Tag: engineered solution

Methods to Create a Safer Industrial Workplace/Environment

Published on by johnball2014Leave a comment

EXAIR has been at the forefront of safety and efficiency when it comes to blow-off devices since 1983.  We understand the importance of keeping personnel and the workplace safe.  Controlling employee’s exposure to hazards is a fundamental method of protecting them. The CDC published a useful guide called “Hierarchy of Controls” detailing five types of control methods as a means to implement effective solutions.

  • Elimination
  • Substitution
  • Engineering controls
  • Administrative controls
  • Personal protective equipment (PPE)

Elimination

Elimination removes the hazard from the source.  Elimination is at the top of the chart because it is the best way to protect workers.  In my previous line of work, we had to use MEK to dilute a solvent-based epoxy.  By switching over to a water-based epoxy, we were able to eliminate the chemical hazard from our process.  In some situations, this can be a difficult task, but the elimination criteria should be the first thing to review.

Substitution

Substitution is looking for a different but safer modification to the source of the hazard.  An example would be static elimination.  If we take into consideration an ionization bar to remove static, there are manufacturers that make “hot” bars that will shock the operator if they get too close to the ionizing point.  EXAIR Gen4 Ionizing Bars are shockless.  By substituting the “hot” bars with EXAIR Gen4 Ionizing Bars, you just removed the shock hazard for your operators.  When considering substitution, it is important to compare the new risk of the replacement to the original risk.  Remember, we are trying to reduce the potential effects of injuries. 

The CDC explains these first two methods with this statement, “Elimination and substitution can be the most difficult actions to adopt into an existing process. These methods are best used at the design or development stage of a work process, place, or tool.  At the development stage, elimination and substitution may be the simplest and cheapest options.  Another good opportunity to use elimination and substitution is when selecting new equipment or procedures.  Prevention through Design is an approach to proactively including prevention when designing work equipment, tools, operations, and spaces.”1

Engineering Controls

Engineering controls are very common.  Companies can evaluate an area for hazards and address them with proven controls.  This can be as simple as adding light curtains to a stamping machine.  Another area would be using compressed air for blow-off applications.  EXAIR has been providing engineered products to reduce these hazards.  We offer Super Air Nozzles, Safety Air Guns, Super Air Knives, and Air Amplifiers to reduce the noise level and dead-end pressure as found in the OSHA directives 29CFR 1910.65(a) for maximum allowable noise exposure and 29CFR 1910.242(b) for dead-end pressure/chip shielding.  By adding an engineered nozzle like our Super Air Nozzle over an open pipe, it will protect your workers, stop OSHA fines, and reduce energy costs. 

Administrative Controls

These controls will move personnel or change the process to limit the length of exposure time to the hazard.  As you notice, this is toward the bottom of the Hierarchy chart as one of the least effective ways for dealing with a hazard.  As an example, an operator is exposed to a blow-off application that has a noise level of 95 dBA.  The maximum exposure time allowed by OSHA is 4 hours.  So, another operator would have to be placed in that area to work another 4 hours.  But, if the company added a Super Air Nozzle to the blow-off device, then the noise level would be reduced to 74 dBA.  Now, you can have one operator run the machine for the full 8 hours.  

PPE

Personal Protection Equipment, or PPE, is equipment that is purchased to help protect the operators from hazards.  What may the problem be?  First, you have to train the operators on how to properly use them, as well as trust that they will follow the instruction explicitly. It also adds cost to purchase and maintain them. This is why this method is the least effective. 

At EXAIR, we have a statement: “Safety is everyone’s responsibility.”  The idea behind the Hierarchy of Controls is to help review hazardous areas and implement safer products.  EXAIR can help your company follow the Hierarchy of Controls, to eliminate or reduce the hazards of compressed air usage.  Many EXAIR products, including Super Air Knives, Super Air Nozzles, Safety Air Guns, and Air Amplifiers are engineered to meet OSHA standards. If you have questions or want to talk to an EXAIR Application Engineer, please contact us to discuss how our products will be beneficial to your work environment’s safety. 

