Return On Investment: Does It Matter, And How Much?

I have a friend who participates in a process known as “extreme couponing.” She has multiple subscriptions to the Sunday edition of our major newspaper, and a couple of local papers that also have coupon inserts. When I see her at the grocery store, she’s got two 4″ binders full of baseball card holders, all stuffed with multiples of clipped coupons, organized by store aisle. The insane amount of money saved is a big factor in her being able to be a stay-at-home mother, which is something else she’s pretty good at.

If you get stuck at step one…or even two…extreme couponing may not be for you!

Now, extreme couponing isn’t for everyone. Even beginners to the process can buy a year’s worth of paper towels for next to nothing. However, that may take up so much room in their house that they need to rent a storage facility for other belongings that folks like you and me simply keep in the garage or basement. It also takes a LOT of time and effort to do it right – as well as discipline. Saving half (or more) on a truckload of stuff you don’t need (or will never use) is a waste of money, time, and space. In fact, I know people who have abandoned extreme couponing for those very reasons…the “return on investment” just isn’t there.

That’s the deal in industry too.  Anyone tasked with finding and exploiting efficiencies – or finding and eliminating inefficiencies – is going to be looking at return on investment.  Like extreme couponing, though, it has to make sense in all aspects of the operation.  For example:

*An OEM taking advantage of a quantity discount for components or subassemblies has to not only have the storage space available, but also has to consider the turnover rate…it costs money to keep product on the shelf.

*A machine shop considering a tooling upgrade has to compare the cost difference with the increased performance and/or lifespan of the “new and improved” product.  A tool that costs 10% more but lasts twice as long is probably a good deal.  A tool that costs twice as much but lasts 10% longer might not provide the “bang for the buck.”

*Any facility, before switching a service or utility provider, will “run the numbers” on promotional rates, contract terms, etc. before making a commitment.

Unlike extreme couponing, EXAIR makes it easy – and beneficial – to evaluate the return on investment:

*Our catalog (if you don’t have the latest, get it here) has complete performance & operational data on all of our products.  This is great if you know what you want it to do.

*If you’re not quite sure, our catalog also has a good number of actual application write-ups for most of our Intelligent Compressed Air Products.  You may be able to find something that’s similar to what you want to do, and further inform your selection from there.

*Once you’ve chosen a product, you can use the Calculator Library on our website to determine actual dollar cost savings associated with replacing a current compressed air powered device with an EXAIR product.

*Application Engineers are available to discuss your application and/or product selection via phone, email, or Live Chat.

*No matter how detailed the discussion, and how confident a plan we may make, the age-old saying about how it “looked good on paper” proves itself every now and again.  When this happens, all catalog products are covered by our 30 Day Unconditional Guarantee.  If you’re not satisfied for any reason within 30 days of purchase, we’ll arrange return for full credit.

*Let’s assume that we’re pretty good at this (because we are) and it actually DOES work out (because it usually does) – we can calculate your new (and improved) operating costs and compare them with the cost of your previous devices.  If you don’t have the instrumentation (flow meters, sound level meters, etc.,) this is a free service we provide in our Efficiency Lab.  Send it in, and we’ll do a full performance test & issue a comprehensive report, all at no charge.  And if you qualify for a Case Study, we can even save you some money on your next order.  Contact me for more details if you’re interested.

Free testing. Verifiable data. EXAIR Efficiency Lab.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

 

 

Coupon Pile Stock Photos courtesy of Carol Pyles  Creative Common License

Compressed Air Uses In Industry

Air Compressor

There are so many uses for compressed air in industry that it would be difficult to list every one of them as the list would be exhaustive.  Some of the uses are the tools used in production lines, assembly & robotic cells, painting, chemical processing, hospitals, construction, woodworking and aerospace.

It is considered as important as water, electricity, petroleum based fuels and often referred to as the fourth utility in industry. The great advantage of compressed air is the high ratio of power to weight or power to volume. In comparison to an electric motor compressed air powered equipment is smoother.  Also compressed air powered equipment generally requires less maintenance, is more reliable and economical than electric motor powered tools.  In addition they are considered on the whole as safer than electric powered devices.

