“Go Green” in 2019 With EXAIR’s Super Air Nozzles & Jets!

If one of your New Year’s resolutions for 2019 is to help improve your impact on the environment, look no further than EXAIR’s Engineered Air Nozzles & Jets. By upgrading your blowoff, cooling, and drying operations to use one of our Super Air Nozzles or Jets you can save as much as 80% of your compressed air usage when compared with an inefficient solution.

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Example of a manifold of open pipes

An open copper pipe or tube, even if “flattened” as we’ll commonly see, wastes an excessive amount of compressed air. This wasted compressed air can create problems in the facility due to unnecessarily high energy costs and the pressure drop that can be experienced affecting other processes. In addition to simply using too much compressed air, an open pipe or tube will often produce sound levels in excess of 100 dBA. At these sound levels, according to OSHA, permanent hearing damage will occur in just 2 hours of exposure.

OSHA Chart

By simply replacing the open tubes and pipe with an EXAIR Super Air Nozzle, you can quickly reduce air consumption AND reduce the sound level. Sound level isn’t the only thing an OSHA inspector is going to be concerned about regarding an open pipe blowoff, in addition OSHA 1910.242(b) states that a compressed air nozzle used for blowoff or cleaning purposes cannot be dead-ended when using with pressures in excess of 30 psig. I don’t know if you’ve ever tried to use an air gun with 30 psig fed to it, but the effectiveness of it is dramatically reduced. This is why there needs to be a device installed that’ll prevent it from being dead-ended so that you can operate at a higher pressure.

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EXAIR Super Air Nozzle entrainment

EXAIR’s Super Air Nozzles are designed with fins that serve two purposes. They help to entrain ambient air from the environment, allowing us to maximize the force and flow from the nozzle but keeping the compressed air consumption minimal. In addition, these fins are what prevents the nozzle openings from being completely blocked off. Using an OSHA compliant compressed air nozzle for all points where a blowoff operation is being performed should be a priority. Each individual infraction will result in a fine if you’re subject to an OSHA inspection. Inspections are typically unannounced, so it’s important to take a look around your shop and make sure you’re using approved products.

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The fins along the outside of the Super Air Nozzle prevent it from being dead-ended

So, go ahead and make 2019 the year of energy savings, increased efficiency, and improving worker safety. You’ll find all of the tools you need in EXAIR’s 32nd edition of the catalog. Click here if you’d like a hard copy sent directly to you! Or, get in touch with us today to find out how you can get saving with an Intelligent Compressed Air Product.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

 

Super Air Nozzles and Stay Set Hoses to Replace Open Tubes

I recently worked with an company that performs energy audits and they were working with a food company to review and propose ways to reduce the energy consumption throughout the plant. One area where we were able to help was on an onion peeling machine, shown below:

Vegetable Peeler Wide
Onion Peeler With Screw Conveyor and Blow off Tubes

The area of machine in question used a screw conveyor and friction source to help loosen the peels and fifteen (15) 1/4″ O.D. open ended tubes, which were noisy and unsafe, to blow the peels completely off and away form the onion. The auditor was able to install an air flow meter on the system and found that the machine was consuming 220 SCFM of compressed air for this operation.

Vegetable Peeler Detail
(15) Total, 1/4″ Tubes Used to Blow Air and Help Remove the Peels

We proposed to replace the tubes with a 6″ Stay Set Hose and the model 1103 Mini Super Air Nozzle.  Each model 1103 Mini Super Air Nozzle will consume just 10 SCFM of 80 PSIG compressed air. Attached to the 6″ Stay Set Hose, the nozzle can be placed exactly where needed and aimed appropriately. A strong blast of air rated at 0.56 lbs (9 ozs.), and ultra quiet at 71 dBA, the Mini Super Air Nozzle delivers the results needed.

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Model 1103 – Mini Super Air Nozzle

1103 Performance

1103 Pattern

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Model 9256 6″ Stay Set Hose

The Stay Set Hose has “memory” and will not creep or bend, simply install the 1/4 NPT fitting into the compressed air supply side, an thread the 1/8 NPT Mini Super Air Nozzle into the other end and position as needed!

