Protect Finishes and Save Liquid with EXAIR No Drip Atomizing Nozzles

A typical “liquid-only” nozzle is capable of producing droplet sizes of 300-4,000 microns. Atomizing Nozzles’ droplet sizes are consistently under 100 microns, and can be as small as 20 microns!

In today’s market, the cost of consumable products are on the rise; especially with paints, oils, and yes, even the cost of water.  You can help ease some of that cost by being more effective in spraying.  The EXAIR Atomizing Nozzles can achieve this objective.  By using compressed air, the liquid can be sheared into small micron-sized droplets.  As a reference, if the diameter of a particle is reduced by one-half, this will multiply the number of droplets by eight.  So, smaller diameter droplets will increase the coverage area and reduce liquid requirement in your application.

EXAIR manufactures three families of Atomizing Nozzles; Internal Mix, External Mix, and Siphon Fed.  We offer a variety of spray patterns and sizes; so, you can accurately target and use the proper amount of liquid in your system.  In this blog, I will narrow my discussion to the No Drip External Mix Atomizing Nozzles.

The No Drip option is offered with all of our Atomizing Nozzles.  This patented design is used to keep the expensive liquid from dripping out of the Atomizing Nozzles during off cycles.  When the compressed air is turned off to the nozzle, a valve inside the body will create a seal on the liquid side.  This No Drip function enhances the External Mix Atomizing Nozzle for intermittent processes as the liquid remains inside the body for quick spraying. With delicate applications, the unwanted drips will not occur to ruin the finish of your product.  Unlike some manufacturers, there is no need to run a separate compressed air line to operate the no drip function.  The External Mix Atomizing Nozzles with the No Drip options can give you the best performance in efficiency, effectiveness, and flexibility without any drips.

No Drip External Mix

To expand on the External Mix Atomizing Nozzle, it atomizes the liquid outside the nozzle.  The air and liquid supply are pressurized and can be controlled independently.  This type of Atomizing Nozzle will allow for higher viscous fluids to be sprayed up to 800 CPS, similar to SAE 40W oil.  Also, with the external mixing, it helps to diminish the drying effects of solutions which will reduce shutdowns for cleaning.  EXAIR manufactures these nozzles with stainless-steel construction making them compatible with many different kinds of liquids.  They are used in many applications like washing, coating, cooling, quenching, and dust control.

Spray nozzles in action.

EXAIR stocks three different body sizes in 1/8” NPT, ¼” NPT, and ½” NPT ports; so, you can create a light mist or a monsoon.  The combination of an air cap and a liquid cap controls the spray patterns and liquid flow rates.  These caps are easily interchangeable for each body size to change the spray patterns, control the amount of fluid, and reduce any downtime for cleaning.  The amount of liquid to be applied is easily adjusted by the inlet air pressure and liquid pressure.  So, you can dial in the exact amount of fluid required for your process to stop any waste or excess.

They have a compact design to mount inside tight areas, and we also have mounting brackets for easy attachment and positioning.   If your application needs versatility, fluid savings, and precise coverage; the No Drip External Mix Atomizing Nozzles could be the nozzle for you.  If you have any questions about our Atomizing Nozzles or spraying applications, an Application Engineer at EXAIR will be happy to help you.

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

 

Benefits of an Ultrasonic Leak Detector

Ultrasonic Leak Detector

As margins get tighter and cost of manufacturing climbs, industries are looking into different areas to be more efficient.  A big focus nowadays is in their compressed air system.  Why is this?  Manufacturers are starting to realize that it takes an abundant amount of electricity to make compressed air.  That is why EXAIR manufactures compressed air products for optimization to get the best efficiency.  But what many manufacturers don’t realize is that quiet little hissing sound from there compressed air lines is costing them much money.   That is why EXAIR has the Ultrasonic Leak Detector.

Finding leaks will save you money

Energy Star, a federal voluntary program ran by the Environmental Protection Agency, offers energy-efficient solutions.  EXAIR has partnered with Energy Star because it underscores our commitment to improve energy savings.  They even wrote an excerpt about compressed air leaks here: Energy Tips: Minimize Compressed Air Leaks.  With compressed air leaks, it can be as much as 30% of your compressed air usage.

When a leak occurs, it emits an ultrasonic noise.  The EXAIR Ultrasonic Leak Detector can pick this up.  It has a frequency range from 20 KHz to 100 KHz, above human hearing, so it can make the inaudible leaks, audible.  With three sensitivity ranges and LED display, you can find very minute leaks.  It comes with headphones and two attachments; the parabola attachment to find leaks up to 20 feet (6 meters) away, and the tube attachment for local proximity to define the exact location of the leak.

