Know How Much Money You Can Save with EXAIR’s Efficiency Lab

 
Free testing. Verifiable data. EXAIR Efficiency Lab.

When it comes to buying new gear for any kind of outdoor hobby the research almost becomes a full-time job to decided what to get. When I’m hanging 200 ft. in the air off of a single rope, I want to make sure that my harness, rope, and all my other gear is top notch and not going to fail me as my literal life is hanging on the line. Sometimes it would be nice to have a professional climber standing there telling you all of the pros and cons, what they like and dislike about it, and weather it’s worth the buy. Outdoor gear is expensive and climbing equipment is no exception, in an ever-changing world of innovation new things are coming out every week and is just to hard for one person to keep up with.

Similarly, EXAIR has multiple product lines, many new products, and countless applications for our products. That is where our Application Engineers come in; as experts on our products and their applications we can provide in-depth knowledge on the various uses and expected outcomes. 

EXAIR’s Products in action

EXAIR has been making compressed air products since 1983, and have since created a culture of making high quality, safe, and efficient compressed air products. With this in mind we started the Efficiency Lab program for people to take advantage to test your current pneumatic blow-off device and compare it to an EXAIR Intelligent Compressed Air product. We will generate a detailed report on our findings and send it to you for your review. This free service provided to U.S. and Canadian companies allows people to test and look into possible upgrades and cost savings.

During my time as a project and process engineer at Valeo and Tyson I wish I had known about this service.  The Efficiency Lab allows you to look at what your current process is, whether it is an open-ended pipe or some other nozzle and have EXAIR compare it to an EXAIR product for free. Its like getting a free inspection of all your gear and having an expert help you find the best replacement if needed.

You may be wondering why we offer this service; it’s simple, compressed air can be expensive and we want to save you money. Not only are open ended pipes unsafe and can violate OSHA Standards on both dead-end pressure and noise level, but they also use a lot of compressed air. To operate an 1/8” open pipe you are looking at over $2000 a year for just one pipe; there isn’t a single plant that is just going to use one pipe. That is a lot of money that can add up over time, which could easily be saved by changing out what you are using.

The Efficiency Lab is quite simple to use. The simplest way is to contact us (my info below) and we can exchange the information needed to get your product into EXAIR. Once received, we will proceed. We will then calibrate the equipment and standardized procedures to test for noise level, air consumption, and force generated. Based off of this information we will recommend a similar product. Don’t be afraid, let us take care of the hard part of choosing which product is best for your application. If you cannot send any product in, use our  Product Efficiency Survey to provide as many details as possible. 

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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Controlling Compressed Air can be Easy, and Save Thousands of Dollars

The history of automated controls can be traced back to inventors in ancient Greece & Egypt, who sought ways to keep more accurate track of time than afforded by sundials and hourglasses.  Their efforts, dating as far back as 300BC, produced devices actuated by water flow, which is actually quite reliable and repeatable: a set amount of water will flow via gravity through a fixed conduit in the exact same amount of time, every time.  These were in fairly common use until the invention of the mechanical clock in the 14th century.

The Industrial Revolution grew the need for automated processes exponentially…the need to control objects or tooling in motion, fluid flow, temperature, and pressure, just to name a few.  As time passed, the sky was literally the limit: modern aircraft & spacecraft rely on a staggering amount of automated processes from production to operation.

All throughout history, though, the benefits of automation remain the same: making processes more efficient.  That’s where the EXAIR EFC Electronic Flow Control comes in, for automating processes involving compressed air use, by turning air flow off when it’s not needed.  In fact, not only do they provide simple on/off control to blow only when a part is “seen” by the photoelectric sensor, there are eight distinct modes to incorporate delay on or off, flicker on or off, signal on/off delay, interval, or “One-Shot,” where the sensor detects the part, delays opening the valve per the timer setting, and blows for one second.

EFC Electronic Flow Control Systems are already assembled & wired for quick & easy installation.

The EXAIR EFC Electronic Flow Control is a true “plug and play” solution for automating a compressed air application.  Mount the sensor, plumb the valve, plug it in, and you’re ready to go.  There’s no complicated PLC wiring or programming, although the aforementioned mode selections do offer a great deal of flexibility other than “on when the sensor sees it; off when it doesn’t” operation, if desired.  Here are some prime examples of that flexibility, and the monetary benefits due to the compressed air consumption savings:

(Left) On/Off Delay setting used in tank refurbishment application to operate a “halo” of Super Air Knives for blow off as tanks exit oven where old paint is burnt off – $3,393 annual air savings. (Center) Interval setting actuates a Super Ion Air Knife for flat panel display dust blow off/static elimination – $2,045 annual air savings. (Right) Interval setting actuates a “halo” of Super Ion Air Knives to clean & remove static charge from plastic automotive bumper covers prior to painting – $5012 annual savings.

