EXAIR’s Efficiency Lab: A Service Providing ROI

EXAIR’s Free Efficiency Lab

Have you ever stood at a dealership wondering what car to buy?  You have a variety of things to consider like safety, gas mileage, quality and price.  But what if the dealership had a professional race car driver to test each car for you and give you a detailed report about each one?  That would definitely help you to make a better choice.  At EXAIR, we are that professional driver when it comes to compressed air products.

EXAIR has been manufacturing compressed air products since 1983, and we created a culture of making high quality products that are safe, effective, and very efficient.  Since we stand by our products, we created a program called the Efficiency Lab.  This program is to compare your current pneumatic blow-off device with an EXAIR engineered product.  We generate a detailed report to send to you for review.  It is a free service that EXAIR provides for U.S. and Canadian companies to “test drive” your current pneumatic blow-off items.

Why do we offer this?  Air Compressors use a lot of electrical power and are considered to be a fourth utility within plants and industries.  Many people do not realize the cost and safety concerns when using improper blow-off devices.  As an example, if you look at a single 1/8” open pipe for blowing compressed air, it can cost you over $2,000 a year to operate.  This will add to your overhead and cut profits.  Another reason to consider your blow-off device is that compressed air can be dangerous.  With that same 1/8” open pipe, it can violate OSHA standards in noise exposure and dead-end pressure.  In deciding your “vehicle” for blowing compressed air, cheap is not the best option.  In reference to my analogy above, it would be like buying a car that gets 3 MPG with faulty brakes.

With our Efficiency Lab, it is quite simple to do.  For starters, you can go to our Product Efficiency Survey on our website to give the conditions for testing.  If you wish for a side by side analysis, you can place your pneumatic device in a box and send it to EXAIR.  We will run the tests at the specified conditions or in a range of settings.  We will then return your pneumatic device back to you at our cost with a detailed report of the comparison.  Your information will be confidential, and we will not share it without your permission.  Many customers like to use this report to show managers, executives, HSE, etc. on the improvements that EXAIR can provide in cost savings and safety.

How do we do the Efficiency Lab?  We use calibrated equipment and standardized procedures to test for noise levels, flow usage, and force measurements.  We will recommend an EXAIR engineered solution as a replacement to your current device to do the comparison.  With the analytical information, we can also figure the total amount of air savings, return on investment, payback period and safety improvements.

Don’t be fooled; not all blow off devices are the same.  You do not want to sacrifice safety, time, and money with a sub-standard product.  Let EXAIR solve this dilemma with our free service; the Efficiency Lab.  As the expert in this industry, you can get a detailed report with a comparison analysis to make a great choice.  “Vroom Vroom!”

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Picture: Checkered Flag by OpenClipart-VectorsPixabay License

Power, Ergonomics and Safety from EXAIR’s Heavy Duty Safety Air Gun

EXAIR offers several types of Safety Air Guns.  Today, we will showcase the Heavy Duty Safety Air Gun.  There are hundreds of combinations that can be configured using the Heavy Duty Safety Air Gun, extensions, chip shield, and our engineered air nozzles.

EXAIR Heavy Duty Safety Air Gun Benefits

The gun has a number of benefits starting with the metal 3/8″ NPT inlet which permits air flows high enough to operate our model 1106 – 1/2″ Super Air Nozzle.  With the 1106 Super Air Nozzle on the gun it will provide 3.3 lbs of force to provide ample cleaning, clearing, or cooling air for the tough industrial jobs.

Secondly, the gun offers an over molded grip that is ergonomic and rugged to handle the industrial environments that maintains its grip even when doused in coolants.

Third, the gun offers a cast 4 finger blade style trigger that permits ergonomic easy trigger pull that can be easily used throughout a work shift.  In the event the trigger becomes damaged it can also be easily replaced with stock parts direct from EXAIR.

Fourth, we easily offer any of the Heavy Duty Safety Air Gun combinations with extensions up to 72″ in length and with or without the Chip Shield option.

Heavy Duty Safety Air Gun Family

Lastly, as mentioned in first point, the gun and extensions can be combined with any of the EXAIR Super Air Nozzles up to 1/2″ NPT inlet.  Whether you need a small precision puff of air from the Atto Super Air Nozzle, the forcefull blast of the 1106 1/2″ Large Super Air Nozzle, or anywhere in between, there is an engineered nozzle for it and we can couple them with the Heavy Duty Safety Air Gun.