Even amusement parks have used compressed air in some capacity in the operation of thrill rides like roller coasters or to enhance the “wow factor” of certain attractions. Compressed air can be found in your dentist’s office where it is used to operate drills and other equipment. You will find compressed air in the tires on your car, motorcycle and bicycles. Essentially, if you think about it, compressed air is being used nearly everywhere.

Here at EXAIR, we manufacture Intelligent Compressed Air Products to help improve the efficiency in a wide variety of industrial operations. Whether you are looking to coat a surface with an atomized mist of liquid, conserve compressed air use and energy, cool an electrical enclosure, convey parts or bulk material from one location to another or clean a conveyor belt or web, chances are we have a product that will fit your specific need.

Atomizing nozzle
Atomizing Nozzles Can Apply Even Coatings
Super Air Amplifier
Air Amplifiers pull in a large volume of ambient air to increase air flow volume and are great for cooling applications!
Heavy Duty Threaded Line Vac
For conveying heavy or abrasive products the Heavy Duty Threaded Line Vacs have male NPT Threads to make permanent and rigid installation into a piping system a breeze.

If you would like to discuss quiet, efficient compressed air products, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
Send me an email
Find us on the Web 
Follow me on Twitter
Like us on Facebook

Standards, Compliance, And You. And EXAIR.

I’m pretty impressed with the number of safety features my car has. Aside from the literal lifesaving functions like seat belts and air bags, it’s got anti-lock brakes…if you’ve ever had to counter-steer out of a skid on an icy road, you will appreciate the value of this for sure.  Those are just some of the ones I’m keenly aware of – the Federal Motor Vehicle Safety Standards comprise dozens of regulations in three categories: crash avoidance, crashworthiness, and post-crash survivability.  None of these prevent me from operating my vehicle at an unsafe rate of speed…an expensive reality that an Ohio State Highway Patrolman dutifully reminded me of last Sunday afternoon.

Likewise, there are many regulations to ensure safety and prevent hazards of all kinds in industry, administered by a host of agencies that are either subordinates of, or accountable to, the federal government.  When you manufacture products that are used with high energy sources (compressed air or high voltage electricity,) a strong commitment to safety is not negotiable.  So, at EXAIR, we commit considerable resources towards the best engineering and manufacturing practices to make our products as safe as possible.  That includes compliance with a number of standards and certifications:

The Occupational Safety and Health Administration (OSHA) is an agency of the U.S. Department of Labor.  Their mission is to “assure safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training, outreach, education and assistance.”  They are a regulatory body in the truest sense, in that they don’t offer certification or approval of products, processes, etc.; they publish guidelines and standards for manufacturers and users to comply with.  OSHA Standard 1910.242(b), for instance, limits the downstream pressure of a compressed air operated device used for cleaning purposes to 30psi. Now, you can regulate the supply pressure to meet this, but that also limits the effectiveness of the air flow generated.  EXAIR Intelligent Compressed Air Products are all designed and manufactured to be in compliance with this standard, at any supply pressure.  Take, for example, our Super Air Nozzles:

Because none of our products can be dead-ended, there’s always a relief path preventing the downstream pressure from exceeding that level.

OSHA also has Standard 1910.95(a), that sets limits for maximum allowable noise exposure.  All EXAIR Intelligent Compressed Air Products, with the exception of some our largest and most power Super Air Nozzles (which aren’t normally used in areas that don’t already require hearing protection anyway) meet the 8-hour exposure limits of this standard.

Hearing loss is the best known, but not the only, ill effect of harmful noise exposure. It can also cause physical and psychological stress, impair concentration, and contribute to workplace accidents or injuries.

CE marking indicates conformity with health, safety, and environmental protection standards for products sold withing the European Economic Area.  Unlike OSHA standards, responsibility for CE marking falls solely with the seller of the product – a CE marked product has been tested and certified to have been made in such a way to meet safety & quality benchmarks specified for that type of product.  All EXAIR products that are defined under applicable directives have been tested according to these standards, and carry the CE mark.

