Video Blog: The Monetary Benefits of an Engineered Solution

This video highlights the value and benefits of an engineered blow off solution.  We take a homemade open pipe blowoff and replace it with an EXAIR model 1100 Super Air Nozzle.  This air nozzle is then controlled through our Electronic Flow Controller, allowing for intermittent On/Off of the compressed air flow.  And, these solutions are wirelessly monitored via Zigbee network using our Wireless Digital Flowmeter.  Implementing these solutions results in a compressed air reduction of over 90%!!!

 

Full calculations along with supporting flow values (pulled from the same data shown in the video above) are shown below.

Screengrab of the flow values shown in the video above. Click for larger image.

The open pipe:

The first compressed air flow values to show up on the EXAIR Logger are for the open pipe blow off.  At 1 BAR operating pressure, this “solution” consumes 22.3 SCFM of compressed air.  At a cost of $0.25 for every 1,000 cubic feet of compressed air, this nozzle will cost $695.76 to operate 8 hours per day, 5 days per week, 52 weeks per year.

The engineered EXAIR Super Air Nozzle

Model 1100 EXAIR Super Air Nozzles consumes 4.7 SCFM at an operating pressure of 1 BAR – a reduction of 79% compared to the open pipe.  These savings prove out in terms of operating cost as well – $146.64 per year, compared to $695.76.

The engineered EXAIR Super Air Nozzle with Electronic Flow Control (EFC)

By controlling the “ON” time for this application with an EFC, we are only blowing for 32% of the time for each minute of operation which changes the required compressed air flow from 4.7 SCFM to a peak value of 1.5 SCFM. This control saves an additional 68% of compressed air flow.  And, these savings are compounded by eliminating the need for constant compressed air flow.  Total annual operating cost for the EXAIR 1100 Super Air Nozzle with Electronic Flow Control is just $46.80.

Implementing an engineered solution can have a TREMENDOUS impact on energy costs and operating costs in your facility.  Compressed air is the most expensive utility to produce and consume, making the impact of proper solutions of high value to any business.  Let us help you utilize engineered compressed air solutions in your facility by contacting an EXAIR Application Engineer today.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Reducing Lubricant in a Blanking Operation

We recently chatted with a customer that was looking to improve the lubrication system for multiple blanking lines.  Blanking involves the cutting of sheet metal in a single step, to separate the piece form the surrounding stock. The part that is cut out is the desired product and  is called the ‘blank.’  This operation can be moderate to fast in speed, and the process creates heat, so a lubricant is used to cool and decrease the wear on the tooling.  Our customer was looking for a better way to apply the lubricant.

We proposed the model AN2010SS, a No Drip, internal mix, narrow angle, round fan Atomizing Nozzle.  The nozzle uses compressed air to create a mist of the liquid with very fine droplet size. When using for the  lubricant, a fine layer can be applied over the entire surface without areas of over coverage and waste.  This leads to lower costs for lubricant, and less mess on the blanks.

No Drip Atomizing Nozzle
No Drip Atomizing Nozzle

To simplify the process, the No Drip model was chosen. The No Drip style has the added benefit of positively stopping liquid flow when the compressed air is turned off.  There is no need to independently control the liquid flow via a control system and valve.

Finally, to control the compressed air side, we recommend the Electronic Flow Control (EFC.)  Utilizing a photoelectric sensor, the open position of the press can be detected and using 1 of many program options, the compressed air can be turned on and off to accurately control the application of the lubricant.  Due to the excessive amount of lubricant being used, the customer was applying every other cycle.  The first blank would be overly lubricated so that there would be some remaining for the next.  With the Atomizing Nozzle and EFC, the right amount of lubricant can be applied for each cycle.  The result is reduced lubricant usage, and a better operation.

EFCp4

If you have questions regarding Atomizing Nozzles or any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Twitter: @EXAIR_BB

Many Ways to $ave on Compressed Air Costs

Using compressed air in the plant is common for many types of processes.  Typical uses are drying, cooling, cleaning and conveying. Compressed air does have a cost to consider, and there are many ways to keep the usage and the costs as low as possible.  The first step is to use an EXAIR Intelligent Compressed Air Product, which has been engineered to provide the most performance while using the least amount of compressed air. The next step is to control the use of the air, to only have it on when needed.

EXAIR offers the EFC – Electronic Flow Control.  It offers the most comprehensive method to maximize the efficiency of compressed air usage.  It combines a photoelectric sensor with a timing control that operates a solenoid valve to turn on and off the air as required. With 8 different program types, an on/off mode that works with any process can be programmed ensuring that the minimum amount of compressed air is used.  You can use the online EFC Savings Calculator to see how quickly the savings add up!