EXAIR’s Free Efficiency Lab

To find out what kind of Safety Air Gun can fill the needs of your application, feel free to contact us.  If you are using an existing non-engineered gun and would like to explore the safe, quiet world of engineered air nozzles coupled with safety air guns, then feel free to reach out to us and inquire about our FREE Efficiency Lab Service.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Engineered Compressed Air Nozzles and Utility Rebates

When EXAIR started to manufacture compressed air products, we created a culture in making high quality products that are safe, effective, and efficient.  Being leaders in this industry, we created a program, the Efficiency Lab, to compare blow-off devices with EXAIR products in noise levels, flow requirements, and force measurements.  With calibrated test equipment, we compare the data in a qualified report to share with our customers.  This information can be helpful to determine the total amount of air savings and safety improvements that EXAIR products can offer.

Flat SANs 1in
Zinc Aluminum models are suitable for general purpose blow off (left) and 316SS models are specified for food/pharma and high heat applications.

In conjunction with the Efficiency Lab, we created a Cost Savings Calculator.  It is a quick way to view payback periods and annual savings when using EXAIR products.  As an example, I used a 1” Flat Super Air Nozzle, model 1126, and compared it to a 1/8” open pipe.  (The reason behind the comparison is that the model 1126 can screw onto the end of the 1/8” NPT pipe.)  With an operation of 24 hours/day for 250 days a year, the amount of air used by an 1/8” open pipe is near 70 SCFM (1,981 SLPM) at 80 PSIG (5.5 Bar).  The model 1126 has an air consumption of 10.5 SCFM (297 SLPM) at 80 PSIG (5.5 Bar).  By putting the information in the Cost Savings Calculator, it determined that the ROI was in 2.1 days.  The annual savings was $5,355 USD per year.  Imagine if you replaced ten blow-off spots in your facility, the amount of money that could be saved.  Here is the worksheet below:

flat 1

The people that started to notice the savings were the utility companies that make electricity.  Depending on your location, electrical suppliers initiated a rebate program to use engineered nozzles in your facility.  Similar to other energy saving rebates, like LED light bulbs and high efficiency furnaces, the electrical providers notice a big savings when using EXAIR products.  If you qualify, the total cost to purchase and implement the EXAIR Super Air Nozzles are reduced.(Even if a rebate program has not been implemented in your area, the idea of saving energy and compressed air makes it very profitable and environmentally sound in changing over to EXAIR products).

To see if your utility offers rebates on compressed air optimizations, go to the DSIRE database. This database is easy to search and informative.

For Example, here in Ohio Duke Energy has a Prescriptive Incentive Program for its customers. The Prescriptive Incentive Program makes it easy for Duke Energy customers to receive an incentive for their natural gas and electric energy efficiency projects. Prescriptive Incentives are energy efficient measures paid per-unit, reimbursing the customer up to the total cost (including materials and labor) after the measures have been installed. See the image below for their incentives for using Engineered Nozzles;

capture.jpg
Ohio Duke Energy Prescriptive Incentive Program

https://www.duke-energy.com/business/products/smartsaver/industrial-equipment

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

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS

 

 

Video Blog: EXAIR’s Efficiency Lab

If you’d like to know how efficient (or not,) quiet (or not,) and effective (or not) your current compressed air devices are, the EXAIR Efficiency Lab can help.  For more details, we hope you’ll enjoy this short video.

If you’d like to talk about getting the most out of your compressed air system, we’d love to hear from you.

Russ Bowman
Application Engineer
EXAIR Corporation
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Return On Investment: Does It Matter, And How Much?

I have a friend who participates in a process known as “extreme couponing.” She has multiple subscriptions to the Sunday edition of our major newspaper, and a couple of local papers that also have coupon inserts. When I see her at the grocery store, she’s got two 4″ binders full of baseball card holders, all stuffed with multiples of clipped coupons, organized by store aisle. The insane amount of money saved is a big factor in her being able to be a stay-at-home mother, which is something else she’s pretty good at.

If you get stuck at step one…or even two…extreme couponing may not be for you!

Now, extreme couponing isn’t for everyone. Even beginners to the process can buy a year’s worth of paper towels for next to nothing. However, that may take up so much room in their house that they need to rent a storage facility for other belongings that folks like you and me simply keep in the garage or basement. It also takes a LOT of time and effort to do it right – as well as discipline. Saving half (or more) on a truckload of stuff you don’t need (or will never use) is a waste of money, time, and space. In fact, I know people who have abandoned extreme couponing for those very reasons…the “return on investment” just isn’t there.

That’s the deal in industry too.  Anyone tasked with finding and exploiting efficiencies – or finding and eliminating inefficiencies – is going to be looking at return on investment.  Like extreme couponing, though, it has to make sense in all aspects of the operation.  For example:

*An OEM taking advantage of a quantity discount for components or subassemblies has to not only have the storage space available, but also has to consider the turnover rate…it costs money to keep product on the shelf.

