Industrial Housekeeping: Vacuum Flow vs. Vacuum Pressure!

EXAIR has vacuums for wet, dry and wet/dry combinations. Shop floors and manufacturing areas can be filthy places with build up from machining, trash, those random spare bolts that are lying around that nobody knows where they belong or came from. An electric vac is a common choice for these kinds of issues, but they tend to burn out their motors as all electric motors will eventually do. Well, there is a solution to this issue and that is a compressed air powered vacuums system. Compressed air powered dry vacs bring the same power as your standard electric vac with one added bonus, they don’t wear out! As long as you supply clean dry air to the vacuum generator that powers the system the unit will run indefinitely. The main question is which system do I get? 

EXAIR has Three categories of industrial vacuums;

We have Dry Vacs,

These systems are best suited handling dry materials due to the high vacuum flow!

Wet Vacs,

These systems are best suited handling fluids due to their high vacuum level!

Last but not least we have our Wet and Dry Vacuums;

Great for use with dry, wet and duty product due to the changeable filter!

Here are a few important features that each product has in common:

  1. 80-100 PSIG is needed for optimal performance with each system
  2. No Electricity needed
  3. No moving parts to break
  4. No motor to repair
  5. 1.5″ vacuum hose (standard is 10 ft long)
    • Inter changeable tools form one system to another
    • Static resistant hose available
  6. Designed to fit on standard 55 gallon drums (5, 30, and 110 gallon drum options are available on certain models).
  7. All have filters for dust / debris – most have options for the level of filtration required.
  8. Quieter than comparable electric vacuums.

So why are dry Vacuums better with higher vacuum flow and liquid vacuums better with lower flow but higher vacuum pressures? Well, that is pretty easy if you think about it! When you are moving a dry product what is moving with the product? Air! So, we need the higher vacuum flow in order to get enough air behind the product to convey it from your floor to the 55 Gallon barrel! And vice versa with a liquid vacuum, when the hose in submerged in a fluid it requires a higher vacuum pressure in order to get the fluid to lift into the barrel!

Then you have the unicorn. The Easy Switch Wet Dry Vacuum is powerful enough to pull high vacuum flows and vacuum levels to be a true dual-purpose vacuum! (It can also be operated with a HEPA filter!)

If you need help selecting the right vacuum for your facility, give us a call. We have a team of Application Engineers on the ready to take you calls and help pick a solution>

Jordan Shouse
Application Engineer

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The Blog of all Blogs: A Quick Resource of Blogs that we Blogged

EXAIR started writing Blogs in 2008. Since then, we have written well over 2000 Blogs. There is a ton of information in our Blog section on the website. There is most likely a Blog or 10 written about nearly each one of our products. These are primarily written by application engineers that know a thing or two about our products. There are also many application Blogs, that may be very relatable to what you are doing. When you journey to our Blog page (or simply click Blog form EXAIR.com), simply type in a key word or two in our search bar. This search bar is located just below the first row of published Blogs on the right hand of the screen, here is a screenshot of that section (right). You can also choose to follow our blog here as well.

As application engineers, we get asked questions every day. Many of these questions are best answered in one (or more) of these 2000+ Blogs. Many times a picture or video can answer your questions much more precisely than a quick conversation or an email. Many times we will send you a blog link to help. Drawing from my own experience, and asking the other Application Engineers for their lists, I wanted to put our most referenced blogs in one helpful location. I’ve categorized these the best that I can, and hopefully this will be a useful resource for you today, and in the future.

OPTIMIZING YOUR COMPRESSED AIR SYSTEM

Six Steps to Optimizing Your Compressed Air System

This is one of the key sections to our blogs. One of our main goals is to help you optimize your system. Here are 6 blogs that go into detail on each of these key points:

  1. Six Steps to Optimization: Step 1 – Measure the Air Consumption
  2. Six Steps to Compressed Air Optimization: Step 2 – Find and Fix Leaks.
  3. Six Steps to Compressed Air Optimization: Step 3 – Use Efficient and Quiet Engineered Products
  4. Six Steps to Optimizing Compressed Air: Step 4, Turn it Off When Not in Use
  5. Installing Secondary Receiver Tanks: Step 5 in Optimizing Your Compressed Air System
  6. Six Steps to Optimization: Step 6 – Control the Air Pressure at the Point of Use to Minimize Air Consumption

INDUSTRIAL HOUSEKEEPING

This is a product line that has a lot of maintenance questions, probably because these products are used to clean up dirt, and where there is dirt, there can be problems, clogs and leaks:

One of the most common questions we have concerns the Reversible Drum Vacuum (RDV) refurbishment Blog. The RDV is used on the Reversible Drum Vac, and the Chip Trapper products. We offer a refurb service for a fee, but most of the time you can do this on your own by watching and following this blog: Cleaning the Reversible Drum Vac

The Chip Trapper has two very popular blogs as well: Finding and Fixing Chip Trapper Vacuum Leaks as well as Cleaning the Chip Trapper’s Directional Valve

