HEPA Vac Improves Cleaning Process AND Keeps Operators Safe!

On a recent visit with our Hungarian Distributor, I had the pleasure of visiting an automotive leather manufacturing plant. They process and cut to order a wide variety of different styles of leather used in the manufacturing of European automobiles. In one of their machines, a grinding process is performed that smooths out the cut edges of the material before they’re stitched together.

The grinding process itself is self-contained within the machine, but the significant amount of leather dust created needs to be periodically cleaned out. If not, it ends up accumulating on some of the internal components and increasing the downtime and maintenance required on the machine. Due to this, they implemented a 2x per shift cleaning operation.

The machine has several tight spaces inside where the dust accumulates. They’d shut off the machine and blow out the dust. Then, sweep up all of the dust into a dustpan and dump it in the trash. This entire process took approximately 30 minutes each time for 1-hr/shift. With three shifts operating 24/7, that’s 3-hrs/day of lost production time for this particular cleaning process, still less than what they were experiencing as a result of the machine downtime when they weren’t regularly cleaning it.

HDHEPAVac559

However, the primary concern of theirs was that they were now blowing dust all over the shop causing a potential health hazard to their operators. They wanted a solution that would allow them to clean the machine, without presenting an additional hazard. We tested with a Mini Chip Vac first, but the dust was a bit too fine and was still passing through the filter bag.

For fine dusts such as this, the Heavy Duty HEPA Vac is the more suitable option. After testing the Heavy Duty HEPA Vac, it was clear that this was the solution they were hoping for. The high-powered vacuum made quick work of the dust inside, while keeping it contained inside of the drum by the HEPA filter.

They still need to stop and clean the machine out 2x/shift, but now the process only took 10 minutes. They reduced their overall downtime on this machine per day by 2/3 to just 1hr, while keeping their operators safe. While this wasn’t the reason for looking at new solutions, it was definitely an added benefit. If you’re looking for a maintenance-free vacuum system for cleaning up in your facility, EXAIR has a wide range of Industrial Housekeeping solutions available from stock.

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

Porous and Non-Porous E-Vac Vacuum Generators

Getting a vacuum from compressed air seems a bit like magic, but it works and it works well. EXAIR’s E-Vac® Vacuum Generators are compressed air powered, single stage vacuum generators. They are a low cost way to create vacuum for pick and place, clamping, lifting, chucking, vacuum forming and other applications.

The Low Vacuum Generators are ideal for ‘porous’ types of applications.  When we say ‘porous’ we are describing those processes where a lighter vacuum level combined with higher vacuum flows are needed. A good example of this is lifting a cardboard box. The cardboard is not air tight, and when you place a vacuum on it, air is able to be pulled through the cardboard. To maintain the vacuum level, the air needs to be able to be pulled through the cardboard and exhausted as fast as it is being pulled through in order to maintain the vacuum level. This requires higher vacuum flow and the design of the Low Vacuum Generator allows for the development of a good vacuum level and a high rate of vacuum flow.

The High Vacuum Generator is ideal for ‘non-porous’ type of applications. ‘Non-porous’ are those processes where the material is air tight, and no or very little air can pass through. Material such as glass, ceramic, and steel are ‘non-porous’. Because little or no air passes through, the need for high vacuum flow is not as important, and the highest of vacuum level can be achieved. A perfect vacuum is 29.92 in-Hg, and the High Vacuum Generator is designed to reach vacuum levels of 27 in-Hg, or a 90% vacuum level.

 

E-Vac Video

 

Click above Image to View the Video

Both the Low Vacuum and High Vacuum Generators come in 7 different sizes, ranging from light to very strong vacuum capabilities, to match any application. Special Kits are  available as a way to experiment with an assortment of vacuum cups to determine the best configuration.

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E-Vac Kit

And for maximum flexibility, EXAIR offers the Adjustable E-Vac Vacuum Generator. Engineered for high efficiency, compressed air can be minimized due to the ability to adjust and tune the vacuum flow and level to perfectly match the application requirements.

