or individual shims can be ordered separately.

*Performance: Before the Super Air Wipe, a ring of nozzles was commonly used.  In fact, they still are, but we’re trying to fix that, at every opportunity we come across.  Problem with those is, it’s hard to get an even air flow all around, which leads to inconsistent blow off.  They can also be loud & inefficient, as we’ve found in numerous Efficiency Lab tests and Case Studies, like this one…

These wasteful and loud modular plastic tube blow offs…
…were replaced with EXAIR Super Air Wipes. 24 such replacements netted the customer an annual compressed air cost savings of over $13,000.00.

…and this one…

Implementing a Super Air Wipe salvaged a $30,000 job for this customer. Click on the picture to read all about it in our Case Study Library (registration required.)

Do you have a challenging blow off application that you need help with?  Call us to find out how an EXAIR Super Air Wipe (or another one of our Intelligent Compressed Air Products) can be a simple, quick & easy solution.

Dollar Savings: Open Pipes vs EXAIR Air Nozzle

Early one morning we received a call from a local metal stamping company that had a problem. They had outstripped the volumetric capacity of their (2) 50 HP air compressors.

They were using open copper tubes to facilitate separating the part from the die on the upstroke and then blow the part backwards into the collection chute. The (5) 1/4” copper tubes were all connected to a single manifold with a valve to control each tube.  Compounding their compressed air shortage was that this setup was duplicated on approximately (8) presses.  Per the plant they run the presses for approximately (4) hours per day.  The volume of air required for one press was calculated as:

One 1/4” open copper pipe consumes 33 SCFM @ 80 PSIG, therefore:

EDV Blog.JPG

Due to the award winning design of EXAIR’s engineered air nozzles the plant achieved faster separation of the part from the die and greater efficiency moving the part to the collection chute, while averting the need to purchase a larger air compressor. They are saving air, reducing energy costs and lowering the noise level in their facility.

If you would like to discuss saving air and/or reducing noise, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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Line Loss: What It Means To Your Compressed Air Supply Pipe, Tubing, And Hose

“Leave the gun. Take the canolli.”

“What we’ve got here is failure to communicate.”

“I’ll get you my pretty, and your little dog too!”

“This EXAIR 42 inch Super Air Knife has ¼ NPT ports, but the Installation and Operation Instructions recommend feeding it with, at a minimum, a ¾ inch pipe…”

If you’re a movie buff like me, you probably recognize 75% of those quotes from famous movies. The OTHER one, dear reader, is from a production that strikes at the heart of this blog, and we’ll watch it soon enough. But first…

It is indeed a common question, especially with our Air Knives: if they have 1/4 NPT ports, why is such a large infeed supply pipe needed?  It all comes down to friction, which slows the velocity of the fluid all by itself, and also causes turbulence, which further hampers the flow.  This means you won’t have as much pressure at the end of the line as you do at the start, and the longer the line, the greater this drop will be.

This is from the Installation & Operation Guide that ships with your Super Air Knife. It’s also available from our PDF Library (registration required.)

If you want to do the math, here’s the empirical formula.  Like all good scientific work, it’s in metric units, so you may have to use some unit conversions, which I’ve put below, in blue (you’re welcome):

dp = 7.57 q1.85 L 104 / (d5 p)

where:

dp = pressure drop (kg/cm2) 1 kg/cm2=14.22psi

q = air volume flow at atmospheric conditions (FAD, or ‘free air delivery’) (m3/min) 1 m3/min = 35.31 CFM

L = length of pipe (m) 1m = 3.28ft

d = inside diameter of pipe (mm) 1mm = 0.039”

p = initial pressure – abs (kg/cm2) 1 kg/cm2=14.22psi

Let’s solve a problem:  What’s the pressure drop going to be from a header @80psig, through 10ft of 1″ pipe, feeding a Model 110084 84″ Aluminum Super Air Knife (243.6 SCFM compressed air consumption @80psig)…so…

q = 243.6 SCFM, or 6.9 m3/min

L = 10ft, or 3.0 m

d = 1″, or 25.6 mm

p = 80psig, or 94.7psia, or 6.7 kg/cm2

1.5 psi is a perfectly acceptable drop…but what if the pipe was actually 50 feet long?

Again, 1.5 psi isn’t bad at all.  8.2 psi, however, is going to be noticeable.  That’s why we’re going to recommend a 1-1/4″ pipe for this length (d=1.25″, or 32.1 mm):

I’m feeling much better now!  Oh, I said we were going to watch a movie earlier…here it is:

If you have questions about compressed air, we’re eager to hear them.   Call us.

Russ Bowman
Application Engineer
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Flat Super Air Nozzles – Quiet and Forceful and Adjustable

The 2″ Flat Super Air Nozzle is a very powerful yet quiet engineered nozzle.  Operation at 80 PSIG of compressed air pressure yields a strong 1.38 lb. of force, at only 77 dBA of sound level.  Compare this with many of the plastic flat nozzles that blow air through a series of holes, with sound levels ranging form 78-83 dBA, not to mention some might violate the OSHA dead ended pressure standard and results in fines being levied.