EFCp4
EFC – Electronic Flow Control

Another method would be to use a solenoid valve with some other method of control. Depending on the process, the solenoid could be energized via a machine control output, or as simple as an electrical push button station. EXAIR offers solenoid valves in a variety of flow rates (from 40 to 350 SCFM) and voltages (24 VDC, 120 VAC and 240 VAC) to match the air flow requirements of the products we provide, while integrating into the facility and available supply voltages.

For control of the Cabinet Cooler Systems, the ETC – Electronic Temperature Control, uses a thermocouple to measure cabinet temperature and cycle the system on and off to maintain a precise cabinet temperature, and provides a digital readout of the internal temperatures and on the fly adjustment.  Also available is the Thermostat Control models, which utilize an adjustable bimetallic thermostat to control the solenoid valve, also cycling the unit on and off as needed to maintain a set cabinet temperature.

ETC CC
ETC – Electronic Temperature Control

There are several manual methods that can be used to control the compressed air.  A simple valve can be used to turn the air off when not needed, whether at the end of the work day, at break time, or whenever the air isn’t required.  We offer several options, from a foot controlled valve, to a magnetic base with on/off valve, to a simple quarter turn ball valve.

footpedalvalve (2)dualstand (2) manual_valves (2)

 

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

Brian Bergmann
Application Engineer

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Find us on the Web
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Twitter: @EXAIR_BB

 

 

Get the Right Tool With the Features You Want

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This year I made a decision to buy a new lawn mower. The previous one I had been using was purchased new about 15 years ago. Just like any new thing any technical oriented type of person buys, you have your own, personal critique of the things you like and don’t like about the current tool that affects your buying choices for the new one.

My old lawn mower was a front wheeled, self-propelled one that was either engaged all the time or off depending on the position of a locking lever you would push. To release it, you had to let go of the safety bar that kills the engine which then killed the engine. Not the best of designs. Also, the front wheels being propelled and not the back ones meant that the wheels with the least amount of weight bearing down on them had to pull the weight of the mower around. This was especially noticeable when the grass catcher bag was full. With this arrangement you end up with wheels digging into the grass/dirt and not really pulling the mower well. A side effect of that over the years; the drive wheels also wear down to a point where there’s no tread and in fact, holes where the nice tread used to be. The old mower did have a bagging attachment but the springs that hold the door down when in mulch mode wore out, so the wind created by the blade would blow grass clippings out all over the operator. A bucket and bungee cord fixed that issue.

Lastly and probably most importantly, the old mower was hard to start. It took the strength of a grown man to get the motor spinning fast enough that the spark would actually ignite the gas and the thing would run. To be quite honest, it never was really all that easy to start and keep running. But that’s one of those things you don’t figure out until you get the thing home and un-packed out of the box. I know, there’s the return policy from the store you buy it from, but that’s never as easy as advertised either. So, I messed around with it and tweaked here and there for 15 years.

This spring, I did my research on-line as well as in the store, comparing all the models available. I must say that there’s no shortage of features and accessories that the lawn mower design guys have cooked up. You can get electric start, self-propelled, 2 wheel drive, all-wheel drive, mulch, bag, side discharge, one blade, two blades, blade stop, electric, gas. You name it. You could get anything from an old-fashioned “reel” mower all the way up to a unit priced more than $1,000.00 USD for a residential quality, walk-behind mower.

I ended up deciding on the features and accessories that were important to me and selecting a middle of the road model that did have the all-wheel drive feature that would kick in and out depending on the position of the handle that the operator pushes on to get it to move. So, it matches the pace of the operator which is very cool and the wheels don’t spin all the time so you don’t tear up your turf or wear down the drive wheels. The unit started on the first pull each time and runs strong even through the thick, spring-time grass we have at the moment. I’ve used it twice now and am very happy I opted for a few of the features that I thought would really take away a lot of the pain in dealing with the “tool” to get the results I wanted with my “application” – cutting my grass.

At the end of this story, what does my lawn mower buying experience have to do with EXAIR and compressed air products?  The point is this, when you are looking at a Vortex Tube, an Air Knife or perhaps a Line Vac, remember, that we provide all of these items with all the possible accessories that one might need in an application to make for easy and convenient installation. Perhaps it is as simple as installing a suitable filter/separator that we recommend which keeps the air clean and dry or a regulator to give you finite control over blowing force from a Super Air Knife. Maybe you would even opt to install an Electronic Flow Controller in line with your Super Air Nozzle array so that it only operates when a target to be blown off is actually present.

EXAIR products are great at helping our customers manage their compressed air based applications. The accessories are also an invaluable set of tools to make the installation and use of our products a real pleasure. Back that up with our 30 day guarantee and a great group of Application Engineers to answer all your questions about the product and you begin to understand the kind of company that EXAIR strives to be.

Neal Raker, International Sales Manager
nealraker@exair.com

 

Lawnmower image courtesy of jeffcovey.  Creative commons license.