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Lifting a Concrete Block with the Adjustable E-Vac Vacuum Generator

If you have questions about vacuum generation and the E-Vac or any of the 15 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

 

Brian Bergmann
Application Engineer
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Compressed Air Vacuums and Their Advantages Over Electric Vacuums

EXAIR‘s line of Industrial Housekeeping Products consist of liquid and dry vacuums that utilize compressed air to operate. They do not have loud electric motors which most ‘all purpose’ electric vacuums rely on.  In industrial settings with harsh conditions and rugged use, EXAIR’s Industrial Housekeeping Products are better suited for the everyday wear and tear of typical manufacturing, commercial and construction environments.

When you look at EXAIR vacuums, you’ll notice there is not an electrical cord.  Because the EXAIR Industrial Housekeeping Products utilize compressed air for operation. This means they do not have the same maintenance issues of an electric motor which breakdown and fail when dirt, dust and temperature take their normal toll on moving parts. With EXAIR vacuums there are no moving parts: no motors to burn up, no bearings to wear out, and no impellers to clog in the vacuum units. They also run quieter than a typical electric vacuum.

They are maintenance free, just supply clean and filtered air, and they can operate for many, many years.

 

EXAIR’s liquid vacuums, there is a built in pressure/vacuum relief device and auto safety shut-off to prevent over-filling.

The Reversible Drum Vac is a two-way liquid pumping system, also made for mounting on standard steel drums…closed top drums, in this case.  They can fill or empty a 55 gallon drum in 90 seconds.  Options include 5, 30, and 110 gallon drum sizes, and a High Lift model – increased suction head for deep wells, underground tanks, or higher viscosity liquids, up to 1,400 cP.

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The heart of our popular coolant filtration system: the EXAIR Chip Trapper.  A Filter Bag in the “fill” line traps chips, swarf, and shavings.  The liquid passes through, and is able to be immediately pumped back out.  Not only is coolant life extended, regular cleaning of the coolant sump prevents loss of coolant flow due to clogging of the supply lines.  The Chip Trapper is available in 30, 55, and 110 gallon sizes, and also in the High Lift version.

Chip Trapper Family
30 gallon, 55 gallon, and 110 gallon Chip Trapper

EXAIR’s dry vacuums provide many pickup and filtration options. They withstand harsh environments, have many filtration and power options and run quieter than electric vacuums.

The EXAIR Chip Vac and Heavy Duty Dry Vac is a powerful industrial vacuum for use on wet or dry chips. Both are for use with 30, 55, or 110 gallon drums, and the Chip Vac can also be used on a 5 gallon drum. The Heavy Duty HEPA Vac has the added benefit of the HEPA quality filter system.  Filtration per IEST-RP-CC-007 to 99.97% minimum filtration at the 0.3 micron level ensures performance meets the needed criteria.

The Chip Vac is also 50% quieter than a comparable electric vacuum at only 77 dBA!!

Chip Vacs-all
From left to right: 5 gallon, 30 gallon, 55 gallon, and 110 gallon Chip Vacs are sized for any cleanup need.

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

Jordan Shouse
Application Engineer
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Built to Last Liquid Vacuum Systems Made by EXAIR

Baseball season is in full swing, temperatures are climbing, and there’s pollen in the air. It must be spring!! The coming of spring means it’s time to start opening up the windows and tidying up around the house. It also means an increase in rain showers. To those of you out there that have experienced the joy of walking down into the basement only to find a nice pool of water I feel your pain. A crack in our foundation allowed a significant amount of water to seep inside, of course all over the brand-new carpet!!

I went out to the garage and grabbed the ol’ trusty shop vac and began vacuuming up as much residual water as I could. Shop vacs are a great tool for cleaning up a variety of messes in your home. However, the very same shop vac is not suitable for use in an industrial environment. EXAIR manufactures a variety of compressed air operated industrial vacuum systems. For the purpose of this blog, I’m going to highlight the systems suitable for use with wet materials.

Electric vacuums have impellers that can clog or break, the motor will eventually burn out, not to mention the risks associated with using electrical products near liquid. With no electricity and no moving parts to wear out, EXAIR’s Industrial Housekeeping products are much better suited to withstand a harsh industrial environment.

The Reversible Drum Vac attaches quickly to any closed head 30, 55, or 110 gallon drum. It’s capable of filling a 55 gallon drum in as little as 90 seconds! With a simple turn of the knob, it’s able to quickly pump the liquid back out of the drum. Coolant sumps can easily be refilled, floor spills contained, or contaminated liquids can be transferred to filtration tanks in minutes.

