Video Blog: EXAIR Efficiency Lab

The video below is a brief introduction to the EXAIR Efficiency Lab, a free service provided by EXAIR for customers within the USA and Canada.

If you have a single point blowoff that does not have an engineered nozzle, or if you have a wider format blowoff, manifold or home-made drilled pipe, contact an Application Engineer with EXAIR and let us help you to reduce your energy waste. Following are some examples of product where we have helped to save some serious air and reduced noise levels which heightens employee comfort.

Non-engineered blowoffs
Drilled and soldered copper pipe.
Custom manufactured inefficient pipe blowoff

 

The EXAIR Efficiency Lab

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

Six Years At EXAIR: What I’ve Learned

Yesterday, I went “over 6” as an Application Engineer at EXAIR Corporation, and I’m still loving every minute of it! I came here with a fair degree of mechanical engineering & technology know-how, but, in reflection, I’ve learned an even fairer degree…some of which I’d like to share with you, dear reader, on the occasion of this ‘work-iversary:’

*Time spent doing something doesn’t always equal “experience.” If you work at something for, say, 20 years, and never learn anything new after your initial training, you don’t really have 20 years’ experience…you have one year of experience, 20 times. Big difference.

*Teamwork is critical to success.  The Patrol Method works.  The value of a “lesson learned” multiplies exponentially when it’s shared with others.  Design Engineers have a universal law of CAD that says “don’t ever draw anything twice.”  Application Engineers “don’t ever test anything twice.”

*Sometimes, there’s one way to find out.  That’s why we devote the resources we do to the Efficiency Lab.  If you want to know more about the performance of your current compressed air products, and how they might compare to one of our quiet, efficient solutions, so do we.

*A picture is worth a thousand words.  We prove this every day, whether it’s a photo (or short video even) of an application, a photo of a product or system for troubleshooting, or a photo of a nameplate or device for product comparison.  I’m old enough to remember doing business before email & digital photos, but I swear I don’t know how we ever got anything done.

*There’s always a ‘better mousetrap’ – and that’s the unofficial motto of EXAIR’s Engineering department.  That’s why we have so many more Atomizing Spray Nozzles than the did six years ago.  And Heavy Duty HEPA Vacs, long Super Air Knives and more product accessories.

*Relationships are vital.  At least a couple of days a week, I spend more time with my co-workers than my wife & kids.  We’re all in this together, and the more we help each other, the better off we are ourselves.

Next week, I’ll be back to blogging about a super cool compressed air product application. If you come up with one in the meantime, I’ll be happy to talk about it with you.  The conversation might just make it into next week’s blog, because one more thing I’ve learned is, when you’ve written 300 or so weekly blogs, “writer’s block” is a very real & present danger!

Russ Bowman
Application Engineer
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How To Solve A Problem with Compressed Air

In my (almost) six years as an EXAIR Application Engineer, I’ve learned a great many things about the capabilities of our products.  The way we do business sure does make it easy:

  • We readily share application information, as a team.  If you ask me a question, you’re asking all of us.  It does neither of us any good if I tell you something MIGHT work if one of my team knows it WON’T – or if someone knows what else DOES work.  If we can offer a solution, we will.
  • We’ll test your product, free of charge.  This is a popular way of finding out which Line Vac is best for conveying a particular product, for example.
  • If you’re considering a quiet, safe, and efficient EXAIR product as an upgrade, we’ll test your current product in our award winning Efficiency Lab, so you can compare accurate performance data and analyze the expected benefits…which can be dramatic.  Try us on that.
exair-testin
Line Vac conveyance rate testing (left;) Efficiency Lab testing (right.)

 

  • We’ll let YOU test our product, risk-free.  All catalog products come with a 30 Day Unconditional Guarantee.  We invite you to put it through its paces for up to a month.  If it’s not working out, we’ll arrange return for full credit.
  • We’ll do the math.  But first, a disclaimer: strictly comparing the force or flow of an engineered product to an open-end blow off won’t always tell the tale.  Our Intelligent Compressed Air Products are creating a laminar flow which won’t generate as high of a force/thrust as open-end blowing (which is turbulent by nature,) but is MUCH more conducive to efficiency and noise reduction, as well as similar (if not improved) performance.  But back to the math: if you know the metrics you need to meet for spot cooling (like a Vortex Tube, Adjustable Spot Cooler, Cold Gun, etc.) or for liquid spraying (the liquid flow rate and/or pattern size & shape from an Atomizing Spray Nozzle, for instance,) or the heat load that a Cabinet Cooler System can handle, we’ll do the calculations and specify the appropriate product.

