Efficiency Lab Leads To Big Savings

EXAIR Corporation manufactures quiet, safe, and efficient compressed air products for industry. We want our customers to get the most out of our products, and, in turn, their compressed air systems. To do that, we offer a unique service called the EXAIR Efficiency Lab. Here’s how it works:

  • An Application Engineer can arrange to have your existing compressed air device(s) sent in to our facility.
  • We’ll use our calibrated test equipment to measure the compressed air consumption, sound level, and force applied of those devices.
  • You’ll receive a detailed test report, along with our recommendations to implement an efficient, quiet, and safety compliant solution.
  • We’ll even send your tested device(s) back to you, at no charge, if you wish.

I recently had the pleasure of conducting just such a test on some air guns.  The caller was the Environmental Health & Safety Director for a plastics manufacturer.  The main concern was safety compliance…a recent audit had shown that some workstations were using handheld blowoff devices that did not comply with OSHA standard 1910.242(b), which limits dead end pressure of compressed air products used for cleaning to 30psi.

After discussing their typical uses for these (and other) air guns, they sent in a couple for testing.  Here’s what we found out:

“Thumb guns” are especially popular for blowoff because of their compact size, ergonomic design. and low price.

The air gun with the 7″ straight extension (top) is a “textbook” example of non-compliance with OSHA standard 1910.242(b).  Because it has an open-end discharge with no relief path, this one could cause an air embolism if it were inadvertently dead-ended into the operator’s skin – a potentially fatal condition.  It also uses a considerable amount of compressed air, and is quite loud.  At 80psig supply pressure:

  • Compressed air consumption is 40.7 SCFM
  • Noise level is 95.5dBA
  • Force applied, at a distance of 12″, is 13oz

For comparison’s sake, EXAIR Model 1210-6 Soft Grip Safety Air Gun is fitted with our Super Air Nozzle, on the end of a 6″ rigid extension:

  • Compressed air consumption is 14 SCFM
  • Sound level is 74dBA
  • Force applied, at a distance of 12″, is 13oz…same as theirs.
Model 1210 Soft Grip Safety Air is fitted with an EXAIR Super Air Nozzle. We can also supply it with a Rigid Extension and Chip Shield (right).

The other one is OSHA compliant (it can’t be dead-ended…the cross-drilled hole provides a relief path, but it was still pretty inefficient and loud.  At our standard test pressure of 80psig:

  • Compressed air consumption is 30.8 SCFM
  • Noise level is 94.8dBA
  • Force applied, at a distance of 12″, is 16.9oz

Although the force generated by the Model 1210 Soft Grip Safety Air Gun isn’t quite as high as theirs, it’s still our recommendation here.  Oftentimes, the flow and velocity generated by the engineered Super Air Nozzle is more than capable of meeting the needs of the typical blow off applications these types of air guns are used in.

EXAIR Efficiency Lab testing proves that replacing these air guns with our Soft Grip Safety Air Guns (or at least replacing the tips with EXAIR Super Air Nozzles…we also have adapters for that) will result in compressed air savings of 66% and 55%, respectively, and lower sound levels to within OSHA standard 1910.95(a) limits:

All EXAIR Soft Grip Safety Air Guns comply with these limits for 8 hour exposure.

If you’d like to know more about the efficiency & safety (or lack thereof) of your current air blow off devices, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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Ion Air Cannon Keeps Paper Recycling Baler Working

One of the cruelest pranks I’ve ever been party to happened during my time in the United States Navy. All it took was:

  • A cigar box
  • A rubber band
  • The scrap “dots” from every 3-hole punch we could find

We cut the lid off the cigar box, filled it with the “dots,” used the lid and the rubber band to make a wind-up flapper that we stretched across the open top of the box, and carefully placed it in our Leading Petty Officer’s (LPO’s) desk drawer.  Then we waited for hilarity to ensue the next time he opened that drawer.

Unbeknownst to us, he was going to a pretty important meeting that morning, so he was wearing his Service Dress Blues (also known as “crackerjacks” – the dark wool one; not the white one on the popular snack mix box).  When he opened his desk drawer, the rubber band-powered flapper flung those little white paper dots all over him.  It was wintertime, in an office space with electric baseboard heat, so the static cling was heinous.  It took several of us with makeshift lint brushes fashioned from duct tape to get his uniform “shipshape” and presentable for the meeting.

I was reminded of this incident recently when I had the pleasure of helping a caller from a paper recycling plant, who was having a static problem in a baler, with, basically, large confetti-like pieces of shredded paper.  These shreds are pneumatically conveyed through a long 8-inch duct, where they picked up enough static to cling to the inside of the baler chute, and built up to a point where they covered the sensors that opened the chute.  This caused the chute doors to cycle without the chute being full, which triggered the baler to activate with nothing there.  The result from the operators was a lot of slamming, frustration, and cursing…which further reminded me of my LPO’s reaction to getting covered in paper dots.

While lint brushes (and duct tape, in a pinch) work just fine for removing statically charged debris from one’s clothing, the baler required a different solution…in the form of a pair of EXAIR Gen4 Ion Air Cannons.  These were installed to blow into the baler, from opposite walls just above the chute, and aimed slightly down towards the sensors.  This keeps the sensors clear until paper shred actually DOES fill the chute, allowing it to dump a whole bale’s worth of scrap, keeping the baler (and the operators) happy.

Whatever you needs, EXAIR has a Gen4 Static Eliminator product to solve your static problem.