The High Lift Reversible Drum Vac operates just the same as the standard, but provides a higher-powered vacuum for use with thicker liquids or for applications that need to lift the liquid from below grade work areas up to 15’ deep. Both the standard and High Lift Reversible Drum Vacs have an automatic safety shutoff valve to prevent the drum from overfilling.

CTR_dirtychiptrapperfamily

The Reversible Drum Vac is also the heart behind our award-winning coolant filtration system: the Chip Trapper. The Chip Trapper is a fast and simple way to clean chips, swarf, and shavings suspended in the coolant sump of your CNC machines. The liquid and suspended solids are vacuumed up into the drum. A filter bag inside traps the debris, chips, and shavings and allows you to pump clean liquid back out of the drum. The filter bag can be removed and cleaned for repeated use. Each system will come with (2) bags to get you started. Not only does this extend the life of your coolant, but can also eliminate the potential for chips and shavings to get clogged in the coolant system and reducing coolant flow. It, too, is available as a High Lift Chip Trapper System for thicker liquids or sumps that are below ground.

If you’re looking for a vacuum system that’s Built to Last, EXAIR has the right tool for you. All of our vacuum systems have no moving parts to wear out and are maintenance-free when supplied with clean and dry compressed air. With all systems available in stock and same day shipment for stock items, you can have one just in time for your annual spring cleaning!

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

Vacuum Generator Accessories

In my last blog, I went over How to Choose/Build an E-Vac system, and you can read about that here–  The E-Vac’s are a compressed air powered, single stage vacuum generator, providing a low cost solution for creating a vacuum for many applications. Today, we will look at the many accessories that are available to complete a vacuum system best suited to your vacuum application.

For pick and place operations and hold down or clamping processes, we offer an array of Vacuum Cups. Available from stock are small and large Round, Oval, and Bellows styles. Round cups are best suited for smooth, flat surfaces.  Oval cups provide the most vacuum due to the larger surface area, making them ideal for lifting heavy loads. The Bellows style is best suited for textured or uneven surfaces, where the folds provide a collapsible area that allows the cup to compress and seal to the uneven surface.

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Small and Large Round, Oval and Bellows Vacuum Cups

For vacuum processes where personnel are nearby, there are two (2) types of mufflers available to reduce the sound level to comply with the limits OSHA Standard 29 CFR – 1910.95(a) has established. The EXAIR E-Vac Mufflers are designed so that the E-Vac exhaust is not impeded, so that the highest and fastest vacuum response is achieved. The Standard Muffler (for use with In-Line E-Vacs only) has a closed end and is best suited for vacuum draws that are free from dust and debris.  The Straight Through Muffler is open all the way through and is recommended for those vacuum draws where there will be dirt and debris, since it will not plug up. The Straight Through style offers the best sound level reduction, up to 26 dBA.

E-Vac Mufflers
Standard and Straight Through Mufflers

The vacuum port of the E-Vacs has an NPT threaded connection and with a suitable connector, a vacuum cup can be closely installed, minimizing the system air volume. When vacuum cups are to be remotely mounted, Push-In Connector Type Fittings of assorted styles are available along with the polyurethane tubing to make the installation and vacuum plumbing a cinch.

E-Vac Fittings
Push-In , Swivel Elbow, Swivel Branch Tee, and Bulkhead Connectors

And finally, to get the best performance and maintenance free operation from your E-Vac, always use a source of clean, dry compressed air. We can help you do that with a wide array of Automatic Drain Filter Separators and Oil Removal Filters sized to pair up with the various E-Vac’s. Also available are Pressure Regulators, Vacuum Gauges, Manual Shut Off Valves, Solenoid Valves, and Compressed Air Hose.

If you have questions about E-Vacs and accessories or any of the 15 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer
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Vac-u-Gun: Low Cost Vacuum, Blowoff and Transfer

What is the Vac-u-Gun?  It is a low cost solution to many types of cleaning operations within an industrial setting.  The Vac-u-Gun is a vacuum gun, a blow gun, and a transfer tool, all-in-one! It is lightweight, easy to use, has durable die cast construction, and best of all, no moving parts to wear out. Simply hook up to a compressed air hose, and get to work.

