Six Steps to Compressed Air Optimization: Step 3 – Use Efficient and Quiet Engineered Products

Compressed air is expensive, and you should treat it that way.  Frequent readers of the EXAIR Blog are familiar with our Six Steps to Compressed Air Optimization, and you may have seen these recent installments on Steps 1 and 2:

Six Steps to Optimization: Step 1 – Measure the Air Consumption

Six Steps to Compressed Air Optimization: Step 2 – Find and Fix Leaks

Now, there isn’t a strict order in which you MUST perform these steps, and they’re not all applicable in every air system (looking at you, Step 5: Use Intermediate Storage,) but these are likely the steps that a certified auditor will take, and the order in which they’ll take them.  If you’re looking for immediate, quantifiable results, though, Step 3 is a great place to start.  Consider:

  • A 1/4″ copper tube blow off can consume as much as 33 SCFM when supplied with compressed air at 80psig.  It’ll give you a good, strong blow off, for sure.  You can crimp the end and get that down to, say, 20 SCFM or so.  Or, you can install a Model 1100 Super Air Nozzle with a compression fitting, and drop that to just 14 SCFM.
    • If you’re tracking your compressed air usage, you’ll see that replacing just one of them saves you 45,600 Standard Cubic Feet worth of compressed in one 5 day (8 hour a day) work week.  That’s $11.40 in air generation cost savings, for a $42 (2020 List Price) investment.
    • If you spend time in the space where it’s installed, you’ll notice a dramatic improvement in the noise situation.  That sound level from the copper tube is likely over 100 dBA; the Super Air Nozzle’s is only 74 dBA.
This user was only a handful of compression fittings & nozzles away from over $800 in annual compressed air savings.
  • Drilled pipes are another common method to create a blow off.  They’re easy & cheap, but loud & expensive to operate.
    • A pipe drilled with 1/8″ holes and supplied @80psig will consume 13 SCFM per hole, and the holes are typically drilled on 1/2″ centers.
    • An EXAIR Super Air Knife consumes only 2.9 SCFM per inch of length, and because it’s an engineered product, it’s a LOT quieter as well.  Drilled pipes are, essentially, open ended blow offs just like the copper tube mentioned above.  When you let compressed air out of a hole like that, all the potential energy of the pressure is converted to force…and noise.
    • Drilled pipes are among the worst offenders; almost always well in excess of 100 dBA.  Super Air Knives generate a sound level of only 69 dBA with 80psig compressed air supply.  They are, in fact, the quietest compressed air blowing product on the market today.
This Model 110048 48″ Aluminum Super Air Knife replaced a drilled pipe for over $5,000 annual compressed air savings.

These aren’t just theoretical “for instances” either – the data, and the photos above, come from actual Case Studies we’ve performed with real live users of our products.  You can find them here, and here (registration required.)

These are two examples of EXAIR product users who only used Step 3 of our Six Steps, although BOTH of them were already practicing Step 4 (Turn off the compressed air when it isn’t in use)…they had their blow offs supplied through solenoid valves that were wired into the respective machine controls, and the Air Knife user HAD to do Step 6 (Control the air pressure at the point of use) to keep their product from being blown clear off the conveyor..

But we’ll be happy to help you with optimizing your compressed air system using any or all of the Six Steps. Give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Super Blast Safety Air Gun Improves Cleanup Process

I had the pleasure of helping a caller out with a cleanup problem not long ago.  Normally, calls involving cleanups involve a discussion of how our Industrial Housekeeping Products might replace an electric shop vacuum or sump pump, but this one was about replacing a broom…with a Super Blast Safety Air Gun.

Now, I need to mention that the folks at Compressed Air Challenge have a list of Inappropriate Uses Of Compressed Air.  Using compressed air for cleaning is on that list, and I couldn’t agree more…as a blanket statement, that is.  Of course, the last paragraph of their document makes it clear that good judgement can, and should, always rule the day: “if safety enhancements, significant productivity gains, or labor reductions will result,” they say, a compressed air solution is certainly worth considering.