*A machine shop considering a tooling upgrade has to compare the cost difference with the increased performance and/or lifespan of the “new and improved” product.  A tool that costs 10% more but lasts twice as long is probably a good deal.  A tool that costs twice as much but lasts 10% longer might not provide the “bang for the buck.”

*Any facility, before switching a service or utility provider, will “run the numbers” on promotional rates, contract terms, etc. before making a commitment.

Unlike extreme couponing, EXAIR makes it easy – and beneficial – to evaluate the return on investment:

*Our catalog (if you don’t have the latest, get it here) has complete performance & operational data on all of our products.  This is great if you know what you want it to do.

*If you’re not quite sure, our catalog also has a good number of actual application write-ups for most of our Intelligent Compressed Air Products.  You may be able to find something that’s similar to what you want to do, and further inform your selection from there.

*Once you’ve chosen a product, you can use the Calculator Library on our website to determine actual dollar cost savings associated with replacing a current compressed air powered device with an EXAIR product.

*Application Engineers are available to discuss your application and/or product selection via phone, email, or Live Chat.

*No matter how detailed the discussion, and how confident a plan we may make, the age-old saying about how it “looked good on paper” proves itself every now and again.  When this happens, all catalog products are covered by our 30 Day Unconditional Guarantee.  If you’re not satisfied for any reason within 30 days of purchase, we’ll arrange return for full credit.

*Let’s assume that we’re pretty good at this (because we are) and it actually DOES work out (because it usually does) – we can calculate your new (and improved) operating costs and compare them with the cost of your previous devices.  If you don’t have the instrumentation (flow meters, sound level meters, etc.,) this is a free service we provide in our Efficiency Lab.  Send it in, and we’ll do a full performance test & issue a comprehensive report, all at no charge.  And if you qualify for a Case Study, we can even save you some money on your next order.  Contact me for more details if you’re interested.

Free testing. Verifiable data. EXAIR Efficiency Lab.

Russ Bowman
Application Engineer
EXAIR Corporation
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Coupon Pile Stock Photos courtesy of Carol Pyles  Creative Common License

Better Understand Your Blowoff Process with EXAIR’s FREE Efficiency Lab

panoramic view
The EXAIR Efficiency Lab

Many customers may not have the means to test the air consumption of their blowoff solutions. With compressed air being the most expensive utility in a manufacturing facility, it’s important to identify places where you can save money on your overall operating costs. EXAIR manufacturers a wide variety of products intended to help you reduce your compressed air usage. If you’re not able to accurately measure the consumption in your own shop, we invite you to send the products into EXAIR for testing. With EXAIR’s Award Winning Efficiency Lab, just simply contact an Application Engineer, box them up and send them to our warehouse in Cincinnati, Ohio.

EXAIR Efficiency Lab

Once we receive it, our engineers will complete some in-depth testing to determine the compressed air consumption, sound level, and force that your current solution provides. With this information, we’ll be able to compare it to an EXAIR Engineered Solution. This way we ensure that you receive the best, safest solution possible also capable of saving money through reduced air consumption and improved efficiency.  We’ll send you back a comprehensive report that’ll help you to make the best decision for your company.

I’ve been recently working with a customer that sent in one of the nozzles they’re using across all their CNC machines. They wanted us to test it out and see if we’re able to offer them something that could reduce their overall compressed air usage. The nozzle was one of the cheap plastic varieties and was attached to a commonly used modular hose. This type of modular hose is not designed for operating under high pressures. These hoses are more suitable for liquid coolant or air that is at or below atmospheric pressure.

IMG_7486
Inefficient and unsafe plastic nozzle

After testing, we found that at 80 psig the nozzle consumed 3.85 SCFM and produced a force of 1.92 oz. We also noticed that after 60 psig, the nozzle began to leak due to a poor seal where the nozzle met the brass hex. The EXAIR nozzle most suitable to replace this was the 1108SS. At just 2.5 SCFM at 80 psig, replacing the plastic nozzle with an engineered solution saves them 35% of their overall consumption for this blowoff. With close to 1000 of these nozzles in operation, that adds up quickly!!

In addition to increasing efficiency, replacing these nozzles also greatly increases overall worker safety. The sound level is reduced from 73 dBA to just 58 dBA and EXAIR’s nozzles also adhere to OSHA 1910.242(b). The plastic nozzles could be dead-ended, posing a hazard that can result in costly fines. These fines are assessed per infraction, so having multiple non-compliant nozzles can easily get very expensive if you’re subject to an unannounced visit by an OSHA inspector.