Many industrial static charge problems have similarities to “real world” experiences that most of us are familiar with.  If you want to talk about static control, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Static Eliminators Essential To Packaging Operations

I had a headache the other day. Of all the things that can make me grumpy, nothing makes me grumpier than a headache. Luckily, there are over the counter medications that work quite well, and quickly, to boot.  And I had a brand new bottle of them in the cabinet.

When I opened the package and removed the tamper-resistant plastic band on the cap, it stuck to my hand when I went to drop it in the trash can.  This raised my grumpiness just a touch.  I shook my hand to try and get it off, and it fell behind the trash can.  My grumpiness elevated a bit further.  I hit my head (you know, the one I was trying to cure the pain in?) on the counter while bending over to retrieve it.  That activated my grumpiness alarm, which sounds just like mild profanity.  My wife silenced that alarm pretty quickly.

The plastic band stuck to my hand, of course, because it’s made of a non-conductive material, and peeling it from the bottle cap, which is also a non-conductive material, generated a static charge.  As a subject matter expert on the topic of static elimination, I am quite familiar with the phenomenon, the problems it causes, and, more importantly, the numerous ways to apply solutions to those problems:

  • One such solution was related to my problem with the tamper-resistant seal.  A mouthwash manufacturer was actually having trouble getting those seals ONTO the bottles on their packaging line.  The bottle caps themselves had so much static charge on them that they repelled the seal as the machine tried to drop it in place before heat shrinking it.  An Ion Air Jet solved the problem:
Gen4 Ion Air Jet ensures bottle caps & necks are static free for application of tamper resistant seals.
  • Speaking of plastic bottles, the finishing process after extrusion can leave small bits of plastic particulate behind, and static charge can keep them on the bottle.  This was a great fit for an Ion Air Cannon:
Gen4 Ion Air Cannon eliminates static & dust prior to filling bottles.
  • Sometimes, air flow isn’t necessary, like in the case of a film that is eventually made into single-use condiment packages, with a static charge that was high enough to fry the print heads that apply the label text.  An Ionizing Bar protects those print heads:
Initial static charge of almost 17kV (left) is almost completely dissipated by the Ionizing Bar (center) to just 0.04kV (right)

EXAIR Corporation’s Gen4 Static Eliminator product line offers a wide variety of options for total static control.  If you need to get rid of nuisance shocks, clinging dust, tearing, jamming or curling of material, misfeeding sheets or rolls, or any of the numerous other problems that static charge can cause, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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What’s So Great About The Gen4 Ion Air Cannon Static Eliminator?

It’s bitter cold this week in southwest Ohio, and one of the consequences of that is dry air in heated indoor areas.  If you’ve walked across a carpeted floor and pet your cat (like I did the other day), you (and your cat) may have experienced a phenomenon known as dissipation of static electricity.

In my defense, Elle The Cat often looks down on me just like she does on Rocky The Dog. Neither of us care.

The relatively low static charge you pick up by shuffling your socks across the rug is pretty small, compared to the charge generated by:

  • High speed rolling & unrolling of plastic film on a shrink wrapper.
  • Plastic pellets traveling through a conveyor system to an injection molding machine.
  • Slitting or trimming of paper, laminates, sheets, etc.
  • Removing protective layers between sheets of delicate materials.

And these can cause issues year-round.  The problems associated with static charge in these situations include:

  • Nuisance shocks to operators.
  • Dust and debris clinging to product finishes and surfaces
  • Product clumping or clinging while in transit.
  • Thin sheets tearing, jamming, folding, or misfeeding.
  • Disruption of sensitive electronic sensors, switches, etc.

EXAIR Corporation has a variety of Static Eliminator Product solutions, depending on the specific needs of a particular application.  To answer the question in the title of this blog, though, the Gen4 Ion Air Cannon is quite versatile, and is often considered alongside our other products.  For example:

  • Gen4 Super Ion Air Knives come in lengths from 3 inches to 9 feet.  If you have a wide web, sheet, or plate to remove static charge from, they’re the best choice, hands down.  For narrower widths, or situations where you have to blow in from the side or at a certain angle due to physical interference, the Gen4 Ion Air Cannon’s small footprint and adjustable mounting bracket provide a great workaround.
  • Gen4 Ion Air Jets generate a focused, concentrated flow of ionized air, for spot cleaning of smaller parts.  Its compact design is ideal for installations in close quarters.  If you have some room, the Gen4 Ion Air Cannon actually uses less compressed air to generate a higher ionized air flow…and it’s quieter, to boot.
  • Gen4 Super Ion Air Wipes are made to blow off and remove static from pipe, cable, extruded shapes, etc.  They come in 2″ or 4″ diameters.  If your product is larger than that, an array of Gen4 Ion Air Cannons can accommodate that.
  • Gen4 Ionizing Points are often installed in ducts to ionize existing air flow.  Arrays of two, three, or four are suitable for ducts up to about 6″ in diameter, depending on the air flow rate.  For larger ducts (or very high flow rates,) Gen4 Ion Air Cannons can be installed to blow into a ‘Y’ connection in duct walls.

Regardless of the nature of the application, if you’ve got a static problem, EXAIR has a solution!

These are just a few of the myriad Static Eliminator applications that EXAIR Corporation has successfully solved over the years.  Many times, the details of the application make one particular product the clear choice.  When there ends up being more than one worth consideration, one of the others is usually the Gen4 Ion Air Cannon.

Again…that’s based on the details of the application, and we’re here to help with that.  If you’ve got a static problem, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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