Fifteen (15) of the Mini Super Air Nozzles will pass 150 SCFM of compressed air compared to the current usage of 220 SCFM, resulting in a 70 SCFM drop, or a 31.8 % reduction.  At a typical cost of $0.25 per 1000 Cubic Feet of Compressed Air, the nozzles would save $1.05 per hour of operation. Rate of Return yields a full pay-off in just 43 days of operation (24 hours per day operation)!

If you are looking for ways to save on compressed air usage in your facility that is safe to operate and quiet to use, we will have a solution for you.

If you have questions about 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.

Brian Bergmann
Application Engineer
Send me an email
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Twitter: @EXAIR_BB

 

2″ Flat Super Air Nozzle Produces High Force to Clean Steel Sheet

I recently worked with a customer at a company that manufactures steel sheets. They grind, polish, and then shot blast the steel sheets. As the material exits the shot blasting chamber, some of the media still sticks to the steel and is carrying over into additional processes. To mitigate this, they installed a 1” pipe with drilled holes at the exit of the conveyor to remove the excess media and keep it contained inside of the machine. While this worked, it was using a substantial amount of compressed air which was resulting in a pressure drop across the rest of the facility when this machine was in operation.

Although their current method was doing the job for them, they couldn’t live with the increased compressed air consumption. After searching the internet, they came across the EXAIR website and were interested in learning about other blowoff methods. Typically for an application involving a wide sheet of moving material we’d look towards one of our Super Air Knives, available from stock in lengths from 3”-108”. But, in this case there was some friction between the shot blasting media and the stainless steel sheet that required brute force. They needed something that was going to give them an increased amount of force, but still reduce their overall consumption.

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(10) HP1125 2″ High Power Flat Nozzles installed on 1″ pipe manifold

I recommended our HP1125 High Power 2” Flat Nozzle. With a .025” thick shim installed, the HP1125 nozzle will produce 2.2 lbs of force when operated at 80 psig. This was more than enough to remove the shot blasting media. They’re also much quieter than an open blowoff, producing a sound level of just 83 dBA. While this wasn’t a motivating factor for them, the reduction in noise was definitely welcomed. They placed some on order and replaced the 1/4″ open holes with (10) Model HP1125 2” Flat Super Air Nozzles.

For comparison, (10) 1/4″ holes will consume 690 SCFM at 80 PSIG while (10) of the HP1125 comes in at just 370 SCFM. By simply installing the HP1125 (which conveniently also has a 1/4 NPT air inlet), they reduced their compressed air consumption by a whopping 46%!! By reducing air consumption they eliminated the system pressure drop, they were also able to increase the force as the compressor was able to maintain the 80 PSIG pressure at the header pipe. This also alleviated the pressure drops experienced elsewhere in the plant.

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HP1125 2″ High Power Flat Super Air Nozzle

At EXAIR we have a wide-range of different products suited to a number of different blowoff  applications. From 4mm nozzles producing just 2 ozs of force, all the way up to our largest nozzle capable of delivering 23 lbs of force and everything in between. No matter the application, EXAIR has something capable of taking care of the job. Odds are it’ll be safer, quieter, and more efficient!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

EXAIR Safety Air Gun Promotion

From August 1st to September 30th, 2018, EXAIR will be giving away a 1” Flat Super Air Nozzle with the purchase of any promotional VariBlast, Soft Grip, or Heavy Duty Safety Air Gun.  EXAIR is stressing the importance of safety in the workplace with the EXAIR Safety Air Guns as well as the versatility of the different types of EXAIR Super Air Nozzles.

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This promotional item, the model 1126 1″ Flat Super Air Nozzle, has a patented shim to blow a 1” wide stream of air to clean surfaces quickly and efficiently and is a $45.00 USD value. For more details on the Promotion, click on the photo/link above. For more information about the Flat Super Air Nozzles, click HERE.

Inexpensive air guns can be purchased just about anywhere- online, via catalogs, and through industrial supply companies. Typical quality is less than ideal – broken triggers, leaky valves – a short lifespan in an industrial setting are merely a few of the issues observed.  Most are loud and inefficient – they just blow large amounts of compressed air, and at noise levels that violate OSHA requirements.  Some may even generate dangerous dead end pressure situations that that can result in serious or fatal injuries if blocked.