That’s exactly what the caller and I did.

See, he works in an equipment service shop.  Their technicians make the company money through billable labor – the time they spend fixing their customers’ equipment.  Of course, they have to spend time on tasks that aren’t billable to jobs…like tool maintenance, paperwork, and keeping a clean shop.  A particular item from a shop audit that caught his attention was the amount of time spent sweeping the floor in the welding area.  Not only did slag & dust get all over the floor out in the open, it accumulated under tables and behind the welding machines themselves.  This meant that technicians had to get down on their hands & knees, and reach brooms under those tables.  Not only was this cumbersome; it wasn’t even 100% effective…when replacing a machine recently, they discovered a surprising amount of debris in a “blind spot” that the broom just couldn’t reach.

After a discussion of the engineered Super Air Nozzles that are available on the Super Blast Safety Air Guns, the caller liked the idea of the Model 1213-7-3.  The hard hitting, tight air flow pattern of the Super Air Nozzle Cluster at the end of a 3 foot extension gave the perfect combination of power & reach for his application.

Super Blast Safety Air Gun makes short work of large area cleanup.

So, at the end of the day, (literally…that’s cleanup time, right?) a task that previously took about 10 minutes for them was reduced to just under two minutes.  Of course, that doesn’t figure in the cost of the compressed air.  The Department of Energy uses a thumbrule that states it costs $0.25 to generate 1,000 Standard Cubic Feet of compressed air.  At 98 SCFM @80psig, the Super Blast Safety Air Gun’s Cluster DOES use a decent amount of compressed air, so we did the math:

98 SCFM X 2 minutes X $0.25/1,000 SCF =   $0.049

We didn’t need to get in to payroll records, employee benefit packages, etc., to realize that an 80% reduction in labor, improved cleanup (air reaches where the brooms couldn’t,) and worker satisfaction (no more crawling along the floor beside the tables) was worth a nickel a day.

The Super Blast Safety Air Gun can be fitted with a variety of Super Air Nozzles, from our Model 1112 3/4 NPT Super Air Nozzle (4.5lbf at 12″) , to our Model 1120 1-1/4 NPT Super Air Nozzle (23lbf at 12″).

As an Application Engineer, I’m always looking for the best ways to apply our products, and quantify the benefits.  If you call me to discuss an application and the math doesn’t prove it out, I’ll let you know.  If you have a task you’re considering a compressed air solution for, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Tried and True Products with Modern Performance and Safety Features

Over Labor Day I got the chance to take my dad and his friend climbing in Seneca Rocks West Virginia for the first time in a very long time. Seneca Rocks is a large Quartzite knife edge located in the Monongahela National forest on route 33. The majority of climbing there is what is known as Trad Climbing, which is just short for traditional climbing and is where one must place their own protection to clip the rope into (also pray it holds when you fall). Trad climbing requires a strong mental fortitude and precise physical movements as you jam different parts of your body into various sized cracks.

Me on the left and my Dad’s friend at the trail head for the hike to “the walls”.

In the ever-expanding world of new technology and advancements of outdoor adventure gear, all trad climbers stick with the same gear that was used some 30+ years ago. Although the materials and performance have improved the very principle and mechanics behind them has not. In this case the old saying “If it ain’t broke don’t fix it!” rings true. Sometimes when it comes to a solution, whether its hanging 200’ in the air or updating a process line, traditional is a great choice due to its simplicity and effectiveness.

Compressed air has been around since 1799 but the idea has been around since 3rd Century B.C. making it one of the oldest utilities next to running water. When it comes to manufacturing applications it’s about as tried and true as you can get, so why not look into our engineered products to help you solve your issues. Their simplicity and effectiveness remain, while their efficiency, safety and performance have been engineered to modern day needs.  These modern needs have insisted that products be safer and more efficient then they were 30+ years ago.  

