The Super Air Knife and the Amplification Ratio

Super Air Knife

The EXAIR Super Air Knife has a 40:1 amplification ratio.  So, what does this mean?  The definition of ratio is a relation between two amounts showing the number of times one value is contained within the other.  For the Super Air Knife, it is a value that shows the amount of ambient air that is drawn into the compressed air.  With an amplification ratio of 40:1, that means that there are 40 parts of ambient air for every 1 part of compressed air; which helps make the most efficient air knifes available in the market.

Super Air Knife has 40:1 Amplification Ratio

Most people think that compressed air is free, but it is most certainly not.  Because of the amount of electricity required, compressed air is considered to be the fourth utility for manufacturing plants.  To save on utility costs, it is important to use compressed air very efficiently.  So, the higher the amplification ratio, the more efficient the compressed air product.  Manufacturing plants that use open fittings, copper tubes, and drilled pipes for blowing are not efficiently using their compressed air system.  These types of products generally have between a 5:1 to 10:1 amplification ratio.  When EXAIR began, they knew that there was a better way in saving compressed air by increasing the amplification ratio.

EXAIR initially created a line of air knives called the Standard Air Knife and Full-Flow Air Knife.  They utilize a Coanda effect to blow air at a 30:1 amplification ratio.  These air knives were much more efficient for blowing air than the open fittings, tubes and drilled pipes.  But, EXAIR knew that we could design a more efficient air knife, the Super Air Knife which has a 40:1 amplification ratio.

I like to explain things in every day terms.  For this analogy, the amplification ratio can be represented by gas mileage.  Like your car, you want to get the most distance from a gallon of gas.  With your compressed air system, you want to get the most utilization for blowing.  With an EXAIR Super Air Knife, it has a 40:1 amplification ratio.; or, in other words, you can get 40 mpg.  If you use the EXAIR Standard or Full Flow Air Knife, you can get 30 mpg.  But, if you use drilled pipes, copper tubes, etc. for blowing, then you are only getting 5 to 10 mpg.  If you want to get the most “distance” from your compressed air system, you want to check the “gas mileage” of your blow-off components.

EXAIR can “tune up” your blow-off systems to make them efficient and safe by contacting an Application Engineer.  We will be happy to help you.

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

A Customer Service Experience

Upon moving to our new house, quite a distance from our old location, my wife and I were looking for a new “go to” restaurant that would be close to our new digs.

I did a Google search and found a place that was only a couple miles away and had good reviews. My wife and I went in and it was a quaint little place. The food was good, as expected, but the service was not.

We discussed the lackluster service and decided to go again about a week later hoping it was an isolated incident. On this visit we had a different server (which turned out to be the owner). Long story short, the service was again not good. It took a long time to place our order and receive our food.

I was ready to just write them off but my wife has a very soft and forgiving heart. So against my vote we go a third time. Which turned out to be a carbon copy of the 1st visit. With one great exception, we left after we had been there 25 minutes and our order was not taken. So, now we drive farther to our “old standby” because the service makes the difference to us.

The chart below is representative of reasons business’s lose customers.

Pie Chart

Fortunately, EXAIR is a customer centric organization.   EXAIR ensures that the staffing is present to handle your needs with the care and quickness you deserve and our culture dictates that we serve you effectively and efficiently!  With both a Customer Service and Application Engineering Department we can handle your questions and requests consistently and accurately. Speak with a real person, and learn from over 159 years worth of combined manufacturing experience.

Did you know that most items are available for same day shipping (limits on quantities) with orders that can be processed by 3:00PM Eastern Time for the USA?  Last but certainly not least EXAIR offer’s a 30 day money back guarantee on all our catalog items within 30 days of the purchase date!

When you are looking for quiet and efficient point of use compressed air products or static reduction devices, give us a call.  Experience the EXAIR difference first hand and receive the great customer service, products and attention you deserve!  We would enjoy hearing from you.

Steve Harrison
Application Engineer
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EXAIR Hoses and Tubes are Great Accessories

EXAIR offers different styles of hoses and tubes as accessories to our product lines.  They are built and designed to easily fit with our products as well as being sized correctly to not affect performance.  It simplifies the use, setup, and integration of EXAIR products in your facility.   You do not have to determine the proper diameters, pressure ratings, or end fittings to best fit the EXAIR products to maximize their performance.  Also, having these items available from one source minimizes the number of purchases and vendors necessary for a complete and working solution. In this article, I will go over the different hoses and tubes that EXAIR can provide.

Conveying Hoses:

The hoses above are used with our Air Operated Conveyors or Line Vacs.  The Line Vacs are designed to move product from point A to point B.  If the Line Vac is the “vehicle”, the Conveyance Hose is the track.  The hoses are made of a durable PVC semi-flexible hose with 6 different diameters from ¾” I.D. to 3” I.D.  The conveyance hose can slip easily onto the EXAIR non-threaded style of Line Vacs.  EXAIR can cut-to-length Conveying Hoses up to 50 feet (15m); in increments of 10 feet (3m).