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

Picture:  Safety First by Succo.  Pixabay License

  1. Note: The Hierarchy of Controls and the statement is from CDC.gov

EXAIR Efficiency Lab at Your Service

Published on by Jordan T ShouseLeave a comment

I couldn’t count the number of times we have written a blog about the EXAIR Efficiency Lab because its that cool, unlike the number of wins the Cincinnati Reds have right now. I can count that on two hand 10………10-26 as of writing this blog and I could go on and on about the pain but I will spare you the tears and write about how amazing the Efficiency lab is for any company that utilizes compressed air!

Is the Mascot signing something? Or hanging his head? We will never Know!

First – what is the EXAIR Efficiency Lab? Well several years ago EXAIR created a free program called the Efficiency Lab.  This program is to compare your current pneumatic blow-off device with an EXAIR engineered product.  The values we compare are air consumption, noise level and force. We generate a detailed report to send to you for review.  It is a free service that EXAIR provides for U.S. and Canadian companies to know more details about solutions you are currently using in your processes.

The EXAIR Efficiency Lab

Why do we offer this?  Air Compressors demand significant electrical power and compressed air is considered to be a fourth utility within plants and industries.  Many people do not realize the cost and safety concerns when using improper blow-off devices.  As an example, if you look at a single 1/8” open pipe for blowing compressed air, it can cost you over $2,000 a year to operate.  This will add to your overhead and cut profits.  Another reason to consider your blow-off device is that compressed air can be dangerous.  With that same 1/8” open pipe, it can violate OSHA standards for noise exposure and dead-end pressure.  In deciding your “vehicle” for blowing compressed air, cheap is not typically best option.  To put it in other terms, a cheap nozzle is like a cheap old car, it’s cheap because it gets 3 MPG with faulty brakes.

With our Efficiency Lab, a comparison it is quite simple to do.  An easy way is to call us and explain the details. These details can be data such as the inside diameter and length of a an open tube you are using, or the actual performance data of a cheap air nozzle you have chosen to use. Perhaps the easiest way to make the comparison is to let EXAIR do it – send in your blowoff product or a sample of the tube, nozzle, modified fitting, etc. We will then put them through our testing process. You can also fill out our Product Efficiency Survey on our website to give the conditions for testing. 

We will run the tests at the specified conditions or in a range of settings.  We will then return your pneumatic device back to you at our cost with a detailed report of the comparison.  Your information will be confidential, and we will not share it without your permission.  We will also provide a simple ROI – many customers like to use this report to show managers, executives, HSE, etc. on the improvements that EXAIR can provide including cost savings and safety.

How do we do the Efficiency Lab?  We use calibrated equipment and standardized procedures to test for noise levels, flow usage, and force measurements.  We will recommend an EXAIR engineered solution as a replacement to your current device to do the comparison.  With the analytical information, we can also figure the total amount of air savings, return on investment, payback period and safety improvements.

Don’t Swing and miss…. (Like the Reds)  You do not want to sacrifice safety, time, and money with a sub-standard product.  Let EXAIR solve this dilemma with our free service; the Efficiency Lab.  Take advantage of our expertise by using the Efficiency Lab service, we will provide you a detailed report with a comparison analysis to make a great choice. 

Jordan Shouse
Application Engineer

Send me an Email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

Reds Image Provided by IndyDina with Mr. Wonderful via Creative Commons Attribution 2.0 Generic (CC BY 2.0)

EXAIR’s Efficiency Lab Shows How Much Compressed Air You Can Save

Published on by Jordan T ShouseLeave a comment
The EXAIR Efficiency Lab

EXAIR has been manufacturing compressed air products since 1983, and we created a culture of making high quality products that are safe, effective, and very efficient.  Since we stand by our products, we created a program called the Efficiency Lab.  This program is to compare your current pneumatic blow-off device with an EXAIR engineered product.  The values we compare are air consumption, noise level and force. We generate a detailed report to send to you for review.  It is a free service that EXAIR provides for U.S. and Canadian companies to know more details about solutions you are currently using in your processes.

Why do we offer this?  Air Compressors demand significant electrical power and compressed air is considered to be a fourth utility within plants and industries.  Many people do not realize the cost and safety concerns when using improper blow-off devices.  As an example, if you look at a single 1/8” open pipe for blowing compressed air, it can cost you over $2,000 a year to operate.  This will add to your overhead and cut profits.  Another reason to consider your blow-off device is that compressed air can be dangerous.  With that same 1/8” open pipe, it can violate OSHA standards for noise exposure and dead-end pressure.  In deciding your “vehicle” for blowing compressed air, cheap is not typically best option.  To put it in other terms, a cheap nozzle is like a cheap old car, it’s cheap because it gets 3 MPG with faulty brakes.