One example of this is EXAIR’s Vortex Tube. Vortex tubes where discovered in 1931 and were exposed to industrial manufacturing in 1945. EXAIR improved upon them when the company began in 1983. Today they are still used for various cooling applications such as replacing mist coolant on CNC machines, cooling down plastic parts during ultrasonic welding, and keeping electrical cabinets cool so they don’t overheat.

Another example is air nozzles, nozzles are used for many different purposes like cleaning or cooling parts. If you are using nozzles from 30 years ago because they are effective, there is a good chance you can improve you r efficiency and increase safety for your personnel with EXAIR’s engineered Super Air Nozzles. They are designed in a variety of styles to fit your needs from tiny micro nozzles to massive cluster nozzles to blow off or cool  a multitude of parts and processes. 

Sub-zero air flow with no moving parts. 3400 Series Vortex Tubes from EXAIR.

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
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EXAIR’s Flat Super Air Nozzles Serve a Variety of Applications

EXAIR’s line of 1” and 2” Flat Super Air Nozzles are rugged, efficient, and ideal for applications that require a wide forceful stream of airflow. The patented design utilizes a special shim to maintain the critical position of the component parts. The result is a laminar, high velocity blast of air with minimum air consumption and sound level.

The Flat Super Air Nozzles are available in a wide range of configurations. With both the 1” and 2” sizes you have the ability to select either Zinc Aluminum alloy or Type 316 Stainless Steel for higher temperature or corrosive applications. They’re also available installed at the end of our Safety Air Guns. The 1” Flat Super Air Nozzles are ideal for our VariBlast Compact Safety Air Gun while the 2” is suitable on either our Soft Grip Safety Air Gun or the Heavy Duty Safety Air Gun. With extensions ranging from 6”-72” and Chip Shields also available, you have the ability to tailor a blowoff gun to your exact application. Since the design of the nozzle prevents any chance for it to be dead-ended, all configurations will be compliant with OSHA directive 29 CFR 1910.242(b). This means you’re able to operate at pressures in excess of 30 PSIG without risking harm to your operators.

In addition to two different sizes and materials, there’s also a wide range of shims that can be installed. Just like the Super Air Knife, the thickness of the shim installed (in addition to the input compressed air pressure) will dictate the force and flow through the nozzle. For both the 1” and 2” Flat Super Air Nozzles, shim thicknesses are available ranging from .005”-.030”. Thicker shims will increase the force and flow, thinner shims will reduce it while also reducing the air consumption. To allow you to experiment with different flows, we make shim sets available that’ll allow you to test out a few different sizes in order to determine the best solution for your application.

EXAIR 1″ and 2″ Flat Super Air Nozzles can be fitted with a variety of shims for variable performance.

New to EXAIR in 2018, the Model 1144 2” Super Air Scraper is a patent pending nozzle used to remove stuck-on debris from work or machine surfaces. It incorporates a strong corrosion resistant scraper blade to add necessary leverage to allow you to get underneath and scrape away debris. The strong airflow from the 2” Flat Super Air Nozzle then is able to get underneath and blow away the material. The scraper nozzle is great for applications involving the removal of tape from floors, gaskets, adhesive, labels and stickers, grease, paint and sealant. It’s also available on the end of our Soft Grip Safety Air Gun with durable ¾” air extensions in lengths ranging from 6”-72” and Chip Shields.

You may have seen (or used) the plastic flat nozzles that come in a variety of different colors. EXAIR’s Flat Super Air Nozzle is a safe, efficient replacement that will maintain a similar airflow pattern at a dramatically reduced operating cost. EXAIR’s flat nozzles also offer a reduced sound level compared to these styles of nozzle. Reducing sound is another directive that OSHA 29 CFR 1910.95 outlines. If you’re using an unsafe nozzle in your facility, OSHA can quickly begin assessing fines for each violation. They don’t announce their visits beforehand, so make sure you do your due diligence and assess your compressed air usage yourself!

All of these possibilities are available from stock with same day shipments. EXAIR’s wide-range of solutions allow you to customize the product to your exact specifications. Stop wasting time and money replacing cheap plastic air nozzles, get yourself a nozzle that’s Built to Last by EXAIR!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_td