Step 4 of the Six Steps to Optimizing your compressed air is to turn off your compressed air when it is not in use. This step can be done using two simple methods either by using manual controls such as ball valves or automated controllers such as solenoid valves. Manual controls are designed for long use and when switching on and off are infrequent. Ball Valves are one of the most commonly used manual shut offs for compressed air and other fluids.
Automated controllers allow your air flow to be tied into a system or process and turn on or off when conditions have been met. Solenoid valves are the most commonly used automated control device as they operate by using an electric current to open and close the valve mechanism within. Solenoid valves are some of the more versatile flow control devices due to the fact that they open and close almost instantaneously. Solenoid valves can be used as manual controls as well by wiring them to a switch or using simple programming on a PLC to turn the valve on or off using a button.
Some good examples of automated controllers are EXAIR’s Electronic Flow Controller (a.k.a. EFC) and EXAIR’s Thermostat controlled Cabinet Coolers.
The EFC system uses a photo eye to detect when an object is coming down the line and will turn on the air for a set amount of time of the users choosing. This can be used to control the airflow for all of EXAIR’s products. EXAIR’s Thermostat controlled Cabinet Coolers are used to control the internal temperature of a control cabinet or other enclosures. This is done by detecting the internal temperature of your cabinet and when it has exceeded a temperature which could damage electrical components it will open the valve until a safe temperature has been reached, then turn off.
By turning off your compressed air, whether it be with manual or automated controllers, a company can minimize wasted compressed air and extend the longevity of the air compressor that is used to supply the plants air. The longevity of the air compressor is increased due to reduced run time since it does not need to keep up with the constant use of compressed air. Other benefits include less use of compressed air and recouped cost of compressed air.
If you have questions about our compressed air control valves or any of the 16 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.
Cody Biehle Application Engineer EXAIR Corporation Visit us on the Web Follow me on Twitter Like us on Facebook
The cheapest and easiest solution isn’t always necessarily the best. The best example I like to use to highlight this is the incandescent light bulb. They’re definitely the cheapest to buy, but over the useful life it will cost more in electricity to operate and it won’t last nearly as long as an LED light bulb. When you compare the costs of electricity as well as the lifespan of an incandescent bulb, it becomes quite clear that the initial price difference between the two will be quickly recouped over the lifetime of the LED bulb. Once it pays for itself, it doesn’t just stop saving you electricity. These savings continue to compound.
The same can be said when comparing the Super Air Knife to a commonly seen homemade alternative, drilled pipe. While it only takes a matter of minutes to drill a few holes into a section of pipe, the operating costs (electricity required to generate the compressed air) are significantly higher than that of the Super Air Knife. In addition, it’s not nearly as effective and is considered unsafe under OSHA 29 CFR 1910.242 (b) and depending on operating pressure is likely also considered dangerous due to the high sound levels as outlined in OSHA 29 CFR 1910.95(a).
Air exiting out of drilled holes in a pipe will create a turbulent airstream. This turbulence not only contributes to the high sound level but it’s ability to entrain surrounding ambient air is minuscule. The air entrainment ratio of a compressed air solution refers to the relationship between supplied compressed air and the free ambient air that is brought into the primary airstream. The higher the amplification ratio, the less compressed air necessary to complete a similar task. For a drilled pipe, the amplification ratio is generally around 3:1. With the Super Air Knife, this is dramatically increased with an amplification ratio of 40:1.
The Super Air Knife has a precisely set air gap across the full length of the knife, allowing for an efficient and quiet laminar airstream. When compared to a drilled pipe, the air consumption is dramatically reduced as is the sound level. For example, let’s take an 18” section of drilled pipe, with 1/16” diameter holes spaced out every ½”. At 80 PSIG, each hole consumes 3.8 SCFM. With a total of 37 holes, this equates to a total of 140.6 SCFM.
3.8 SCFM x 37 = 140.6 SCFM
A Super Air Knife, operated at 80 PSIG with .002” stock shim installed will consume a total of 2.9 SCFM per inch of knife. An 18” SAK would then consume just 52.2 SCFM.
2.9 SCFM x 18 = 52.2 SCFM
140.6 SCFM – 52.2 SCFM = 88.4 SCFM saved
Replacing an 18” drilled pipe with a Super Air Knife represents a total reduction in compressed air consumption of 63%! How much does this equate to in $$$? A reasonable average of cost to generate compressed air is about $0.25/ 1000 SCF. Let’s assume just a 40hr workweek:
88.4 SCFM x 60 mins x $0.25/1000 SCF = $1.33/hr
$1.33 x 40hr workweek = $53.20 USD
$53.20 x 52 weeks/year = $2,766.40 USD in yearly savings
The 2019 list price on a Model 110018 Super Air Knife is $397.00. By replacing the homemade solution with an 18” Super Air Knife, the return on investment is just over 38 working days of an 8-hr shift. If your plant runs multiple shifts, or works on weekends, it pays for itself even quicker.
Once the knife has paid for itself, it doesn’t just simply stop saving you money. That savings continues to compound and add to your bottom line. Don’t waste unnecessary air (and money) by using solutions that aren’t engineered to do the job in a safe and efficient manner. Reach out to an Application Engineer and get yourself an Intelligent Compressed Air Product that’s Built to Last.
There is no denying it, saving compressed air is a process. This process often involves some type of energy audit or at the very least an evaluation of something going wrong with production and a way to improve it. Many programs, consultants, and sales reps will devise a solution for the problem.
Often times the solution is to create a more efficient supply side of the compressed air system. The supply side is essentially everything within the compressor room or located in close proximity to the actual air compressor. While optimizing the supply side can amount to savings, many of these solutions and services can involve great expense, or capital expenditure processes. These processes can often lead to delays and continued waste until the solution is in place. What if there was a way to lower compressed air usage, save energy, solve some demand issues on the compressed air system and save some money while the capital expenditure process goes through for the larger scale project.
These solutions are a simple call, chat, email or even fax away. Our Application Engineers are fully equipped to help determine what points of your compressed air demand side can be optimized. The process generally starts with our Six Steps To Compressed Air Optimization.
Once the points of use are evaluated the Application Engineer can give an engineered solution to provide some relief to the strain on your compressed air supply side. For instance, an open copper pipe blow off that is commonly seen within production environments can easily be replaced with a Super Air Nozzle on the end of a Stay Set Hose that will still bend and hold position like the copper pipe does while also saving compressed air, reducing noise level, and putting some capacity back into the supply side of the compressed air system.
This amounts to saving compressed air and understanding how much air is being saved, adding capacity back into your supply side which will reduce strain on the air compressor, give the ability to increase production while the capital expenditure for the end solution of controls and higher efficiency on the supply side is approved to then save even more compressed air and energy.
The point is this, savings and efficiency doesn’t have to involve a capital expenditure, if that is the end game for your project that is great! Let EXAIR provide you a solution that you can have in house by the next business day to save money NOW and then put that savings towards another project. No matter the method, it all starts with a call, chat, email or fax.
A food manufacturing company was looking for a more efficient way to dry polypropylene trays that were filled with food product. With their current operation, they would send already packed and sealed food trays through a washing system that used sterilized water. The trays would then have to be dried prior to bulk packaging. The operators would place the trays side by side on a 24” wide open-mesh stainless steel metal conveyor with two or three trays at a time (depending on the tray dimensions). They contacted EXAIR because they wanted to replace their “old and inefficient system” with something better.
In my discussions, they gave some additional details of the operation and the problems that they were seeing. The dimensions of the trays ranged from 150 to 200mm long by 100 to 150mm wide by 35 to 50mm in height. They were cleaning at a rate of 30 trays per minute through the washing and drying system. The washer was designed to recycle the water to improve “green” operations. But the trays were carrying much of the water outside the machine. Thus, they would have to stop and refill the wash system with fresh water.
After the washing cycle, the drying section began. It consisted of two parts; a sponge roller and a heated chamber that would blow hot air. First the trays would run under the sponge roller to absorb the water from the top of the trays. A feature that they did not like was the continuous adjustment to the sponge roller for the different tray heights. They had to make sure that they had good contact without stopping the movement.