Coiled Hoses:

To get compressed air from the piping system to the Safety Air Guns, we offer a series of Coiled Hoses.  They are made of a durable abrasion-resistant nylon material that is 12 feet long (3.6 meters).  They have swivel fittings to allow for easy uncoiling, and a spring strain relief to keep the hose from kinking.  The coiled design makes it easy to reach around the work area and retract back to the substation.  This will help to keep the hose off the ground where potential dangers could occur.  We offer 3 different connection sizes of 1/8” NPT, ¼” NPT, and 3/8” NPT to attach right to the Safety Air Guns.  With the proper size, the Coiled Hoses can supply the required amount of compressed air with a minimal amount of pressure drop.

Compressed Air Hoses:

If you need a compressed air line to reach from overhead or around equipment, the EXAIR Compressed Air Hoses would work with these applications.  They are made from a reinforced synthetic rubber in 3/8” I.D. and 1/2” I.D. diameters.  We can make specific lengths up to 50 feet (15m).  They are rated for 250 PSIG (17 bar) air pressure, and the hose material works well for long lasting protection against ozone, weathering and temperatures up to 158oF (70oC).  They come with two male ends in ¼” NPT or ½” NPT.

Stay Set Hoses:

The Stay Set Hose gives you that possibility of manually adjusting or re-adjusting Super Air Nozzles.  The hose has a “memory” function, and it will not creep or droop until you physically move it.  They work well to direct air flows in specific target areas.  They can be used with Super Air Nozzles, Safety Air Guns and Blow-off Kits.  The Stay Set Hoses come in lengths from 6” (15cm) to 36” (91cm), and they are offered with ¼” NPT male on both ends or with a 1/8” NPT female and a ¼” NPT male connections.  These hoses are rated for 250 PSIG (17 bar) and are made from reinforced synthetic rubber.  If positioning is required for accurate blowing or re positioning for different areas, the Stay Set Hose would be a nice addition to your equipment.

Vacuum Tubing:

For our E-Vac product line, EXAIR offers vacuum hoses to connect the E-Vac vacuum generators to the suction cups.  They are made from polyurethane in ¼” O.D. and 3/8” O.D.  The tubing is very flexible for moving product, and they can resist the vacuum pressures created by the E-Vac.  They slip easily into our Push-In Connectors to quickly attach vacuum cups to the E-Vac system.  EXAIR can sell both types of tubing up to 50 feet (15m) in increments of 10 feet (3m).

Hoses and tubes may seem like simple things, but EXAIR already did all the research in determining the best material and correct size for optimum performance.  You can leverage this information to save you time and money when using EXAIR products in your application.  If you need help in selecting the correct model, you can contact an Application Engineer.  We will be happy to help you.

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

EXAIR’s Case Study Library

Did you know that you can find 35+ published Case Studies regarding many of the EXAIR products and how customers were able to save on compressed air and increase safety simply by installing and using one of our Intelligent Compressed Air Products?  Case studies provide real world results and highlight any dollar savings, production increases, quality improvements, safety improvements, and/or problems solved. The Case Studies are a valuable tool which can help determine success within your plant or aid in convincing a manager to implement an air savings project. With registration, they can be found under the Knowledge Base tab on the main page of the website, or simply click here.

Once on the Case Study page, you can search and sort by Product type or Application. Reading through the Case Studies of the type of product(s) of interest can provide valuable information on the compressed air savings and safety improvements that others have achieved, and that you might be able to realize as well.

Capture

The Case Studies involve measurable data from actual processes and offer learnings that can relate to applications and processes that are similar to those in your facility.

  • Each Case Study begins with the Application Goal – what was it that was to be achieved by the installation and use of the EXAIR product.
  • Then, we review the Before EXAIR condition –  what was the problem, and what was being used initially.
  • Next, we show the After EXAIR process – this details the EXAIR product(s) that were implemented, and how it was able to improve the process.
  • Finally, the Summary section – this shows the cost savings attained, from less compressed air usage, faster operation rates, lower quality defects, reduced sound levels, and so forth that have been achieved and documented.

We invite you to read, download, and share the Case Studies, and use them as another tool available to you to learn about EXAIR products and how they can improve your processes.

We are always interested in learning about the compressed air savings and increased safety that have been realized by the use of an EXAIR product, and if you could share that information with us and have it result in a Case Study, we would love to talk to you and discuss how we can work together.