CABINET COOLERS

  1. Calculating Heat loads for Cabinet Coolers
  2. Finding the correct internal temperature of your Electrical Cabinet – don’t use a temp gun
  3. Thermostat & Solenoid Valve
  4. How To Install An EXAIR NEMA 4 or 4X Cabinet Cooler® System
  5. EXAIR Side Mount Kits for NEMA Type 4-4X Cabinet Cooler® Systems
  6. Cold Air Distribution Kit Installation
  7. Installing A Dual Cabinet Cooler Hardware Kit
  8. How to identify your Cabinet Cooler

VORTEX TUBES

  1. Vortex Tubes for Dummies
  2. Adjusting the Vortex Tube
  3. Vortex Tube Cold Fraction – effects on flow and temperature
  4. Application: Creating Freeze Seals for water lines

SUPER AIR KNIVES

  1. Application: Bottle Drying with Super Air Knife (instead of blower)
  2. Application: Super Air Knives drying automotive parts
  3. How to position and mount your Air Knife
  4. Which Air Knife should you choose?
  5. Super Air Knife Plumbing Kits
  6. Maximizing Super Air Knives with Shims

LINE VACS / CONVEYOR SYSTEMS

  1. Why Line Vacs need ambient air
  2. How to drill out Line Vac Generator Holes for increased performance
  3. Application: Conveying Coffee Beans

AIR AMPLIFIERS

  1. Super Air Amplifier Ratios explained
  2. Air Amplifier vs Fan – for cooling
  3. Application: Super Air Amplifier evacuating smoke or fumes

AIR ATOMIZING SPRAY NOZZLES

  1. Choosing the right Atomizing nozzle
  2. No-Drip Nozzle repair video
  3. Atomizing Nozzle identification
  4. Application: Atomizing Spray nozzles and Gummy Bears

SAFETY AIR GUNS

  1. Putting the Safe in Safety Air Guns
  2. Safety Air Gun Accessories, Extensions, Chip Shields and more
  3. Chip Shield sizes and selections

GEN 4 STATIC ELIMINATORS

  1. Changing the Gen 4 Power Supply Fuse
  2. Replacing the rocker switch on a Gen 4 Power Supply
  3. Changing the high power cord on the Gen 4 Ion Air Cannon
  4. Application: Solving Static and Print quality in food packaging

E-VAC VACUUM GENERATORS

  1. How to build a custom E-Vac System
  2. Choosing the right size Vacuum Cups

ACCESSORIES – FILTERS AND REGULATORS

  1. Filter Separator and Pressure Regulator with coupling kit installation 
  2. Rebuilding an Automatic Drain Filter Separator 
  3. Overview of EXAIR accessories

CALCULATIONS AND MORE

  1. Calculating SCFM at any pressure
  2. ROI Calculations with EXAIR products
  3. Do you need a receiver tank?
  4. EXAIR’s Calculator Library
  5. EXAIR’s OSHA compliance

OPTIMZATION – EFC, FLOWMETERS, AND ULTRASONIK LEAK DETECTORS

  1. EFC – Application: Candy Company saves big money with EFC
  2. Flowmeter – How to install a Hot Tap Flowmeter
  3. Flowmeter – Moving and or using Block-Off rings

There are many more blogs and videos at your disposal. This is just a recap of many of our most used, most viewed and most helpful for the day-to-day conversations that happen here at EXAIR. If you have ideas for new blogs – we would love to hear that as well. Please feel free to reach out at any time for more information on any of our intelligent compressed air products.

Thank you for stopping by,

Brian Wages

Application Engineer

EXAIR Corporation
Visit us on the Web
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Cover photo by clker-free-vector-image licensed by Pixabay

Bed Coffee and the Coanda Profile

Photo by Stocksnap and licensed by Pixabay

Every weekend my wife craves her “bed coffee”. I do my best to bring her some coffee in bed at least one, if not both weekend days. It makes her happy, and when she’s happy… The only thing I truly despise about this act of kindness is the actual pouring of the coffee. Now, I’m a decently smart guy but pouring this weekend coffee is a mess. Every time I end up with coffee on the counter, and many times on the mug. And when it gets on the mug it’s over, because it goes to the bottom of the mug and if I forget to wipe that off? Well, it gets on the sheets, because she inevitably rests her coffee on the sheets, and somehow this is my fault, and now she’s not happy anymore… (in fairness, she is still happy and just busts my chops about this part). But why does this happen to me?

It is a little refreshing to realize that I am just a victim of this scientific phenomenon called the Coanda profile. When I start to pour the coffee, the stream adheres to the outer wall of the coffee pot. This causes the coffee to run down the pot and onto the counter, where the cups are sitting (getting that mug bottom soaked in coffee). This is partially caused by the Coanda effect, and partially caused by me not being awake enough to outsmart a coffee pot. The simple solution is to simply increase the flow rate, right? This is correct however, this does not eliminate the Coanda Effect. In fact, even if you are smarter than me you will notice, after you pour the coffee, there is liquid on the side of the pot. That liquid may only be in the form of steam but it’s there, just to a lesser degree. The solution to avoid the mess, is to adjust the pot so that the pour angle is such that gravity overpowers the majority of the Coanda effect. Many times, in my case, this adjustment is too late…

The Coanda phenomena closely depends on several factors, the speed of the jet flow (pouring at a steeper angel), the flow rate (pouring more or less volume over time), and the profile of the container. I believe that a mad scientist invented my particular coffee pot with full intention of messing up countertops all over the world. In fact, he may be a super villain.

