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.
Intelligent Use of Compressed Air – Most industrial facilities have at least one air compressor. The compressor is used to power anything from pneumatic tools, air powered equipment, compressed air cylinders, blowoffs and many more types of operations. Improper use of compressed air can lead to unnecessary energy costs, high noise levels and dangerous exposure of personnel to high pressure air.
The EXAIR Super Air Knife uses only 1/3 of the compressed air of typical blowoffs.
By taking advantage of the Super Air Knife’s highly efficient design and the action of air entertainment, the Super Air Knife draws in large amounts of surrounding free outside air into the air stream. The result is a strong powerful air flow made up of a small amount of compressed air and a large amount of ambient air.
Compressed air flows through an inlet (1) into the plenum chamber of the Super Air Knife. The flow is directed to a precise slotted orifice. As the primary airflow exits the thin slotted nozzle (2), it follows a flat surface that directs the airflow in a perfectly straight line. This creates a uniform sheet of air across the entire length of the Super Air Knife. Velocity loss is minimized and force is maximized as room air (3) is entrained into the primary air stream at a ratio of 40:1. The result is a well defined sheet of laminar airflow with hard-hitting force and minimal wind shear is delivered.
By using a Super Air Knife – and the advantage of the high amplification via air entertainment – for part blowoff, cooling, or drying you can reduce energy costs, reduce noise levels, and eliminate harmful dead end pressures. Other air knives typically entrain surrounding air at a ratio of 30:1 or less.
EXAIR offers the Super Air Knife with materials of construction of aluminum, Types 303 and 316 Stainless Steel, and PVDF to cover a wide variety of application temperatures and environments. Other materials may be possible, pending review by our Product Design Engineers. The Super Air Knives are offered as the knife only, as part of a full kit, which also includes a shim set, auto drain filter separator, and pressure regulator. The Super Air Knife can be fitted with Plumbing Kits and/or Electronic Flow Control making installation easier and help to save on air usage.
If you have questions about Super Air Knives, or would like to talk about 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.
On November 2, 2017 at 2 PM EDT, EXAIR Corporation will be hosting a FREE webinar titled “Optimizing Your Compressed Air System In 6 Simple Steps”.
During this short presentation, we will explain the average cost of compressed air and why it’s important to evaluate the current system. Compressed air can be expensive to produce and in many cases the compressor is the largest energy user in a plant, accounting for up to 1/3 of the total energy operating costs. In industrial settings, compressed air is often referred to as a “fourth utility” next to water, gas and electric.
Next we will show how artificial demand, through operating pressure and leaks, can account for roughly 30% of the air being lost in a system, negatively affecting a company’s bottom line. We will provide examples on how to estimate the amount of leakage in a system and ways to track the demand from point-of-use devices, to help identify areas where improvements can be made.
To close, we will demonstrate how following six simple steps can save you money by reducing compressed air use, increasing safety and making your process more efficient.
From pneumatic hand tools like impact wrenches or nail guns to larger scale industrial applications like stamping presses, the use of compressed air can be found in almost any industry. In fact, it is often referred to as a “fourth utility” next to water, gas and electric.
Take for example in construction, workers will use a pneumatic riveter to join steel framing because of the power generated by the tool over an electrically powered device, not to mention it provides for a safer operation by removing an electrical hazard. Many companies use compressed air operated diaphragm pumps or air motor driven pumps to move expensive or viscous liquid from one location to another. These types of pumps are self priming drawing the liquid in and provide positive displacement meaning they fill and empty the liquid chamber with the same amount of liquid through a common inlet and outlet.
Amusement parks have used compressed air in some capacity in the operation of thrill rides like roller coasters or to enhance the effect of certain attractions. Compressed air can be found in hospitals where it is used for specialized breathing treatments or to power surgical instruments in an operating room. Educational facilities use compressed air for laboratory testing. You can even find compressed air in the tires on your car. Basically, when you think about it, compressed air is being used just about anywhere.
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 dry 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.
To discuss your particular application or for help selecting the best product, contact an application engineer at 800-903-9247 for assistance.
My great big TV bit the dust recently. It was a 65” rear projection, high definition…quite an upgrade over the 32” tube set that it replaced, a decade ago. One thing I remember from the day I bought it: the seller said to me as we were loading it up, “A warning: you’ll never be able to watch anything smaller.” The other thing I remember from that day was getting it back to the house and set up before my wife got home. She walked in, looked at its huge awesomeness in our modestly sized living room and said, “That’s almost embarrassing!” To which I replied, “I KNOW!!!” Now, it WAS a little big for the room, but we acclimated quickly.
Until last month, when the display started to malfunction. I looked it up, and it was a fatal flaw: the parts would cost almost as much as a new 65” flat screen. Which we’re saving our money for…for now, though, we’re “getting by” with a 42” plasma TV that we “repurposed” from the back room. And the seller’s warning proved mostly true, although I’ve almost adjusted to the smaller screen. First world problems; I know.
One benefit of the smaller screen and advanced technology (plasma vs. those three big light bulbs in the rear projection) was decreased operating cost. Turns out, the 42” plasma uses less than 1/3 the power of the 65” rear projection (91 Watts vs. 283 Watts, respectively.) When my next electric bill comes, I’m wondering if I’m going to be pleased with the reduction, or if it’s going to put into perspective just how much TV I really watch. Stay tuned for more on that…
I recently had the pleasure of helping a customer realize a similar “a-ha” moment, with the amount of compressed air they were using throughout their plant. They were running (40) production machines, turning out custom plastic parts. Each machine had a ¼” crimped-end copper tube, which blows off the part as it’s being machined.
Each of the crimped copper lines uses approximately 30 SCFM when supplied at 80psig. These are being replaced with our Model 1100 Super Air Nozzles. They were able to quickly and easily adapt these by simply cutting off the crimped end, and installing a compression adapter fitting:
The Super Air Nozzle consumes just 14 SCFM @80psig, so we should be looking at around a 50% reduction in their compressed air usage in the operation, across their (40) machines. While all the data is still not compiled to determine their actual savings, the noise reduction alone has made a noticeable difference in the plant, which they’re getting used to a LOT quicker (and more agreeably) than I am to the smaller TV screen. But enough about that…I’ll be all right; really.
So that’s two of us, waiting for the next electric bill to see just how happy we can be with our energy savings. I don’t know what they’re going to do with their savings, but mine’s going into the 65” (energy efficient) TV fund.