If you think you may have an opportunity to improve upon your existing blowoff methods, give us a call. We’ll be happy to take a closer look and have you send the product back to EXAIR for a quick trial in our Efficiency Lab. You’ll be glad you did!

Tyler Daniel
Application Engineer
E-mal: TylerDaniel@exair.com
Twitter: @EXAIR_TD

Super Air Nozzles; Rebates, Environmental Protection, and Energy Savings.

Family of Nozzles

Recently, I wrote a blog, “Flat Super Air Nozzles: Build Your Own System Overview”.  It described how the Flat Super Air Nozzles could be used singly or joined together with accessories for flexibility in your application.  In addition, it demonstrated the amount of compressed air savings and reduction in energy consumption to save you money.  Tyler Daniel, a colleague, wrote a similar blog on “ROI – Is it Worth the Investment?”  He explains the quick payback or ROI (Return on Investment) by using EXAIR Super Air Knives.  In both posts, the word “Super” is intertwined with the product name.  To expand a bit further, the word, “Super” is more than just a word.  It is about cost savings, efficiency, and energy conservation.   In this post, I will dive a bit more into the reasons why EXAIR uses the word, “Super”, and how it can help you.

When EXAIR started to manufacture compressed air products, we created a culture in making high quality products that are safe, effective, and efficient.  Being leaders in this industry, we created a program, the Efficiency Lab, to compare blow-off devices with EXAIR products in noise levels, flow requirements, and force measurements.  With calibrated test equipment, we compare the data in a qualified report to share with our customers.  This information can be helpful to determine the total amount of air savings and safety improvements that EXAIR products can offer.

With the total amount of energy savings that the EXAIR products can provide, EXAIR was able to partner with Energy Star and the Environmental Protection Agency.  This commitment by EXAIR for reducing energy to protect the environment for future generations is a cornerstone for our business model.  Compressors use electricity to produce compressed air.  In most industries, they consider compressed air as a fourth utility.  If you have pneumatics in your facility wouldn’t it be best to use it, and the electricity it requires, as efficiently as you can?

In conjunction with the Efficiency Lab, we created a Cost Savings Calculator.  It is a quick way to view payback periods and annual savings when using EXAIR products.  As an example, I used a 1” Flat Super Air Nozzle, model 1126, and compared it to a 1/8” open pipe.  (The reason behind the comparison is that the model 1126 can screw onto the end of the 1/8” NPT pipe.)  With an operation of 24 hours/day for 250 days a year, the amount of air used by an 1/8” open pipe is near 70 SCFM (1,981 SLPM) at 80 PSIG (5.5 Bar).  The model 1126 has an air consumption of 10.5 SCFM (297 SLPM) at 80 PSIG (5.5 Bar).  By putting the information in the Cost Savings Calculator, it determined that the ROI was in 2.1 days.  The annual savings was $5,355 per year.  Imagine if you replaced ten blow-off spots in your facility, the amount of money that could be saved.  Here is the worksheet below:

Why did I bring this up?  Besides showing the “hidden” extra cost that is wasted when using sub-standard blow-off devices, it also shows the amount of compressed air that was saved.  By using the model 1126, we were able to save 21,420,000 cubic feet of air per year (596,043 cubic meters of air per year).  With this amount of energy savings, people take notice.

The people that did take notice were the utility companies that make electricity.  Depending on your location, electrical suppliers initiated a rebate program to use engineered nozzles in your facility.  Similar to other energy saving rebates, like LED lightbulbs and high efficiency furnaces, the electrical providers notice a big savings when using EXAIR products.  If you qualify, the total cost to purchase and implement the EXAIR Super Air Nozzles are reduced.  (Even if a rebate program has not been implemented in your area, the idea of saving energy and compressed air makes it very profitable and environmentally sound in changing over to EXAIR products).  The website is DSIRE.  “DSIRE is the most comprehensive source of information on incentives and policies that support renewables and energy efficiency in the United States.”  Check it out to see if your area has instituted a rebate program.

When EXAIR uses the word “Super”, it is much more than just an adjective.  It shows the quality and precision that EXAIR uses in manufacturing our products, and the amount of cost and energy savings that can be generated.  Being backed by Energy Star, EPA, and rebate programs, EXAIR can help companies to upgrade their pneumatic systems.  Together, we can save energy, improve the environment, and reduce compressed air.  If you would like to discuss how EXAIR can work for you, you can contact an EXAIR Application Engineer to see if we can put the word, “Super”, into your compressed air program.

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