EXAIR’s Safety Air Guns have been engineered and designed to eliminate these issues. They are durable for use in industrial situations and comfortable to use for extended periods of time.  With an EXAIR engineered air nozzle, each model provides top performance by entraining large volumes of surrounding air into the air-stream. Operation is assured to be safe along with low compressed air consumption and noise levels.  Due to the design, the airflow that exits the nozzle cannot be blocked, as required by OSHA Standard 29 CPR 1910.242(b).

Safety Air Guns
The EXAIR VariBlast, Soft Grip and Heavy Duty Safety Air Guns

The VariBlast style of safety air gun offers variable force based on the range of trigger pull. Force can be varies, form a light breeze, to full force maximum output. This cast aluminum air gun can be fitted with any of the EXAIR 1/8 NPT engineered air nozzles.

The Soft Grip style of safety air gun  has a durable cats aluminum body suited for rugged, industrial use. The ergonomic design has a soft vinyl cover, a large trigger for easy operation, and a hanger hook for easy storage.

The Heavy Duty style of safety air gun is powerful with a durable aluminum cast body and ergonomic composite rubber grip, best suited for rugged industrial environments. Hours of fatigue free operation are possible.

With all of the Safety Air Guns styles, Chip Shields and Extension Pipes are available, from 6″ to 72″ in length.

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Soft Grip Safety Air Gun, with Chip Shield and 12″ Extension

With many nozzle options, from a whisper quiet 58 dBA and 2.5 SCFM of flow up to 60 SCFM and 87 dBA (still below the OSHA 8 hour noise level threshold) there is a model that will fit practically any application. Application Engineers are available by phone, email, and chat to review your specific blow off needs, and help to select the best possible solution available.

We invite to you to try out an EXAIR Safety Air Gun, and get the free 1″ Wide Flat Super Air Nozzle as a bonus.

To discuss your application and how an EXAIR Intelligent Compressed Air Product can improve your process, 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

Send me an email
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Twitter: @EXAIR_BB

EXAIR Flat Super Air Nozzles – Adjustable, Flexible and Powerful

As an Application Engineer here at EXAIR, we get calls from customers looking for an air knife, but shorter than our typical 3″ stocked size.  We can make an air knife to any length needed, but we will look at the 1″ and 2″ Flat Super Air Nozzles as a possible solution.

Like an air knife, the Flat Nozzles provide a wedge shaped pattern of air that maintains the width of the nozzle, to create a concentrated, powerful air flow.  Thus, a 1″ Flat Super Air Nozzle has air stream 1″ wide, and the 2″ Flat Super Air Nozzle has one 2″ wide.

The Flat Super Air Nozzles are available in zinc aluminum alloy or type 316 stainless steel construction, to meet environmental conditions of the process.  Both the 1″ and 2″ nozzles contain a changeable, patented shim that maintains the critical air gap, which allows the release of a precise amount of air through the thin slot, across a flat surface. The result is a wide, forceful stream of high velocity, laminar airflow, with minimal air consumption and noise.

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1″ and 2″ Flat Nozzles, in Zinc aluminum Alloy and Type 316 Stainless Steel

Shims are available in thicknesses of 0.005″, 0.010″, 0.015″, 0.020″, 0.025″, and 0.030″.  Shim Sets with either 2 or 3 shims are available for both sizes to allow for adjustment of the performance to best meet the application need.

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Patented, Interchangeable Shims

Table below shows the stock offerings of 1″ and 2″ Flat Super Air Nozzles, along with Air Consumption, Force and Sound Level data for your review.

Flat Nozzle Table

If you have any questions about the Flat Super Air Nozzles, or any EXAIR nozzle or other 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

Send me an email
Find us on the Web 
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Twitter: @EXAIR_BB

Flat Super Air Nozzles – Quiet and Forceful and Adjustable

The 2″ Flat Super Air Nozzle is a very powerful yet quiet engineered nozzle.  Operation at 80 PSIG of compressed air pressure yields a strong 1.38 lb. of force, at only 77 dBA of sound level.  Compare this with many of the plastic flat nozzles that blow air through a series of holes, with sound levels ranging form 78-83 dBA, not to mention some might violate the OSHA dead ended pressure standard and results in fines being levied.