Vac u Gun Hose

The Vac-u-Gun contains a nozzle insert that dictates the direction of air flow and operation. By simply unscrewing the the cap, reversing the orientation of the nozzle insert, and re-installing the cap, the gun is changed from a vacuum device to a blowoff device, and vice-versa.

vac u gun orientation
Reverse the direction of the nozzle insert to change from vacuum to blowoff

The Vac-u-Gun can be used in three modes- Vacuum, Transfer and Blowoff-

Vacuum Mode – Vacuum shavings, absorbents, sawdust, or spills into a reusable bag, or into a receptacle via the vacuum hose. Why blow it off and the have to sweep it up later?

Transfer Mode – Transfer small parts, pellets, or trim over long distances, using the smooth bore vacuum hose.

Blowoff Mode – Blow chips, water, coolant, or scrap away from the work area. The large 1-1/4″ diameter outlet directs the air over a larger area in less time. The Vac-u-Gun uses less compressed air than an ordinary blow gun.

Vac-U-Gun Specifications

There are many advantages to a Vac-u-Gun, and some are:

Low cost, no moving parts/maintenance free, durable die cast construction, easy to switch form vacuum to blow mode, safe – no electricity, meets OSHA pressure requirements, lightweight and portable, versatile, and quiet.

Versatile!  In just seconds, the Vac-u-Gun can transform from a powerful, handheld vacuum tool into an efficient blow gun or transfer tool for lightweight materials. Each Vac-u-Gun System comes with the attachments needed to suit numerous industrial applications.

Three (3) Vac-u-Gun System options are available and shown below-

Vac-u-Gun System Options

All of the Systems include the Vac-u-Gun, brush, crevice tool, skimmer tool and (2) extension wands.

The Model 6192 Collection System also includes the reusable bag with clamp for debris collection.

The Model 6292 Transfer System also includes the vacuum hose, for transferring the debris to a collection point.

The Model 6392 All Purpose System also includes both the reusable bag and clamp and the transfer hose, providing the most versatility of all.

To view a video that shows the Model 6392 All Purpose System, and demonstrates how it works, please view the video below-

 

If you have questions about the Vac-u-Gun or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
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E-Vac Vacuum Generators- For More Than Just Pick and Place

A textbook application for vacuum generators is the ‘pick and place’ function.  With ever increasing automation and robotic cells, more and more opportunities present themselves to utilize the E-Vac Vacuum Generator as a part of the system to ‘pick up’ an object and ‘place’ it in a new position. But the E-Vac’s can be used for many more types of applications.

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In-Line E-Vac

Another popular usage is to hold something in place. One of our customers uses an array of Adjustable E-Vacs to pull a vacuum and hold down various sizes of Styrofoam sheets during a machining operation. The previous system was a 1 hp blower type, and did not offer any flexibility for handling different size sheets. Sheets would slip and produce off quality results. After installing the new design, the system was able to handle any size sheet, and scrap levels went down dramatically.

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Adjustable E-Vac

A unique implication that was solved with an E-Vac was to deflate sporting balls.  The customer printed custom logos, and preferred the items to be flat for the printing operation. Using a commercial grade electric shop vac didn’t completely deflate the balls, and motors burned out often.  Using a low vacuum In-Line E-Vac with a quiet Straight Through Muffler, the customer can now quickly and quietly, fully deflate the balls.

Another popular use for the E-Vac is to pull a vacuum for drawing up liquids or gases. A customer that manufactures automotive seats was having issues with the process, where the expanding foam was producing a gas, and the gas would produce pockets and voids in the foam after setting.  The customer used a model 800017 In-Line E-Vac to create a vacuum inside the mold and draw off the gas, eliminating the pockets and the voids in the final product.

Lastly, as I am big fan of recycling, anything and everything, we worked with a customer that recycles the old CRT style of computer monitor  (remember those?) The housing would be sawed in half, so that access to the internal components could be made. Because of the variability in the size and shape of the monitors, the customer was using an adjustable chuck system, which took time to set-up for every monitor, each being a bit different. To speed up the process, an EXAIR In-Line E-Vac and 5″ Suction Cup was implemented, and the monitor held in place by the screen, which was was very consistent in shape from monitor to monitor. This change reduced the set-up time required.

These and other Applications for the E-VACs and all other EXAIR products can be found on the EXAIR website on the Products page, under the Related Info section toward the bottom of each page.

If you have questions regarding E-Vac Vacuum Generators or any EXAIR Intelligent Compressed Air® Product, 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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Twitter: @EXAIR_BB