The Restriction of Hazardous Substances Directive, or RoHS, is another standard borne from the European Union, and is geared towards public & workplace safety by restricting the use of hazardous materials in the manufacture of electronic & electrical equipment.  Since its inception in 2006, similar standards have been vigorously adopted around the globe.  Electrical portions of EXAIR’s Static Eliminators, EFC Electronic Flow Controls, ETC Electronic Temperature Controls, Digital Flowmeters, Solenoid Valves, and Thermostats all comply with the RoHS Directive.

Section 1502 of the Dodd-Frank Wall Street Reform and Consumer Protection Act doesn’t address a concern for product users, but rather a particularly troubling human rights issue – Conflict Minerals.  For almost two decades, trade in tin, tantalum, tungsten and gold in the Democratic Republic of the Congo (DRC) has been used by some very bad people to finance violent campaigns against their neighbors.  EXAIR thoroughly and systematically documents our supply chain compliance with this act.  We are proudly committed to our support for this effort to the world a better place for everyone…especially those in desperate circumstances beyond their control.

EXAIR Intelligent Compressed Air Products have been successfully implemented into a variety of uses where application- or industry-specific standards are in force.  We’re happy to work with you to determine if our products meet those standards…or can be made to meet them.  If you’ve got such an application, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Heat Transfer – 3 Types

When you have two objects and they are of different temperatures, we know from experience that the hotter object will warm up the cooler one, or conversely, the colder object will cool down the hotter one.  We see this everyday, such as ice cooling a drink, or a fan cooling a person on a hot day.

The Second Law of Thermodynamics says that heat (energy) transfers from an object of a higher temperature to an object of a lower temperature. The higher temperature object has atoms with higher energy levels and they will move toward the lower energy atoms in order to establish an equilibrium. This movement of heat and energy is called heat transfer. There are three common types of heat transfer.13580963114_f222b3cdd9_z

Heat Transfer by Conduction

When two materials are in direct contact, heat transfers by means of conduction. The atoms of higher energy vibrate against the adjacent atoms of lower energy, which transfers energy to the lower energy atoms, cooling the hotter object and warming the cooler object. Fluids and gases are less heat conductive than solids (metals are the best heat conductors) because there are larger distances between atoms.  Solids have atoms that are closer together.

Heat Transfer by Convection

Convection describes heat transfer between a surface and a liquid or gas in motion. The faster the fluid or gas travels, the more convective heat transfer that occurs. There are two types of convection:  natural convection and forced convection. In natural convection, the motion of the fluid results from the hot atoms in the fluid moving upwards and the cooler atoms in the air flowing down to replace it, with the fluid moving under the influence of gravity. Example, a radiator puts out warm air from the top, drawing in cool air through the bottom. In forced convection, the fluid, air or a liquid, is forced to travel over the surface by a fan or pump or some other external source. Larger amounts of heat transfer are possible utilizing forced convection.

Heat Transfer by Radiation

Radiation refers to the transfer of heat through empty space. This form of heat transfer does not require a material or even air to be between the two objects; radiation heat transfer works inside of and through a vacuum, such as space. Example, the radiation energy from the sun travels through the great distance through the vacuum of space until the transfer of heat warms the Earth.

EXAIR‘s engineered compressed air products are used every day to force air over hot surfaces to cool, as well as dry and/or blow off hot materials. Let us help you to understand and solve your heat transfer situations.

To discuss your application and how an EXAIR Intelligent Compressed Air Product can improve your process, feel free to contact EXAIR, myself, or one of our other Application Engineers. We can help you determine the best solution!

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_BB

 

The picture “Energy Transfer – Heat” by Siyavula Education is licensed under CC BY 2.0

The Case For The Flat Super Air Nozzles

What do you think of when someone says “air nozzle?” Is it a crimp or a “crush” on the end of a piece of tubing? Is it a device that attaches to the end of a pipe or a hose? If so, does it have engineered features that focus the stream, amplify the flow (through entrainment, perhaps,) reduce the noise level, or provide an element of safety?