Regardless of the application, if it can be solved with compressed air, it’s very likely that we have a great solution.  Call me to find out how we can help.

Russ Bowman
Application Engineer
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Stop Trying To Squeeze More Out Of That Air Gun!

At EXAIR, we LOVE to talk about efficient use of compressed air. That’s why I was thrilled to get a call from an engineer that works for a non-profit firm that promotes energy efficiency to enable businesses in their area improve sustainability, improve the environment, and save money.

They were working with a local company to, among other things, optimize their use of compressed air and wanted to take advantage of our free Efficiency Lab service to get the “before” data on the current blow off devices.

Don't let this happen to your air gun...use an EXAIR Precision Safety Air Gun with a quiet, efficient Super Air Nozzle instead.
Don’t let this happen to your air gun…
Squeeze the trigger on a Model 1410SS Precision Safety Air Gun with Nano Super Air Nozzle instead!
Squeeze the trigger on a Model 1410SS Precision Safety Air Gun with Nano Super Air Nozzle instead!

As you can see, they were trying to “squeeze” a little more performance out by, literally, squeezing the tip down.  Thing is, it’s STILL loud and non-compliant with OSHA’s regulations about dead end pressure.  And as far as performance goes, this results in only a slight change in the air flow pattern, with a minimal reduction in compressed air consumption…they’ve changed the geometry of the discharge opening, but not the cross sectional area.  Our Efficiency Lab Test results provide the final answer:

cry for help lab

Efficiency. Saving money. Safety. Sustainability. “Going Green.”   If you’d like to talk about how EXAIR can help you with any…or all…of these things, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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I Love It When They Show The Math

In every math or science class I ever took – from high school Algebra I, to CHEM101 in college, or a variety of classified material courses in Naval Nuclear Power School – it was always good form to show your work. And by “good form” I mean “necessary to avoid an F.” I’ve found, through helping my teenage sons with their homework (whether they want me to or not, but that’s another story,) the same rules apply today. And rightly so.

My oldest is slightly (at least) more interested in athletics than academics. Sunday night, as I was going to bed, I saw him in the living room. His face was not obstructed by his cell phone and he didn’t have his headphones on, so I saw a rare opportunity for a real-time conversation. He was watching game 7 of the NBA Championship, and it was near enough to the end of the game that I figured I could watch it with him and not sacrifice too much desperately needed sleep.

If you watched the series, you saw some phenomenal play by both the Cleveland Cavaliers and the Golden State Warriors. If you saw the end of game 7, you saw “the block” – Cleveland’s LeBron James came out of NOWHERE to rob Andre Iguodala of a quick two points on a breakaway lay-up. During the obligatory replays, I kept thinking that what James had done might border on the physically impossible. Then, ESPN’s “Sport Science” reel put into perspective just how close to that border he came:

Now, we don’t have anyone who can chase down a professional athlete and jump 12 feet in the air to take a basketball away from him, but we DO have a staff of engineers who can test air blow off products and “do the math” on how much better a fit to your application an EXAIR Intelligent Compressed Air Product would be. Our Efficiency Lab service is free and tests your current product to provide you a report comparing air savings, noise reduction, force values and a simple return on investment.

In our defense, I believe we are MUCH better at this than LeBron James or Steph Curry would be.
In our defense, I believe we are MUCH better at this than LeBron James or Steph Curry would be.

Do you want to find out how much quieter and efficient an EXAIR Intelligent Compressed Air Product might be than what you’re using now?  Give me a call…you can try one of our products in your facility, or we’ll test one of yours in ours.

Russ Bowman
Application Engineer
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EXAIR’s Efficiency Lab can Help With your Energy Audit, Quantify Savings and Provide an ROI

I recently received an inquiry from a customer to test their current air guns through our Efficiency Lab service. According to the operators, the handheld blow gun they were purchasing from a commercial retailer was too loud and complaints were rolling in.  They were also hoping to save some compressed air in the process as they were performing an energy audit at the same time.

Commercial Air Gun w/ Cross Cut Hole
Commercial Air Gun w/ Cross Cut Hole
Cross Cut Hole Nozzle
Cross Cut Hole Nozzle

The gun they sent in looked fairly similar to our Precision Safety Air Gun but it did not have an engineered nozzle on the tip of it.   Instead, it was simply a cross cut hole in a piece of material.   The air inlet to the gun was a 1/4″ NPT just like our Precision Safety Air Gun, the extension on the gun was slightly longer, the only significant variance I saw was the tip.

EXAIR Model 1410SS-CS
EXAIR Model 1410SS-CS
The Model 1110SS Nao Super Air Nozzle and Chip Shield
The Model 1110SS Nao Super Air Nozzle and Chip Shield

To try and get as much information as possible I measured the O.D. and I.D. of the extension, the hole size was approximately .140″.  I measured the extension on our Precision Safety Air Gun just to see what is different, it came in at the same size.  So, I flow tested the competitive blow gun with their tip on it and came up with air consumption of 12.69 SCFM, noise level of 92 dBA at 3′ away, and a blowing force of 11.5 oz at 80 psig.   I then measured the same attributes of EXAIR’s model 1410SS-CS Precision Safety Air Gun at 80 psig inlet pressure.  The model 1410SS-CS measured 8.3 SCFM, gave 8.1 ozs of working force, and only produced a 75 dBA sound level from 3′ away.

The sound level reduction was a total of 17 dBA which is below the OSHA standard for allowable noise level exposure, as well as reduced their air consumption by 4.39 SCFM.  That is almost a 35% reduction in their compressed air usage per gun replaced.  After seeing these levels of reduction the customer had more than enough information to provide management with in order to replace the blow guns not just for noise level reduction but also because it will reduce air use and save money. A clear supportive role in their energy audit.

If you would like to discuss how EXAIR can provide some free force, flow, and noise level testing for your facility, please contact an Application Engineer or check out the Efficiency Lab page on our site.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

Calculating Compressed Air Cost & Savings Made Easy

If you have ever looked through our catalog, website, blog, twitter feeds, or even our Facebook page, you will see that we can almost always put a dollar amount behind the amount of compressed air you saved by installing EXAIR’s Intelligent Compressed Air Products.   No matter which platform we use to deliver the message, we use the same value for the cost of compressed air which is $.25 per 1,000 Standard Cubic Feet of compressed air. This value is derived from average commercial and industrial energy costs nationwide, if you are on either coast this value may increase slightly. On the positive side, if your cost for compressed air is a bit more, installing an EXAIR product will increase your savings.

So where does this number come from?   I can tell you this much, we didn’t let the marketing department or anyone in Accounting make it up.   This is a number that the Engineering department has deemed feasible and is accurate.

To calculate the amount we first look to what the cost per kilowatt hour is you pay for energy.  Then we will need to know what the compressor shaft horsepower  of the compressor is, plus the run time percentage, the percentage at full-load, and the motor efficiency.

If you don’t have all of these values, no worries.   We can get fairly close by using the industry accepted standard mentioned above, or use some other general standards if all you know is the cost of your electricity.

The way to calculate the cost of compressed air is not an intense mathematical equation like you might think.  The best part is, you don’t even have to worry about doing any of the math shown below because you can contact us and we can work through it for you.

If you prefer to have us compare your current compressed air blow off or application method to one of our engineered products, we can do that AND provide you a report which includes side by side performance comparisons (volume of flow, noise, force) and dollar savings. This refers to our free Efficiency Lab service.

EXAIR's Efficiency Lab is a free service to all US customers.
EXAIR’s Efficiency Lab is a free service to all US customers.

If you already know how much air you are using, you can use the Air Savings Calculators (USD or Euro) within our website’s knowledge base. Just plug in the numbers (EXAIR product data is found on our website or just contact us) and receive air savings per minute, hour, day and year. We also present a simple ROI payback time in days.

Now, back to the math behind our calculation.
Cost ($) =
(bhp) x (0.746) x (#of operating hours) x ($/kWh) x (% time) x ( % full load bhp)
——————————————————————————————————————————
Motor Efficiency

Where:
bhp
— Compressor shaft horsepower (generally higher than motor nameplate Hp)
0.746 – conversion between hp and KW
Percent Time — percentage of time running at this operating level
Percent full-load bhp — bhp as percentage of full load bhp at this operating level
Motor Efficiency — motor efficiency at this operating level

For an average facility here in the Midwest $0.25/1,000 SCF of compressed air is accurate.   If you would like to attempt the calculation and or share with us your findings, please reach out to us.   If you need help, we are happy to assist.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF