EXAIR Efficiency Lab at Your Service

I couldn’t count the number of times we have written a blog about the EXAIR Efficiency Lab because its that cool, unlike the number of wins the Cincinnati Reds have right now. I can count that on two hand 10………10-26 as of writing this blog and I could go on and on about the pain but I will spare you the tears and write about how amazing the Efficiency lab is for any company that utilizes compressed air!

Is the Mascot signing something? Or hanging his head? We will never Know!

First – what is the EXAIR Efficiency Lab? Well several years ago EXAIR created a free program called the Efficiency Lab.  This program is to compare your current pneumatic blow-off device with an EXAIR engineered product.  The values we compare are air consumption, noise level and force. 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 know more details about solutions you are currently using in your processes.

The EXAIR Efficiency Lab

Why do we offer this?  Air Compressors demand significant electrical power and compressed air is 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 for noise exposure and dead-end pressure.  In deciding your “vehicle” for blowing compressed air, cheap is not typically best option.  To put it in other terms, a cheap nozzle is like a cheap old car, it’s cheap because it gets 3 MPG with faulty brakes.

With our Efficiency Lab, a comparison it is quite simple to do.  An easy way is to call us and explain the details. These details can be data such as the inside diameter and length of a an open tube you are using, or the actual performance data of a cheap air nozzle you have chosen to use. Perhaps the easiest way to make the comparison is to let EXAIR do it – send in your blowoff product or a sample of the tube, nozzle, modified fitting, etc. We will then put them through our testing process. You can also fill out our Product Efficiency Survey on our website to give the conditions for testing. 

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.  We will also provide a simple ROI – many customers like to use this report to show managers, executives, HSE, etc. on the improvements that EXAIR can provide including 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 Swing and miss…. (Like the Reds)  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.  Take advantage of our expertise by using the Efficiency Lab service, we will provide you a detailed report with a comparison analysis to make a great choice. 

Jordan Shouse
Application Engineer

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EXAIR’s Efficiency Lab Shows How Much Compressed Air You Can Save

The EXAIR Efficiency Lab

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.  The values we compare are air consumption, noise level and force. 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 know more details about solutions you are currently using in your processes.

Why do we offer this?  Air Compressors demand significant electrical power and compressed air is 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 for noise exposure and dead-end pressure.  In deciding your “vehicle” for blowing compressed air, cheap is not typically best option.  To put it in other terms, a cheap nozzle is like a cheap old car, it’s cheap because it gets 3 MPG with faulty brakes.

With our Efficiency Lab, a comparison 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 (nozzle, open tube, modified fitting, etc.) 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.  We will also provide a simple ROI – 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.  Take advantage of our expertise by using the Efficiency Lab service, we will provide you a detailed report with a comparison analysis to make a great choice. 

Jordan Shouse
Application Engineer

Send me an Email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

6 Important Factors when Choosing a Safety Air Gun

If you look at operating costs alone, compressed air can be just about the most inefficient method there is for cleaning parts. If you just look at the risks, it’s potentially very dangerous too. Don’t even get me started on the insufferable noise it can make.

For cleaning parts, most folks are familiar with the use of an air gun. You can find the simplest of these in many industrial settings: a valve (often in the form of a handheld trigger device) fitted with a nozzle of some sort (often in the form of an open ended tube, pipe, or fitting to focus or direct the air flow). These have all three of the “downsides” I opened this blog with. Of course, these concerns can be mitigated to a high degree by using the right tool for the job. That’s where engineered products like EXAIR Safety Air Guns come in. Let’s look at how we can address these three “downsides”:

Efficiency: This is all about compressed air consumption. In the simplest of air guns mentioned above, consumption is only limited by the passages in the valve (or trigger) and the discharge fitting…and those limits are usually negligible. Modifying the ends (see examples below) to focus the air flow usually has minimal effect, because you’re not appreciably changing the total cross sectional area of the discharge opening:

Here are a few modified thumb trigger air guns that were sent in for Efficiency Lab testing. Left to right, compressed air consumption at 80psig supply pressure was 34.2 SCFM, 30.9 SCFM, and 28.2 SCFM. For comparison (more on this later,) EXAIR Model 1210 Soft Grip Safety Air Gun uses only 14 SCFM and generates a very similar flow pattern.

Safety: Remember learning about kinetic and potential energy in grade school? Well, when you compress air to 100psig, fitting all that air into a much smaller space creates a TREMENDOUS amount of potential energy:

The block on the left represents a cubic foot of air at atmospheric pressure. The one on the right represents how much space the first one takes up when compressed to 100psig. The energy imparted by this process HAS to be handled with care.

One problem with the thumb guns above is, if you were to jam into the palm of your hand and pull the trigger, a large component of that potential energy (pressure) turns into kinetic energy (force)…more than enough to break the skin and cause a potentially fatal condition known as an air embolism. In the United States, OSHA (Occupational Safety and Health Administration) regulates compressed air devices used for cleaning purposes. All EXAIR Safety Air Guns comply with Standard 1910.242(b) by providing a relief path to ensure that it cannot be dead ended, and thus never create over 30psi measurable at the outlet)

EXAIR Super Air Nozzles cannot be dead ended, ensuring the outlet pressure won’t reach OSHA limits, regardless of supply pressure.

Noise: Another problem is, another component is turned into sound pressure…discharging air from a direct opening is quite loud. OSHA standards address these with limitations on outlet pressure and sound level. All EXAIR Safety Air Guns comply with Standard 1910.242(b), which limits the outlet pressure (by providing a relief path to ensure that it cannot be dead ended, and thus never create over 30psi measurable at the outlet) and all but our largest Super Blast Safety Air Guns comply with Standard 1910.95(a) limits for continuous 8 hour sound level exposure.

