Award Winning Compressed Air Nozzle Saves Hundreds of Dollars Annually

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EXAIR’s 1 Inch Flat Super Air Nozzle won the Gold Award for Compressed Air from Plant Engineering in 2014. We won the award for the immense savings that our customers reap by using this nozzle to replace open blow offs. While saving compressed air, we also reduce noise level and comply with an OSHA regulation 192.242(b).  Do not leave that blow off open. It is costing you everyday in dollars; it may cost you more in OSHA fines later, and it will cost your employees hearing later.

A 1/4″ copper tube can use 33 SCFM at 80 PSIG of inlet pressure. This homemade blow off will use 1,980 standard cubic feet per hour. Typical industrial compressed air cost $0.25 per 1,000 standard cubic feet.  That 1/4 copper tube is costing you $0.50 every hour to run. Each year, one 1/4″ copper tube costs $2,970*.

The 1 inch Flat Super Air Nozzle, model 1126, uses 10.5 SCFM or 22.5 SCFM less than 1/4″ Copper tube.  Saving your company 22.5 SCFM, is the same as saving $0.34 every hour or $2,025 every year.*  Saving 22.5 SCFM also, means that your compressor system doesn’t have to work as hard.  A 5 HP compressor will put out 20 SCFM, so replacing one 1/4″ Copper Tube with a model 1126 will save you from upgrading compressor system as your company expands.

Regardless of the $2,025 you just saved by replacing the homemade blow offs with engineered nozzle, it is also an industry best practice because it can lower the noise exposure for personnel and prevent any harm from dead end pressure.  OSHA standard 29 CFR – 1910.95(a) requires that if an employee is exposed to greater than 100 dBA for 2 hours, he or she needs to wear hearing protection.  A 1/4″ copper tube will easily exceed 100 dBA.  The model 1126 will lower the noise level to 77 decibel, 13 dBA lower than the OSHA requirements for an 8 hour day.

Finally, the 1″ Flat Super Air Nozzle cannot be dead ended, which protects your employees from serious injury. In the event, that a compressed air orifice is blocked with no means of escape, air may enter the bloodstream from an open cut or wound in the skin. Compressed air must be kept below 30 PSIG to eliminate this danger when using an open pipe, tube or many commercial air nozzles. With EXAIR nozzles, pressure to the nozzle  can remain at line pressure and produce the maximum velocity and force for a successful application.

*Assuming 24 hours a day and 250 working days

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

Spool of Dispair

I had an application this week that showed the difference in power of HP1126 nozzle from an 1126.  A spool of nylon thread needed to be pushed from a ramp onto its side on top of a conveyor that would pass the spool under a bar code reading station.  I had my own skepticism if the 1″ Flat nozzle would be able to topple the 8″ diameter spool that weighs 3 pounds, but the customer agreed to try the 1126 Flat nozzle for the application, but she also purchased a HP1126 in case she needed more force.  It was very little risk to her if it didn’t work, because of EXAIR’s 30 Day Unconditional Guarantee.

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She set the system up, but could not get the spool to fall over.  She called in with the results and how it was set up so we could go through the troubleshooting steps. We asked the customer to put a pressure gauge on a pipe tee just before the nozzle.  The inlet pressure was 80 PSIG at the gauge, so we had a good air supply.  They changed the angle and position of the air blow off, but still no luck.  Fortunately for our customers, EXAIR’s flat Super Air Nozzles (1″ or 2″ wide) are the only flat nozzle family to allow for adjusting the air gap and force from the nozzle. In this case the customer bought one of each nozzle, a standard force and a high power version. But they could have chosen to simply purchase additional shims which can be changed to produce different levels of force. EXAIR’s flat nozzle family have shims from .005″ through .030″ in order to solve the broadest range of applications. Sure enough the nozzle the customer was using only had a 0.015″ shim.  The 1126 Flat Nozzle features a 0.015″ and the HP 1126 uses a 0.025″ shim. The next step in the process was to try  the HP1126 high power version. The larger shim in the second nozzle made all the difference in the world.  The spool moved easily off of the ramp onto the conveyor belt.

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If you have any questions or have your own application that you are doubtful of, feel free to contact us.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW