Tag: distribution

Where is EXAIR?

Published on by John BallLeave a comment

Since the establishment of EXAIR in 1983, customer satisfaction, quality, and quick turnaround have always been the cornerstone of our business model.   And with this type of business model, our company continues to grow each year.  Now EXAIR is recognized as a brand of excellence worldwide.  With thousands of products in stock, we are able to ship with over 99.9% on-time delivery.  EXAIR offers free expert technical advice and shares solutions to pneumatic issues through EXAIR Blogs, Case Histories, videos, an application library, and social media.

In today’s market, many companies are global and have plants and facilities worldwide.  If details like cost savings, safety, increased productivity, problem-solving, and energy efficiency were shared, it would be very beneficial for everyone.  It can help to grow profits, protect employees, improve throughput, and save energy, which will help to protect the environment.  Since EXAIR is a leader in these areas with compressed air products, we can help you and your affiliates with pneumatic solutions.

EXAIR sells direct in the U.S.A. and Canada, and we have over 50 distributors located throughout the rest of the world.  EXAIR has structured our world-wide presence by country on our International Map located at EXAIR.com on the banner of our website.  It is simple to use.  To find a distributor, click on this link, International.  Fill in your name, email, and the country in which you wish to find a distributor.  We also ask if you would like to receive news about EXAIR products in the future.  The news will include new products, special notices, or featured products.  If you wish to receive this monthly update, then click “Yes”.  If we do not have a distributor in your area, EXAIR does have an International Department that can assist you directly. 

There are many ways to save money within your industry.  And one way is to use your compressed air efficiently.  If you or your affiliates use compressed air to cool, dry, clean, convey, vacuum, or remove static electricity, EXAIR can improve these processes.  And if you have locations outside the U.S. and Canada, we can still help you.  You can contact us directly or visit our International Map.  You may find someone near you that can speak your language and discuss the values that EXAIR can provide.  And if we do not have anyone in that country, and you wish to speak to us about becoming an EXAIR Distributor, you can contact us HERE.

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

Photo: International world by GDJ.  Pixabay content license.

Press Release – EXAIR and BETE Announce Strategic Merger

Published on by John BallLeave a comment

I am glad to announce that EXAIR, a leader in engineered compressed air solutions and static elimination, and BETE, a renowned engineered spray nozzle and spraying systems manufacturer, has a definitive merger agreement under which EXAIR has acquired BETE. This landmark combination promises to do what both companies have been doing for decades – create something that has never existed before – and to do it with an unprecedented market appeal.

This merger will allow both companies to significantly enhance product offerings and customer engagement. The combined market reach and engineering capacity will drive innovation and product value for a worldwide network of customers, distributors, resellers and OEM’s.

Strategic Benefits of the Merger:

  1. Enhanced Product Lines: The EXAIR/BETE merger enables a diversified portfolio of products by integrating BETE’s pioneering technologies and engineering acumen with EXAIR’s robust manufacturing capabilities. This synergy will address a broader spectrum of market demands, fostering a new era of invention.
  • Expanded Market Reach: The combined entity will leverage new market access, product lines, direct-to-end-user sales strategies, and long-term relationships with large project customers.
  • Expanded Market Support: With a strengthened go-to-market strategy, the merger enhances our ability to provide high quality, precision engineered products to all levels of the market, big or small.  EXAIR and BETE will be able to bring unparalleled support to large-scope projects, OEM relationships, a worldwide network of distributors and directly to end users. 

What This Means for the Market:

  1. The merger of EXAIR and BETE redefines the industry landscape. Customers now have access to a more diversified line of efficient, engineered industrial solutions. This pairing creates new standards for quality, performance and customer satisfaction within industrial manufacturing. Our combined expertise will accelerate technological advancements and the development of next-generation products, thus delivering enhanced value to our customers. When combined with embedded service level standards, no other company is capable of doing what EXAIR and BETE can do together. 

Here is a message from the President of each company.

From Kirk Edwards, President of EXAIR: “For our valued customers and partners, this merger means improved service, new products and competitive prices. You will benefit from the combined expertise of two industry giants coming together to deliver comprehensive solutions that meet your needs”

From Tom Fitch, President of BETE: “As we embark on this exciting new chapter, EXAIR and BETE are committed to a seamless integration process, focused on our shared vision of quality, advanced engineering and service. We look forward to bringing together our teams, cultures and communities to build a stronger future. We are, without a doubt, better together”

For more information about EXAIR and BETE, you can view our websites at www.EXAIR.com  or www.BETE.com. 

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

Photo: Puzzle Collaboration Partnership by Peggy_Marco.  Pixabay license

Compressed Air Distribution System, Keeping Pressure Drop to a Minimum

Published on by John BallLeave a comment

Compressed air is used to operate pneumatic systems within a facility, and it can be separated into three categories; the supply side, the demand side, and the distribution system.  The supply side is the air compressor, after-cooler, dryer, and receiver tank that produce and treat the compressed air.  They are generally located in a compressor room somewhere in the corner of the plant.  The demand side is the collection of devices that will use that compressed air to do “work”.  These pneumatic components are generally scattered throughout the facility.  To connect the supply side to the demand side, a compressed air distribution system is required.  Distribution systems are pipes which carry the compressed air from the compressor to the pneumatic devices.  For a sound compressed air system, the three sections have to work together to make an effective and efficient system.

An analogy that I like to use is to compare the compressed air system to an electrical system.  The air compressor would be considered the voltage source, and the pneumatic devices would be marked as light bulbs.  To connect the light bulbs to the voltage source, electrical wires are needed which will represent the distribution system.  If the gauge of the wire is too small to supply the light bulbs, the wire will heat up and a voltage drop will occur.  This heat is given off as wasted energy, and the light bulbs will be dim.  The same thing happens within a compressed air system.  If the piping size is too small, a pressure drop will occur.  This is also wasted energy.  In both types of systems, wasted energy is wasted money.  One of the largest systematic problems with compressed air systems is pressure drop.  If too large of a pressure loss occurs, the pneumatic equipment will not have enough power to operate effectively and efficiently.  As shown in the illustration below, you can see how the pressure decreases from the supply side to the demand side.  With a properly designed distribution system, energy can be saved; and, in referencing my analogy above, it will keep the lights on.

Pressure Drop Chart

To optimize the compressed air system, we need to reduce the amount of wasted energy.  This can be caused from leaks or pressure drop.   Leaks can be hidden and are typically located at connections within the distribution system.  In a poorly maintained system, a study found that 30% of the compressor capacity is lost through air leaks on average.  Even though leaks are the “silent killer” to a compressed air system, they can be found with the Ultrasonic Leak Detector. 

Pressure drop is more of a wide range issue.  It is based on restrictions, obstructions, and piping surface.  Out of these, restrictions are the most common types of pressure drops. The air flow is forced into small areas, causing high velocities.  The high velocity creates turbulent flow which increases the losses in air pressure.  Flow within the pipe is directly related to the velocity times the square of the diameter.  So, if you cut the I.D. of the pipe by one-half, the flow rating will be reduced by 25% of the original rating.  Restriction type of pressure drop can be found in different forms like small diameter pipes or tubing; restrictive fittings like quick disconnects and needle valves, and undersized filters, regulators and valves.

As a rule, air velocities will determine the correct pipe size for the distribution system.  It is beneficial to oversize the pipe to accommodate for any expansions in the future.  For header pipes, the velocities should not be more than 20 feet/sec (6 meter/sec).  For the distribution lines, the velocities should not exceed 30 feet/sec (9 meter/sec).  In following these simple rules, the distribution system can effectively supply the necessary compressed air from the supply side to the demand side.

To have a properly designed distribution system, the pressure drop should be less than 10% from the reservoir tank to the point-of-use.  By following the tips above, you can have the supply side, demand side, and distribution system working at peak efficiency.  If you would like to reduce waste even more, EXAIR offers a variety of efficient, safe, and effective compressed air products to fit within the demand side.  This will include the EXAIR Super Air Knives, Super Air Nozzles, and Safety Air Guns.  This would be the pneumatic equivalent of changing those incandescent light bulbs into LED light bulbs.  If you wish to go further in optimizing your system, an Application Engineer at EXAIR will be happy to help you. 

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

Photo:  Lightbulb by qimono.  Pixabay Licence

Pressure Drop Chart by Compressed Air Challenge Organization.

Compressed Air Pipe

Compressed Air and Pneumatic Systems

Published on by John BallLeave a comment

Compressed Air Pipe

Compressed air is used to operate pneumatic systems in a facility, and it can be segregated into three main sections; the supply side, the demand side, and the distribution system.  The supply side is the air compressor, after-cooler, dryer, and receiver tank that produce and treat the compressed air.  They are generally found in a compressor room.  The demand side is a collection of devices that will use the compressed air to do “work”.  These pneumatic components are generally scattered throughout the facility.  To connect the supply side to the demand side, a distribution system is required.  Distribution systems are pipes or tubes which carry compressed air from the air compressor to the pneumatic devices.  The three sections have to work together to make an effective and efficient system.

Compressed air is a clean utility that is used in many different ways, and it is much safer than electrical or hydraulic systems.  But most people think that compressed air is free, and it is most certainly not.  Because of the cost, compressed air is considered to be a fourth utility in manufacturing plants.  For an electrical motor to reduce a volume of air by compressing it, it takes roughly 1 horsepower (746 watts) to compress 4 cubic feet (113L) of air every minute to 125 PSI (8.5 bar).  With almost every manufacturing plant in the world utilizing air compressors larger than 1 horsepower, the amount of energy needed is extraordinary.

Let’s determine the energy cost to operate an air compressor by Equation 1:

Equation 1:

Cost = hp * 0.746 * hours * rate / (motor efficiency)

where:

Cost – US$

hp – horsepower of motor

0.746 – conversion KW/hp

hours – running time

rate – cost for electricity, US$/KWh

motor efficiency – average for an electric motor is 95%.

As an example, a manufacturing plant operates a 100 HP air compressor in their facility.  The cycle time for the air compressor is roughly 60%.  To calculate the hours of running time per year, I used 250 days/year at 16 hours/day.  So operating hours equal 250 * 16 * 0.60 = 2,400 hours per year.  The electrical rate for this facility is $0.10/KWh. With these factors, the annual cost to run the air compressor can be calculated by Equation 1:

Cost = 100hp * 0.746 KW/hp * 2,400hr * $0.10/KWh / 0.95 = $18,846 per year in electrical costs.

Filters and Regulator

If we look at the point-of-use or demand side, the compressed air is generally conditioned to be used to run and control the pneumatic system.  The basic units include filters, regulators, and lubricators.  The filters are used to remove any oil, water, vapor, and pipe scale to keep your pneumatic system clean.  They fall into different types and categories depending on the cleanliness level required.

Filter Separators are more of a coarse filtration which will capture liquid water, oil, and particulate.  The Oil Removal Filters are more of a fine filtration which can capture particles down to 0.03 micron.  They are also designed to “coalesce” the small liquid particles into larger droplets for gravity removal.  One other group is for removing oil vapor and smell.  This type of filter uses activated charcoal to adsorb the vapor for food and pharmaceutical industries.  Filters should be placed upstream of regulators.

Pressure Regulators change the pressure downstream for safety and control.  Pneumatic devices need both flow and pressure to work correctly.  The lubricator, which is placed after the Regulator, helps to add clean oil in a compressed air line.  Air tools, cylinders, and valves use the oil to keep seals from wearing with dynamic functions.  Once the compressed air is “ready” for use, then it is ready to do many applications.

For EXAIR, we manufacture products that use the compressed air safely, efficiently, and effectively.  EXAIR likes to use the 5-C’s; Coat, Clean, Cool, Convey and Conserve.  We have products that can do each part with 16 different product lines.  EXAIR has been manufacturing Intelligent Compressed Air Products since 1983.  Compressed air is an expensive system to operate pneumatic systems; but, with EXAIR products, you can save yourself much money.  If you need alternative ways to decrease electrical cost, improve safety, and increase productivity when using compressed air, an Application Engineer at EXAIR will be happy to help you.

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