Which brings us to the topic of this blog: How exactly did THEY (our customer who used to use the thumb guns above) select the right Safety Air Gun, and how can we apply that to getting the right Safety Air Gun for YOU?

These steps aren’t all-inclusive, and they don’t necessarily need to be followed in order, but if you call an EXAIR Application Engineer about selecting a Safety Air Gun, here’s what we’re gonna talk about:

Ergonomics: We offer five distinctive styles of Safety Air Guns:

From small part cleaning by hand, to wide area blowoff, and all points in between, EXAIR has a Safety Air Gun for most any application.

Our thumb gun user (as I alluded to above) chose the Model 1210 Soft Grip Safety Air Guns (top right). They had a number of typical industrial applications where the operators had the parts or surfaces to be blown off right in front of them. They liked the integral storage hook and rubberized hand grip, but the VariBlast Compact (top middle) or Heavy Duty Safety Air Guns (bottom left) were also considered. The VariBlast Precision (top left) and Super Blast Safety Air Guns (bottom right) were too focused or more powerful, respectively, than needed.

Airflow pattern: Honestly, I could make a good case for this being the first consideration. Selection of any blowoff product – be it an Air Nozzle, Air Amplifier, Air Knife, Air Wipe, etc., will largely depend on the size and shape of the airflow.

variety of airflow patterns…and effective distances…are available from EXAIR’s comprehensive line of Super Air Nozzle products.

Application specific concerns: Everything we’ve discussed so far has involved aiming the blow off stream away from the operator, in the direction the device is aimed. In addition to wide variety of engineered Air Nozzles, EXAIR offers a number of options for these products:

Atto Back Blow Nozzles can blow out recesses or holes as small as 1/4″ in diameter.
Scrape off, and blow away, stubborn debris with the Model 1244-48 Soft Grip Super Air Scraper.

If you’re looking for a portable, hand-held compressed air blow off product that’s quiet, safe, and efficient, look no further than EXAIR Corporation’s extensive line of Safety Air Guns. If you’d like to find out more, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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Efficiency Lab Leads To Big Savings

EXAIR Corporation manufactures quiet, safe, and efficient compressed air products for industry. We want our customers to get the most out of our products, and, in turn, their compressed air systems. To do that, we offer a unique service called the EXAIR Efficiency Lab. Here’s how it works:

  • An Application Engineer can arrange to have your existing compressed air device(s) sent in to our facility.
  • We’ll use our calibrated test equipment to measure the compressed air consumption, sound level, and force applied of those devices.
  • You’ll receive a detailed test report, along with our recommendations to implement an efficient, quiet, and safety compliant solution.
  • We’ll even send your tested device(s) back to you, at no charge, if you wish.

I recently had the pleasure of conducting just such a test on some air guns.  The caller was the Environmental Health & Safety Director for a plastics manufacturer.  The main concern was safety compliance…a recent audit had shown that some workstations were using handheld blowoff devices that did not comply with OSHA standard 1910.242(b), which limits dead end pressure of compressed air products used for cleaning to 30psi.

After discussing their typical uses for these (and other) air guns, they sent in a couple for testing.  Here’s what we found out:

“Thumb guns” are especially popular for blowoff because of their compact size, ergonomic design. and low price.

The air gun with the 7″ straight extension (top) is a “textbook” example of non-compliance with OSHA standard 1910.242(b).  Because it has an open-end discharge with no relief path, this one could cause an air embolism if it were inadvertently dead-ended into the operator’s skin – a potentially fatal condition.  It also uses a considerable amount of compressed air, and is quite loud.  At 80psig supply pressure:

  • Compressed air consumption is 40.7 SCFM
  • Noise level is 95.5dBA
  • Force applied, at a distance of 12″, is 13oz

For comparison’s sake, EXAIR Model 1210-6 Soft Grip Safety Air Gun is fitted with our Super Air Nozzle, on the end of a 6″ rigid extension:

  • Compressed air consumption is 14 SCFM
  • Sound level is 74dBA
  • Force applied, at a distance of 12″, is 13oz…same as theirs.
Model 1210 Soft Grip Safety Air is fitted with an EXAIR Super Air Nozzle. We can also supply it with a Rigid Extension and Chip Shield (right).

The other one is OSHA compliant (it can’t be dead-ended…the cross-drilled hole provides a relief path, but it was still pretty inefficient and loud.  At our standard test pressure of 80psig:

  • Compressed air consumption is 30.8 SCFM
  • Noise level is 94.8dBA
  • Force applied, at a distance of 12″, is 16.9oz

Although the force generated by the Model 1210 Soft Grip Safety Air Gun isn’t quite as high as theirs, it’s still our recommendation here.  Oftentimes, the flow and velocity generated by the engineered Super Air Nozzle is more than capable of meeting the needs of the typical blow off applications these types of air guns are used in.

EXAIR Efficiency Lab testing proves that replacing these air guns with our Soft Grip Safety Air Guns (or at least replacing the tips with EXAIR Super Air Nozzles…we also have adapters for that) will result in compressed air savings of 66% and 55%, respectively, and lower sound levels to within OSHA standard 1910.95(a) limits:

All EXAIR Soft Grip Safety Air Guns comply with these limits for 8 hour exposure.

If you’d like to know more about the efficiency & safety (or lack thereof) of your current air blow off devices, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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