At EXAIR, we utilize the Coanda Profile to our benefit on most products. Here are 2 products that are perfect examples of how we use the Coanda Profile to maximize the performance of our products.

Air Amplifiers use the Coanda Effect to generate high flow with low consumption.
Compressed air flows through the inlet (1) to the Full Flow (left) or Standard (right) Air Knife, into the internal plenum. It then discharges through a thin gap (2), adhering to the Coanda profile (3) which directs it down the face of the Air Knife. The precision engineered & finished surfaces optimize entrainment of air (4) from the surrounding environment.

As you can see above, using the Coanda Profile correctly, dramatically increases the efficiency and the entrainment of air in our products. Between the Coanda effect, and the air entrainment, some of our products like the Super Air Amplifiers can output up to 25 times the amount of air that they consume.

Please contact us at anytime to see how the intelligent compressed air products of EXAIR can assist you in your application. And, don’t forget about bed coffee, it’s a win win for you and your spouse…

Thank you for stopping by,

Brian Wages

Application Engineer

EXAIR Corporation
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Cover Photo by monileoni and licensed by Pixabay

Villain image by chrismaguirang and licensed by Pixabay

3-1/2 EXAIR Pro Tips for Compressed Air Use

EXAIR offers industry leading Intelligent Compresses Air Products. Our products are engineered to comply with all relevant OSHA standards and are CE certified. When you purchase an EXAIR product, be it a Super Air Knife or a brass bulkhead fitting, you are expecting to receive a high quality and high performing product, and you will. If the product is not performing there is a very high probability that the problem is not the product.

So whatever could it be? And how can we fix the issue? Air supply going to the product is a common issue, so first we need to insure that there is a steady flow of the appropriate pressure and volume of air. Even though you may have a 100HP compressor, the distance form the product, the size of the pipes delivering the air, the smoothness of the inside of the pipes (is there internal rust and buildup), leaks and other restrictions of air flow rate all contribute to the overall performance.

A large majority of the product performance issues that are brought to us are caused by insufficient air supply in one form or another. Sometimes this is due to the overall size of the system, but many times it is at the point of use. Let’s assume that you have the right sized compressor to power all features in the shop. These next items are where we would want to focus and correct.

EXAIR Digital Flowmeter

Pro tip #1 – Use EXAIR Digital Flowmeters to monitor your air consumption. You should have a log of how much each compressed air tool / machine uses, and compare that to how much air is traveling down that leg of your facility. Leaks, corrosion, rust, and accidents happen. By monitoring and logging your SCFM in each major leg of your system, you will easily be able to narrow down root problems, and track leaks. You will also have solid answer when asked – “Do you have enough air for this?”.

Pressure Regulators “dial in” performance to get the job done without using more air than necessary.

Pro Tip #2 – Use a Tee Fitting and install a Pressure Regulator with Gauge at the point of use. This allows you to see, and control the pressure for each product. This removes all questions of air pressure at the point of use. Although your system seems large enough, many times the pressure is less at the point of use, due to restrictions, unknown leaks etc… Having the information from tip #1 and #2, you will easily be able to identify if your issue is the system, or the tool.

Pro Tip #2.5 – Turn it down (the pressure) if you can… Operate each compressed air application at a pressure just high enough for your desired result – not necessarily full line pressure. We have discussed in many other blogs how compressed air is your 3rd or 4th highest utility. If you optimize the pressure per application, you can save dollars. As a rule of thumb, if your system is operating at the 100 psig level, lowering the pressure by 2 psig will save 1% of energy used by the air compressor. A great example of this would be our Super Air Knives. Optimal use is at 80 psig, and “X” SCFM (based upon length of the Super Air Knife). At 80 psig and the proper SCFM, this flow will feel like having your hand out the window of your car when you are driving about 50 MPH. Your application may not need that much air flow, to get the job done. Turn it down and test it. Start at 80 psig and using the tools from tip #2, turn it up or down until your needs are met. Many of our products do not need to be used at full pressure to effectively solve your process problem.

Pro tip #3 – Use the proper sized lines, connectors and fittings. Pipe restriction can kill performance. Quick connects can be very problematic. Most quick connects are rated at the same size as the incoming pipe, tube or hose, but may actually have a much smaller inner diameter. As you can imagine, this oversight can cause significant performance issues, and end up costing more lack of production or defective product. Be it a quick connect, or any other connector or fitting, it is imperative not to restrict the air. This will result in problems, and lack of performance.

Please do not hesitate to reach to discuss any performance issues, or find out how we can help.

Thank you for stopping by,

Brian Wages

Application Engineer

EXAIR Corporation
Visit us on the Web
Follow me on Twitter