If so…you’re right. Any of the above descriptions, strictly speaking, qualify as an “air nozzle,” in fact, just a plain open-ended pipe or tube meets the criteria. As long as it serves to discharge a stream of air towards a target, it’s an air nozzle.

Even the devices with those efficient, quiet, and safe engineered features come in a variety of styles, types, and models. Consider EXAIR’s product line of Air Nozzles and Jets…we have seventy-two distinct models, in a range of sizes, materials of construction, and performance.  That’s a LOT to choose from, and it doesn’t even take into account the products that can be fitted with different shims that, technically, make them a wholly different nozzle, performance-wise.  Which brings us, dear reader, to the focus of today’s blog: the Flat Super Air Nozzle.

Flat nozzles are not unique to EXAIR…there are dozens of others on the market in a variety of sizes and materials.  What IS unique about EXAIR’s Flat Super Air Nozzles is their performance…

Efficiency: When a competitor’s flat nozzle was replaced with a Model 1122 2″ Flat Super Air Nozzle, consumption was reduced from 31 SCFM to 21.8 SCFM.  Since the nozzle was operated 24/7, this resulted in a savings in compressed air cost of $3.31 per day…meaning the nozzle paid for itself in under three weeks.

EXAIR’s Flat Super Air Nozzles have been blowing away the competition since 2003.

Durability: Both our 1″ and 2″ Flat Super Air Nozzles are available in rugged Zinc Aluminum alloy, or heat & corrosion resistant Type 316 Stainless Steel.

Zinc aluminum models are perfect for general purpose blow offs (left,) while 316SS models are specified for food/pharma and high heat or corrosive environments (right.)

Versatility: A 0.015″ thick shim is installed in the Flat Super Air Nozzles.  These provide optimal performance in a wide variety of typical industrial and commercial blow off applications.  We also offer High Power versions, with a 0.025″ thick shim, for additional flow and force.  You can also experiment with other shims, from 0.005″ to 0.030″ in thickness, for customized applications.  These shims are all 316SS, and are available in sets, or individually.  The patented design of these shims, in fact, is key to their high efficiency, as explained in this video:

Ingenuity: While this EXAIR characteristic is not specific to the Flat Super Air Nozzles, our most recent ingenious development features them: the Super Air Scraper.  By combining a scraping blade with the 2″ Flat Super Air Nozzle, we’ve turned our very popular Soft Grip Safety Air Gun into the perfect tool for easy removal of sticky or stubborn debris from most any flat surface.

Scrape off, and blow away, stubborn debris with the Model 1244-48 Soft Grip Super Air Scraper.

EXAIR Flat Super Air Nozzles are Intelligent Compressed Air Products with a 15 year history of successfully solving all kinds of air blowing applications.  To find out more about how they can work for you, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Knowing Your Symbols Is Key To Understanding Your Drawings

There are all kinds of engineering drawings, used for all kinds of purposes:

  • Pipe fitters and millwrights use Plan & Elevation drawings to make sure fluid system flanges, elbows, tees, etc., line up with each other, and don’t run into anything.
  • Exploded view drawings help maintenance folks identify parts, and, when they need replaced, make sure the new ones go in the same way the old ones came out.
  • Fabrication and machining drawings (usually to scale) are used to ensure the part being made is the right size & shape, that mounting holes are in the right place, and that critical surfaces are as flat & smooth as they need to be.
  • Then there’s the Piping & Instrumentation Diagram (P&ID)…it depicts an overall view of a system, showing the flow (usually fluid or electricity) through that system’s components, giving the viewer an understanding of the operation, and expected results from said operation.  It should not be confused with its simpler cousin, the flow chart that is so dreaded by OTE-types (“Other Than Engineer”…you know who you are,) of which these are my favorite examples:
There’s a lot of “life lesson” in these two graphics.

The big difference between a flow chart and a P&ID is the symbols.  In fact, you can find ISO & ANSI standard symbols for many components you’ll find in fluid & electrical P&ID’s.  Some examples of symbols you might find in a compressed air system are:

Compressors:

The one on the left can be used for any air compressor. The others denote specific types of air compressor (from left:) Centrifugal, Diaphragm, Piston, Rotary, and Screw.

Air preparation & handling:

The symbols on the left denote the EXAIR products on the right: Automatic Drain Filter Separator, Oil Removal Filter, and Pressure Regulator

Instrumentation and control:

The symbols on top denote the EXAIR products below (left to right): Flowmeter, Pressure Gauge, and Solenoid Valve

Occasionally, we’re asked if there are standard ANSI or ISO symbols for any of our  engineered Intelligent Compressed Air Products…and there aren’t.  Perhaps one day they might make the cut, but for now, their standard convention is to choose a shape (user preference…you’re the one it’s gotta make sense to) and call it out by name.  It might look something like this:

From top left, and then down: Automatic Drain Filter Separator, Oil Removal Filter, Pressure Regulator, and Super Air Knife

Oh, and if you’ve ever got any questions about your compressed air system that you think looking at a drawing together could help us solve, you can send that drawing to us at techelp@exair.com, and one of us will be happy to help.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

The Value Of A Pressure Regulator At Every Point Of Use

regulator
EXAIR Pressure Regulator

To understand the value of a having a Pressure Regulator at every point of use we should start with identifying the two types of Pressure Regulators, Direct Acting & Pilot Operated.  Direct Acting are the least expensive and most common (as shown above), however they may provide less control over the outlet pressure, especially if they are not sized properly.  However when sized properly they do an outstanding job.  Pilot Operated Regulators incorporate a smaller auxiliary regulator to supply the required system pressure to a large diaphragm located on the main valve that in turn regulates the pressure.  The Pilot Operated Regulators are more accurate and more expensive making them less attractive to purchase.  The focus of this Blog will be on the Direct Acting Pressure Regulator.

The Direct Acting Pressure Regulator is designed to maintain a constant and steady air pressure downstream to ensure whatever device is attached to it is operated at the minimum pressure required to achieve efficient operation.  If the end use is operated without a regulator or at a higher pressure than required, it result’s in increased air demand and energy use. To clarify this point, if you operate your compressed air system at 102 PSI it will cost you 1% more in electric costs than if the system was set to run at 100 PSI! Also noteworthy is that unregulated air demands consume about 1% more flow for every PSI of additional pressure.  Higher pressure levels can also increase equipment wear which results in higher maintenance costs and shorter equipment life.

Sizing of the Air Regulator is crucial, if it is too small to deliver the air volume required by the point of use it can cause a pressure drop in that line which is called “droop”.  Droop is defined as “the drop in pressure at the outlet of a pressure regulator, when a demand for compressed air occurs”.  One commonly used practice is to slightly oversize the pressure regulator to minimize droop.  Fortunately we at EXAIR specify the correct sized Air Regulator required to operate our devices so you will not experience the dreaded “droop”!

Standard Air Knife Kit
EXAIR Standard Air Knife Kit Which Incudes Shims, Properly Sized Pressure Regulator & Filter Separator

Another advantage to having a Pressure Regulator at every point of use is the flexibilty of making pressure adjustments to quickly change to varying production requirements.  Not every application will require a strong blast sometimes a gentle breeze will accomplish the task.  As an example one user of the EXAIR Super Air Knife employs it as an air curtain to prevent product contamination (strong blast) and another to dry different size parts (gentle breeze) coming down their conveyor.

EXAIR products are highly engineered and are so efficient that they can be operated at lower pressures and still provide exceptional performance!  This save’s you money considering compressed air on the average cost’s .25 cents per 1000 SCFM.

Super Air Knife Performance
EXAIR Super Air Knife Performance Specifications At 5 Different Pressures.

If you would like to discuss Air Regulators or quiet and efficient compressed air devices, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
Send me an email
Find us on the Web 
Follow me on Twitter
Like us on Facebook