The patented technology utilizes a changeable shim to generate the high flow of air in a smooth and laminar flow, to keep noise down and power and strength up. With (6) stainless steel shim thicknesses available, the 2″ Flat Super Air Nozzle offers a very flexible package that can be set and tuned to meet exacting performance criteria, while using the minimum amount of compressed air, and at the quietest possible sound levels.

2 Inch Flat
2″ Flat Super Air Nozzle

The model 1122 is offered in a zinc aluminum alloy body and cap, and the 1122SS is constructed from type 316 stainless steel.  All shims are stainless steel. The shim thickness for the 1122/1122SS is 0.015″ thick.

Also available, for extra blowing force, are the HP1125 and HP1125SS.  The nozzles utilize the same zinc aluminum alloy or stainless steel body and cap and have the 0.025″ shim installed – and deliver 2.2 lbs of force, while only increasing sound levels to 83 dBA.

Shim sets for any of the 2″ Flat Super Air Nozzles are available.  The 1132SS shim set includes shims of thickness of 0.005″, 0.10″, and 0.020″.  For higher force levels, the HP1132SS shim set includes the 0.020″ and 0.030″ shims.

1132ss
Shims are available, from 0.005″ up to 0.030″ for maximum versatility and performance tuning

As you can see- for a versatile, forceful and quiet engineered air nozzle, it is hard to beat the EXAIR 2″ Flat Super Air Nozzle.  If a 1″ wide nozzle better suits your needs, the same flexibility and power can be found in the 1″ Flat Super Air Nozzle as well.  Check it out as well.

If you would like to talk about Flat Super Air Nozzles or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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More Efficient Compressed Air Use Could Lead To Energy Rebates

The use of compressed air can be found in almost any industry and is often referred to as a “fourth utility” next to water, gas and electric. The generation of compressed air accounts for approximately 1/3 of all energy costs in an industrial facility, in many cases, it’s the largest energy user in an industrial plant. With an average cost of $ 0.25 per every 1,000 SCF used, compressed air can be expensive to produce so it is very important to use this utility as efficiently as possible.

Utility companies recognize the benefit of using engineered products to reduce compressed air usage, like the ones manufactured by EXAIR, and offers rebate incentives for making a switch. Our local utility provider here in Cincinnati, Duke Energy, offers a $ 20 incentive for each replacement engineered nozzle.

 

Our Model # 1100SS 1/4″ FNPT and Model # 1101SS 1/4″ MNPT Super Air Nozzles

In their specification, the nozzle must meet a certain volumetric flow rate (SCFM) at 80 PSIG operating pressure for a given pipe size. For example, when looking at a 1/4″ nozzle, the flow rate must be less than or equal to 17 SCFM when operated at 80 PSIG. Our most popular nozzles for “general” blowoff applications would be our Model # 1100 (1/4″ FNPT) or our Model # 1101 (1/4″ MNPT) Super Air Nozzles. These nozzles require 14 SCFM @ 80 PSIG so this would be the ideal solution to reduce the air demand and take advantage of the rebate.

Here at EXAIR, much of our focus is to improve the overall efficiency of industrial compressed air operating processes and point of use compressed air operated products. If you’d like to contact one of our application engineers, we can help recommend the proper engineered solution to not only save on your compressed air usage but also assist with possible energy rebates available in your area.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

Increase Safety and Gain OSHA Compliance By Using An Engineered Solution

In 1972, the US Department of Labor’s Occupation Safety & Health Administration (OSHA) established Standard 29 CFR 1910.242(b) to reduce the outlet pressure to less than 30 psi, of an open pipe, nozzle, air gun, etc. when being used for cleaning. The intent of this directive was to prevent injury to operators. They determined that 30 psi was the pressure in which the skin could be broken if the device were dead-ended against the operator’s body, causing an injury known as an air embolism…the dead-ended force of the air, under pressure, breaks the skin and introduces air flow inside the body. This is a VERY dangerous condition which can quickly lead to serious injury, possible stroke or ultimately death.

While OSHA doesn’t recommend any type or manufacturer of device, they do provide two methods you can follow to gain compliance.

The first would be to reduce the operating pressure below 30 PSI, as shown in the below line drawing.  This, of course, limits the strength and usefulness of the exhausting air flow before it reaches the nozzle and before it is used upon the application.

 

The other method indicates using a nozzle which includes a pressure reducer or a relief device which will reduce the air pressure to less than 30 psi if the nozzle is dead ended. All of EXAIR‘s products are engineered to meet or exceed this Standard. In the case of our Super Air Nozzles, the air exits through a series of jets, recessed behind an array of fins, so the outlet holes cannot be blocked directly, any potential obstruction of the outlet air holes results in the air having an alternative route to avoid injury to operators and personnel. This allows the full pressure (the highest energy) to reach the nozzle and the application

Open air lines and homemade blow offs violate OSHA standard 1910.242(b) because of harmful dead end pressures. If you would like to discuss how EXAIR products can help you gain OSHA compliance to increase personnel safety and avoid costly fines, please give me a call, I’d be happy to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Line drawings used from OSHA’s website