If you’d like to find out more about the EFC Electronic Flow Control can save you time, air, and money, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Compressed Air Efficiency – How It Benefits Business

It is estimated that typically plants can waste up to 30 percent of their generated compressed air and that cost is substantial.  Considering the average cost to generate compressed air here in the Midwest is .25 cents per 1,000 Standard Cubic Feet, that translates into .075 cents for every .25 cents spent!  Compounded with the fact that energy costs have doubled in the last five years, it couldn’t be a better time to make your air compressor system more efficient.

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The following steps will help you save air and in turn save money.

  1. Measure the air consumption to find sources that use a lot of compressed air.

Knowing where you stand with your compressed air demand is important to be able to quantify the savings once you begin to implement a compressed air optimization program. Placing a value upon your compressed air consumption will also allow you to place a value on its costs and the savings you will reap once you start to reduce your consumption. (EXAIR’s Digital Flow Meter)

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  1. Find and fix the leaks in your compressed air system.

Not fixing your compressed air system leaks can cause your system pressure to fluctuate and affect your equipment negatively. It may cause you to run a larger compressor than necessary for your compressed air needs and raise your total costs. Or it could cause your cycle and run times to increase which leads to increased maintenance to the entire system. (EXAIR’s Ultrasonic Leak Detector)

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  1. Upgrade your blow off, cooling and drying operations using engineered compressed air products.

Your ordinary nozzle with a through hole and a cross drilled hole can be an easy choice based upon price, but if you do not consider the operating cost you do not really know how much it is costing you. An Engineered Air Nozzle will pay for itself and lower operating costs quickly. Engineered Air Nozzles are the future of compressed air efficiency and are made to replace ordinary nozzles, homemade nozzles and open line blow offs. Engineered Nozzles reduce air consumption and noise levels; ordinary nozzles cannot compete. Engineered Nozzles maintain safety features and can qualify for an energy savings rebate from a local utility; ordinary nozzles fall short. Open blow off or homemade blow off applications typically violate OSHA safety standards; Engineered Nozzles do not.  (EXAIR’s Air Nozzles)

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EXAIR Nozzles
  1. Turn off the compressed air when it is not in use.

Automated solutions add solenoid valves and run them from your machine controls. If the machine is off, or the conveyor has stopped – close the solenoid valve and save the air.  And blow off applications can benefit from any space in between parts by turning the air off during the gaps with the aid of a sensor and solenoid. (EXAIR’s automated  Electronic Flow Control)

 

  1. Use intermediate storage of compressed air near the point of use.

Also known as secondary receivers, intermediate air storage is especially effective when a system has shifting demands or large volume use in a specific area. Intermediate storage is the buffer between a large demand event and the output of your compressor. The buffer created by intermediate storage (secondary receiver) prevents pressure fluctuations which may impact other end use operations and affect your end product quality. (EXAIR’s Receiver Tanks)

  1. Control the air pressure at the point of use to minimize air consumption.

This is a very simple and easy process, all it requires is a pressure regulator. Installing a pressure regulator at all of your point of use applications will allow you to lower the pressure of these applications to the lowest pressure possible for success. Lowering the pressure of the application also lowers the air consumption. And it naturally follows that lower air consumption equals energy savings. (EXAIR’s Pressure Regulators)

By increasing your awareness of the health of your air compressor system and implementing a PM program you can significantly reduce your costs from wasted energy and avoid costly down time from an out of service air compressor.

If you would like to discuss improving your compressed air efficiency or any of EXAIR’s engineered solutions, I would enjoy hearing from you…give me a call.

Jordan Shouse
Application Engineer
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Video Blog: EXAIR’s Efficiency Lab

If you’d like to know how efficient (or not,) quiet (or not,) and effective (or not) your current compressed air devices are, the EXAIR Efficiency Lab can help.  For more details, we hope you’ll enjoy this short video.

If you’d like to talk about getting the most out of your compressed air system, we’d love to hear from you.

Russ Bowman
Application Engineer
EXAIR Corporation
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