Also, with bulk of the water being on top of the trays, the sponge surface would get saturated. They would have to stop the process to change with a dry foam pad or replace due to wear. After the sponge roller, it would move into a heated chamber to remove the remaining portion of the water from the trays. They used a 11 KW heating system to blow hot air. This part of their system required a lot of electricity to run. They wondered if EXAIR could help streamline their process and reduce energy costs.
They sent a photo of their system, reference above. As described, the trays were moving intermittently through the wash cycle and then into the drying operation. When gaps are present in a process, the Electronic Flow Control, or EFC, becomes a great product for energy efficiency. It is designed to use a photoelectric sensor to detect a part and initiate a timing sequence. Using a solenoid valve, it will turn on the compressed air only when needed. With the drying operation, I suggested that they could remove the sponge roller and heated chamber, and replace them with two Super Air Knives. In conjunction with the EFC, we can decrease energy usage, reduce downtime, and increase savings. Profit margins can be critical in the food industry, and EXAIR has many ways to help.
To expand a bit more about revitalizing the “old and inefficient system” with EXAIR products, I made some suggestions. I recommended two Stainless Steel Super Air Knife Kits, model 110224SS, to be placed near the end of the conveyor. One Super Air Knife would be positioned above the tray to blow across the top; and one would be positioned below the tray under the mesh conveyor to blow across the bottom.
At a slight blowing angle in a counter-flow direction, the air streams would remove the water from the top and bottom of the tray at the same time. This would create a non-contact “wiping” solution. Now they do not have to worry about parts wearing out due to contact. Another unique feature of the Super Air Knife is the strength of the laminar air stream. It is consistent from 3” (76mm) to 12” (305mm) away from the target. Thus, they can easily set the height of the Super Air Knives to dry all the different trays without adjusting it.
And as an added benefit, the water that was being blown off the trays by the Super Air Knives remained within the washing system. The sterilized water was not being wasted and could be recycled. With the Electronic Flow Control, I recommended the model 9056. It is a user-friendly device with eight different timing sequences. They were able to position the photoelectric sensor near the outlet of the washing system. As soon as the trays were detected, the Super Air Knives would turn on to blow two or three trays at the same time. With the EXAIR products installed, the system went from using 11 KW down to 4 KW, a 63% savings.
EXAIR has helped many customers like this one above. When it comes to energy savings, EXAIR leads the way. With two Super Air Knives and an EFC, we were able to modernized their system; save on water, improve productivity, reduce the overall footprint, and save on their energy usage. If you have a similar application, you can contact an Application Engineer at EXAIR. We will be happy to update your system.
Recently I worked with a customer on an application to remove contaminants from the inside of glass bottles. During production, dust from the ambient environment was collecting inside of the bottles. They needed a way to remove it prior to filling. The solution was to briefly pause the conveyor, pulsing air into the bottles to free any dust that had accumulated. Their problem was that while the dust was blowing out of the bottle without an issue, some of it was settling back down into the bottles.
The customer needed a way to mitigate the risk of dust particles resettling into the bottles after it was removed. The solution was to install a Model 2012 12” Standard Air Knife to provide a curtain of air across the top of the bottles, catching any freed dust particles and blowing them away from the conveyor.
After noticing positive results, we wanted to take things one step further and help to reduce overall air consumption in the process. The blowoff was achieved with (8) ¼” open tubes operating at a pressure of 80 PSIG. Although they were only operating for a fraction of a second, they still consume a whopping 33 SCFM! Replacing them with Model 1101 ¼” NPT Super Air Nozzles (14 SCFM at 80 PSIG) resulted in compressed air savings of 58%!!
In addition to saving compressed air, the noise level was also dramatically reduced. At just 74 dBA, we’re below the threshold for an 8-hour exposure time for operators according to OSHA. Where earplugs were necessary before, they’re now able to operate safely without the need for PPE to protect their hearing. The second most effective fundamental method of protecting workers, according to NIOSH, is to substitute or replace the hazard with an engineered solution. It’s not possible to eliminate the hazard as a compressed air blowoff was necessary, but the next best step is to replace it with something safer.