In the Energy Tips from Energy Star, they reference estimated leak rates and costs associated with these leaks.  They also recommend a leak prevention program with reference materials to help improve energy savings.  As part of that program, an Ultrasonic Leak Detector is the best way to begin.

Checking pipe fittings

To tell a common success story about the Ultrasonic Leak Detector, an EXAIR customer had a 50-horsepower air compressor.  It started to overwork, overheat, and occasionally shut down.  He thought that he would need to buy a larger air compressor to keep his plant running.  In discussing his problems and requirements, he decided to purchase an Ultrasonic Leak Detector from EXAIR to check for leaks as a possible cause.  He checked every fitting and connection in his facility.  When he finished checking the compressed air system, he found 91 leaks.  (You will be surprised with your system if it is not well maintained).

If we look at a very small 1/16” (1.6mm) diameter hole at 80 PSIG (5.5 bar), it will cost you $360 a year per leak (based on 6000 working hours per year).  Thus, 91 leaks at $360/year will equal $32,760 per year.  After the fittings were reworked with piping compound, the compressor was back operating in a normal range.  There was no need to buy a larger air compressor with capital funds, and he was able to save $32,760 a year by finding and fixing the leaks.

As a little secret with the Ultrasonic Leak Detector, it can do more than find compressed air leaks.  Any issue that creates an ultrasonic noise, the Ultrasonic Leak Detector can find it.  This will include air damper seals, circuit breakers, cracked rubber belts, gas burner leaks, refrigerant leaks, worn bearings, and air brake systems on trucks.  It is a handy tool to find potential issues or problems in other areas other than compressed air systems.

For optimization of your compressed air system, it is very important to find and correct leaks in your piping system.  The Ultrasonic Leak Detector can help you do that.  It is an inexpensive way to solve an expensive problem, compressed air leaks.  If you would like to discuss the features and benefits in more detail, you can contact an Application Engineer at EXAIR.  We will be glad to help you.

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

Happy Earth Day 2019!

Today marks the 49th annual Earth Day and it will be observed in over 193 countries.  For EXAIR, this year marks our 36th year helping compressed air users save compressed air energy and electrical resources.

It is also another year that we continue to focus on manufacturing our products with minimal impact and doing our part to help protect our planet. We are proud to manufacture efficient products, implement processes and programs throughout our facility to help use our resources wisely and recycle everything we possibly can. 

First and foremost, we manufacture and sell Intelligent Compressed Air Products that are specifically designed to reduce the use of compressed air throughout facilities.  On top of that, when you purchase an EXAIR product it will arrive in fully recyclable packaging and, in most cases, is made from a material that will be recyclable should it reach a point it is no longer useful.

Over the past years we continually look for improvement opportunities within our systems and processes. Recently we have made improvements to the efficiency of our computers and computer servers which require fewer Kilowatt hours (KWH) per day. We have further reduced our wastewater for reclamation by another 17%, and minimized our own compressed air use by 1 million cubic feet.

We use our very own Chip Trapper Systems in our manufacturing areas to extend the water soluble coolant life from 6 weeks per changeover to 6 months per changeover. Keeping our coolant clean allows us to minimize the total amount of wastewater we recycle each year. 

EXAIR recycles 100% of the metal scrap from our machining processes, which equates to 6.5 tons. Our cardboard and mixed paper products are also recycled 100%. Of the waste we place into our trash dumpsters – 80% is recycled and 20% is sent to the landfill.     

In total over the past year, EXAIR recycled 36.6 tons of paper and cardboard which equates to 80% of the solid waste we produce is recycled.  We focus on more ways to improve this percentage every year.

Another waste reducing factor that has proven to work out well for EXAIR is asking every customer if they accept digital invoices rather than requiring them to be printed and mailed.   Thanks to our wonderful customers we have been able to eliminate 91% of all printed and mailed invoices which helps to reduce our resources used as well as the amount of materials that are possibly turned into solid wastes at their facilities. This also prevents the gas and vehicles necessary to deliver all of these invoices by mail. 

On top of all the efforts above, we also continue to maintain RoHS compliance on all electronic products, as well as actively track our supply chains to ensure no Conflict Minerals are being sourced from the Democratic Republic of Congo.

If you have any questions on how we can help your facility reduce their volume of compressed air or why we continue to reduce our wastes and increase our recycling efforts, contact us.

Happy Earth Day from EXAIR!