The patented technology utilizes a changeable shim to generate the high flow of air in a smooth and laminar flow, to keep noise down and power and strength up. With (6) stainless steel shim thicknesses available, the 2″ Flat Super Air Nozzle offers a very flexible package that can be set and tuned to meet exacting performance criteria, while using the minimum amount of compressed air, and at the quietest possible sound levels.

2 Inch Flat
2″ Flat Super Air Nozzle

The model 1122 is offered in a zinc aluminum alloy body and cap, and the 1122SS is constructed from type 316 stainless steel.  All shims are stainless steel. The shim thickness for the 1122/1122SS is 0.015″ thick.

Also available, for extra blowing force, are the HP1125 and HP1125SS.  The nozzles utilize the same zinc aluminum alloy or stainless steel body and cap and have the 0.025″ shim installed – and deliver 2.2 lbs of force, while only increasing sound levels to 83 dBA.

Shim sets for any of the 2″ Flat Super Air Nozzles are available.  The 1132SS shim set includes shims of thickness of 0.005″, 0.10″, and 0.020″.  For higher force levels, the HP1132SS shim set includes the 0.020″ and 0.030″ shims.

1132ss
Shims are available, from 0.005″ up to 0.030″ for maximum versatility and performance tuning

As you can see- for a versatile, forceful and quiet engineered air nozzle, it is hard to beat the EXAIR 2″ Flat Super Air Nozzle.  If a 1″ wide nozzle better suits your needs, the same flexibility and power can be found in the 1″ Flat Super Air Nozzle as well.  Check it out as well.

If you would like to talk about Flat Super Air Nozzles or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_BB

EXAIR’s Flat Nozzles: Safe, Reliable, and Efficient

Here on the EXAIR Blog we frequently discuss dead-end pressure as explained in OSHA Standard 1910.242(b). This directive states that the when compressed air is used for cleaning purposes, the dead-ended pressure must not exceed 30 psig. When pressures greater than this occur, there is potential for an air embolism. This animation shows and explains how an air embolism can affect the body.

EXAIR’s Flat Nozzles adhere to this OSHA directive. The Flat Nozzles consist of three primary components: the body, the cap, and the shim. The thickness of the shim will dictate the flow and force through the nozzle and can be easily adjusted. The cap slightly protrudes from the body and shim, creating a gap when it is pressed up onto the skin. By ensuring that there is always an avenue for that air to escape, there is no potential for it to be dead-ended.

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From top to bottom: Model 1126, 1126SS, 1122, and 1122SS

EXAIR’s flat nozzles are available in two sizes: 1” and 2”. Each size has a shim set that can be purchased for adjusting both the flow and force from the nozzle. These nozzles are available in both zinc/aluminum alloy as well as 316 grade Stainless Steel. They can be used by themselves, installed on our Safety Air Guns, or in conjunction with our Stay Set Hoses that allow for easy re-positioning.

You may have seen (or used) the plastic flat nozzles that come in a variety of different colors. EXAIR’s flat nozzle is a safe, efficient, and more robust replacement that will maintain a similar airflow pattern at a dramatically reduced operating cost. Where plastic nozzles may become damaged or break off, the rigid construction of EXAIR’s Flat Nozzle will not. In addition to be safe, durable, and reliable, EXAIR’s flat nozzles also offer a reduced sound level compared to these styles of nozzle. Reducing sound is another directive that OSHA 29 CFR 1910.95 covers. If you’re using an unsafe nozzle in your facility, OSHA can quickly begin assessing fines for each violation. They don’t announce their visits beforehand, so make sure you do your due diligence and assess your compressed air blowoff products yourself!

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EXAIR 2″ Flat Super Air Nozzle “blows” away the competition!

If you would like to discuss how to make your compressed air use safer and more efficient, give us a call. Our team of highly-trained Application Engineers is standing by, ready to help you make the switch to an Intelligent Compressed Air Product.

Tyler Daniel
Application Engineer

E-mail:TylerDaniel@exair.com
Twitter:@EXAIR_TD