In addition to complying with OSHA 1910.95(a), the Super Air Nozzle also cannot be dead-ended. In applications for compressed air blowoff with unsafe nozzles, pipes, or tubes, the pressure must be regulated down to below 30 PSIG according to OSHA 1910.242(b). The installation of an engineered compressed air nozzle by EXAIR allows you to operate safely at much higher pressures.
If you have inefficient blowoff processes in your facility, give one of our Application Engineers a call. We’ll be happy to take a closer look at your application and recommend a safe, reliable, engineered solution!
It is estimated that typically plants can waste up to 30 percent of their generated compressed air and that cost is substantial. Considering the average cost to generate compressed air here in the Midwest is .25 cents per 1,000 Standard Cubic Feet, that translates into .075 cents for every .25 cents spent! Compounded with the fact that energy costs have doubled in the last five years, it couldn’t be a better time to make your air compressor system more efficient.
The following steps will help you save air and in turn save money.
Measure the air consumption to find sources that use a lot of compressed air.
Knowing where you stand with your compressed air demand is important to be able to quantify the savings once you begin to implement a compressed air optimization program. Placing a value upon your compressed air consumption will also allow you to place a value on its costs and the savings you will reap once you start to reduce your consumption. (EXAIR’s Digital Flow Meter)
Find and fix the leaks in your compressed air system.
Not fixing your compressed air system leaks can cause your system pressure to fluctuate and affect your equipment negatively. It may cause you to run a larger compressor than necessary for your compressed air needs and raise your total costs. Or it could cause your cycle and run times to increase which leads to increased maintenance to the entire system. (EXAIR’s Ultrasonic Leak Detector)
Upgrade your blow off, cooling and drying operations using engineered compressed air products.
Your ordinary nozzle with a through hole and a cross drilled hole can be an easy choice based upon price, but if you do not consider the operating cost you do not really know how much it is costing you. An Engineered Air Nozzle will pay for itself and lower operating costs quickly. Engineered Air Nozzles are the future of compressed air efficiency and are made to replace ordinary nozzles, homemade nozzles and open line blow offs. Engineered Nozzles reduce air consumption and noise levels; ordinary nozzles cannot compete. Engineered Nozzles maintain safety features and can qualify for an energy savings rebate from a local utility; ordinary nozzles fall short. Open blow off or homemade blow off applications typically violate OSHA safety standards; Engineered Nozzles do not. (EXAIR’s Air Nozzles)
Turn off the compressed air when it is not in use.
Automated solutions add solenoid valves and run them from your machine controls. If the machine is off, or the conveyor has stopped – close the solenoid valve and save the air. And blow off applications can benefit from any space in between parts by turning the air off during the gaps with the aid of a sensor and solenoid. (EXAIR’s automated Electronic Flow Control)
Use intermediate storage of compressed air near the point of use.
Also known as secondary receivers, intermediate air storage is especially effective when a system has shifting demands or large volume use in a specific area. Intermediate storage is the buffer between a large demand event and the output of your compressor. The buffer created by intermediate storage (secondary receiver) prevents pressure fluctuations which may impact other end use operations and affect your end product quality. (EXAIR’s Receiver Tanks)
Control the air pressure at the point of use to minimize air consumption.
This is a very simple and easy process, all it requires is a pressure regulator. Installing a pressure regulator at all of your point of use applications will allow you to lower the pressure of these applications to the lowest pressure possible for success. Lowering the pressure of the application also lowers the air consumption. And it naturally follows that lower air consumption equals energy savings. (EXAIR’s Pressure Regulators)
By increasing your awareness of the health of your air compressor system and implementing a PM program you can significantly reduce your costs from wasted energy and avoid costly down time from an out of service air compressor.
If you would like to discuss improving your compressed air efficiency or any of EXAIR’s engineered solutions, I would enjoy hearing from you…give me a call.