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

Brian Bergmann
Application Engineer

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Gen4 Super Ion Air Knives Remove Pesky Dust from Crepe Paper Manufacturing Process

Paper Measuring Equipment

A paper manufacturer was having issues with their measuring equipment (reference photo above).  They were producing 6” (152mm) wide crepe paper which is very thin and dusty.  As it would pass through the machine, a real-time measurement of basis weight and moisture content was being performed.  The basis weight of the sheet was around 14g/m2 which is like facial tissue.  The machine was giving false errors in the basis weight measurement.  As they opened the device, they noticed dust particles on the optical lens.  Because the basis weight was so small, any dust would cause a false reading.  They contacted EXAIR to see if we could help with their problem.

With a dry fibrous material like crepe paper, static can be a big issue.  Static has a strong force that can cause small fragments to “stick” to surfaces.  As you can see in the photo, the paper material is sticking to the sides and lens of the measuring device.  For this application,  I recommended two pieces of the model 112206 Gen4 Super Ion Air Knife Kits.  The Gen4 Super Ion Air Knife is uniquely designed to have two functions; remove static and blow off dust.  The Gen4 Ionizing Bar creates both positive and negative ions to remove any type of static charge.  The Super Air Knife creates a laminar air stream to carry the ions and also generate an even blowing force to remove the dust particles from the surface.  With this combination, it becomes a very effective non-contact way to remove the contamination.  This was an important requirement as the crepe paper is very thin and could break very easily.  They were able to mount one Super Ion Air Knife above and below the paper in order to blow the dust particles in a counter-flow direction.  This would keep the particles from entering the measurement device.

Super Ion Air Knife Kit

The Super Ion Air Knife Kit includes the Super Air Knife with a Gen4 Ionizing Bar attached.  The kit also includes a power supply, filter, regulator, and a shim set.  The power supply is specifically designed for the Gen4 Static Eliminators.  The Gen4 Super Ion Air Knives use the high voltage from the power supply to generate enough ions to remove static from the paper at a running speed of 49.5 ft/sec (15m/sec).  The filter will remove any contamination and liquid water from the compressed air system before it enters the Super Ion Air Knife.  This is important to keep the product clean.  The shim set is a set of three different shims with a thickness of 0.001” (0.025mm), 0.003” (0.076mm), and 0.004” (0.1mm).  They are used to dramatically change the blowing force from the stock shim at 0.002” (0.05mm) thick.  Being that the paper was extremely thin, they opted to put the 0.001 (0.025m) thick shim inside the Super Ion Air Knife.  With the regulator in the kit, the customer could “dial” in the correct amount of force to keep the machine running optimally without breaking the delicate paper.

When the customer installed the Gen4 Super Ion Air Knives just before the entrance into the measuring device, the air stream was able to carry the ions to neutralize the static and to remove the dust from the paper surface.  The system was now able to make accurate measurements without disruptions.

For this customer above, the Gen4 Super Ion Air Knives made their system run accurately and consistently by removing any pesky dust particles.  If you have an optical device that needs to stay clean, you can contact an Application Engineer to review your application.

John Ball

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

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

Compressed Air Uses In Industry

Air Compressor

There are so many uses for compressed air in industry that it would be difficult to list every one of them as the list would be exhaustive.  Some of the uses are the tools used in production lines, assembly & robotic cells, painting, chemical processing, hospitals, construction, woodworking and aerospace.

It is considered as important as water, electricity, petroleum based fuels and often referred to as the fourth utility in industry. The great advantage of compressed air is the high ratio of power to weight or power to volume. In comparison to an electric motor compressed air powered equipment is smoother.  Also compressed air powered equipment generally requires less maintenance, is more reliable and economical than electric motor powered tools.  In addition they are considered on the whole as safer than electric powered devices.

Even amusement parks have used compressed air in some capacity in the operation of thrill rides like roller coasters or to enhance the “wow factor” of certain attractions. Compressed air can be found in your dentist’s office where it is used to operate drills and other equipment. You will find compressed air in the tires on your car, motorcycle and bicycles. Essentially, if you think about it, compressed air is being used nearly everywhere.

Here at EXAIR, we manufacture Intelligent Compressed Air Products to help improve the efficiency in a wide variety of industrial operations. Whether you are looking to coat a surface with an atomized mist of liquid, conserve compressed air use and energy, cool an electrical enclosure, convey parts or bulk material from one location to another or clean a conveyor belt or web, chances are we have a product that will fit your specific need.

Atomizing nozzle
Atomizing Nozzles Can Apply Even Coatings
Super Air Amplifier
Air Amplifiers pull in a large volume of ambient air to increase air flow volume and are great for cooling applications!
Heavy Duty Threaded Line Vac
For conveying heavy or abrasive products the Heavy Duty Threaded Line Vacs have male NPT Threads to make permanent and rigid installation into a piping system a breeze.

If you would like to discuss quiet, efficient compressed air products, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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