 

Image Credit: NASA/NOAA/GSFC/Suomi NPP/VIIRS/Norman Kuring

E-Vac for Epoxy Recycling

Recently, a manufacturer of custom magnetics called in about a special application. In the manufacturing of certain electronic systems, a very expensive, thick epoxy glue is used. They were exploring ways to be able to collect the excess after application.  They had used a system in the past and were looking to replicate it.  The previous system had an old boxy vacuum generator, and they asked us if we could provide a vacuum source that matched the performance specifications but in a more compact design.  After researching the specifications and a comprehensive comparison, we could offer the EXAIR model 810013 Inline E-Vac, generating up to 27 ” Hg of vacuum.  A basic sketch of the design concept is shown below-

Capture

By using the model 810013 to create a vacuum within the chamber, a strong suction can be generated at the tube inlet, strong enough to draw in the excess epoxy. The glue can be collected in the chamber for recycling and reuse, and because of the design, the glue does not pass through the E-Vac and cause any issues with build up or blockage that would hinder the performance, leading to the need to clean the unit.

In-LineE-VacFamily
The Many Sizes of E-Vac Models Available

EXAIR manufactures E-Vac’s for both porous and non-porous applications, as well as a line of Adjustable E-Vac Generators.  Smallest units use only 1.5 SCFM of 80 PSIG compressed air and the largest Adjustable E-Vac unit can pull 81 SCFM of air at open draw and 15″ Hg vacuum level setting.  With a wide range of sizes and types, there is a model available to meet your vacuum generation needs.

As a side note – the EXAIR Reversible Drum Vac, High Lift Reversible Drum Vac, Chip Trapper, and High Lift Chip Trapper all use this same basic principle of applying a vacuum to a chamber, but on a much larger scale, to turn a 5, 30, 55 or 110 gallon drum into an industrial liquid vacuum system.  The vacuum generating unit is of a different design, made specifically for the Industrial Housekeeping Products.

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

Brian Bergmann
Application Engineer

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Twitter: @EXAIR_BB

 

History of Compressed Air

The first use of compressed air did not come from compressors but the human lung. Healthy lungs can exert a pressure of .3 to 1.2 psi. Primitive people used the power of their lungs to propel darts from a blow gun. We use our lungs to blow off debris, stoke a fire, create sounds by voice and by musical instruments.

Around the third millennium B.C. , people began to melt metals such as gold, copper, tin and lead. Higher temperatures were needed requiring large volumes of air to stoke the furnaces: more than what the human lung could provide. Egyptian and Sumerian metallurgists used the wind directed through pipes for their work. Eventually tbellowhese were replaced by hand-operated bellows and then around 1500 B.C. the more efficient foot bellows came into use.

Bellows driven by foot or by water wheel proved a reliable compressor for more than 2,000 years. But as blast furnaces developed, so did the need for increased air compression. In 1762, John Smeaton built a water wheel-driven blowing cylinder that began to replace the bellows. Inventor John Wilkinson introduced an efficient blasting machine in England in 1776 and age of pneumatic energy became universally embraced.

Thus far, air compression was used mostly for the mining and the fabrication of metals. Blowing machines supplied a combustion blast to metallurgic furnaces and ventilation to underground mines. The idea of using compressed air to transmit energy became popular about 1800 when the newly invented pneumatic rock drill was used to connect Italy and France with an 8-mile rail tunnel under Mt. Cenis. This was a super feat for its time and garnered international interest spawning a flurry of inventions from air operated motors to clocks to beer dispensers.

Many engineers theorized compressed air as the energy distribution system of the future. However, electricity advocates held strong to their belief that pneumatic plants would eventually be trumped by electricity. Neither side was truly right and the debate still festers today. Much emphasis is being placed on energy conservation and the use of compressed air. The argument holds true today as it did back then, compressed air is a viable sources of transferring energy and will not go away. It’s prudent use of compressed air, as with any energy source, that is paramount.

Engine block blow off

The use of drilled or open pipe is energy wasteful. For 30 years EXAIR has been helping conserve compressed air with their engineered nozzles. These are designed to provide greater volumes of air than the volume of compressed air used which is a green alternative to drying, cooling, and blow off applications.

If you are interested in conserving your compressed air, one of our application engineers would be happy to assist you. Feel welcomed to give them a call at 1-800-903-9247 or click the chat icon in the upper left hand corner of this page.

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363
Web: http://www.exair.com
Twitter: http://www.twitter.com/exair_jp
Facebook: http://www.facebook.com/exair