With our Efficiency Lab, a comparison it is quite simple to do.  For starters, you can go to our Product Efficiency Survey on our website to give the conditions for testing.  If you wish for a side by side analysis, you can place your pneumatic device (nozzle, open tube, modified fitting, etc.) in a box and send it to EXAIR.  We will run the tests at the specified conditions or in a range of settings.  We will then return your pneumatic device back to you at our cost with a detailed report of the comparison.  Your information will be confidential, and we will not share it without your permission.  We will also provide a simple ROI – many customers like to use this report to show managers, executives, HSE, etc. on the improvements that EXAIR can provide in cost savings and safety.

How do we do the Efficiency Lab?  We use calibrated equipment and standardized procedures to test for noise levels, flow usage, and force measurements.  We will recommend an EXAIR engineered solution as a replacement to your current device to do the comparison.  With the analytical information, we can also figure the total amount of air savings, return on investment, payback period and safety improvements.

Don’t be fooled; not all blow off devices are the same.  You do not want to sacrifice safety, time, and money with a sub-standard product.  Let EXAIR solve this dilemma with our free service; the Efficiency Lab.  Take advantage of our expertise by using the Efficiency Lab service, we will provide you a detailed report with a comparison analysis to make a great choice. 

Jordan Shouse
Application Engineer

Send me an Email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

Mufflers to Protect Manufacturing Workers Hearing

Published on by johnball2014Leave a comment
Mufflers

Many manufacturing plants have a strong focus on safety for their workers.  One major safety concern that is overlooked is noise.   OSHA, Occupational Safety and Health Administration, has a directive that defines the noise exposure over time; 29CFR 1910.95(a).   For an eight-hour day, the maximum noise level is 90 dBA.  Hearing loss is irreversible, but it can be preventable.  The CDC, Center for Disease Control, and NIOSH, National Institute for Occupational Safety and Health, report that “approximately 18% of all manufacturing workers have hearing difficulty”1. 

EXAIR manufactures engineered products to reduce noise levels in the work environment.  We offer Super Air Nozzles and Safety Air Guns for blow-off applications and pneumatic mufflers for discharge exhaust.  In this blog, I will cover the different types of EXAIR Mufflers that we offer.   

  1. Reclassifying Mufflers are designed to have two functions. They can cut noise levels by 35 dB and remove oil mist from the exhaust air.  Cylinders and valves that exhaust pressurized air may have oil in the line to keep the seals from sticking.  When exhausted, it can create a fine mist which is dangerous for operators.  The Reclassifying Mufflers can reduce the loud noise as well as collect any contamination from the exhaust air.
  2. Sintered Bronze Mufflers are simple in design, cost effective, and easy to install. They have a minimal back pressure to not restrict operations of the pneumatic device.  They come in sizes from #10-32 thread to 1-1/2” NPT.  For a quick and simple way to reduce noise, the Sintered Bronze Mufflers are in stock for fast delivery.
  3. Straight-Through Mufflers offer a way to reduce noise levels without worrying about clogging. They have an aluminum shell lined with sound absorbing foam, and they can reduce the noise level by 20 dB.  EXAIR offers them with ports of ¼” NPT, 3/8” NPT, and ¾” NPT.  One side has a female thread while the opposite side will have a male thread.  This can allow you to connect other items like hose kits to reduce noise.
  4. Heavy Duty Mufflers are used within aggressive environments.  They have an outer aluminum shell with an internal stainless-steel screen.  They protect components like valves and cylinders from contamination entering into the part.  And, the Heavy Duty Muffler can keep contaminant like rust from being ejected at high speed into the work area. They have a typical noise reduction of 14 dB.

Here is a test for you.  If you go and stand in your plant, you can probably hear loud noises coming from your compressed air system.  EXAIR has an engineered product to solve most of them.  On the Hierarchy of Controls for NIOSH, Personal Protection Equipment, PPE, is the least effective.  A better control would be to isolate your operators from the hazard with an engineered product.  EXAIR can offer that solution for many of your blow-offs and pneumatic discharges to reduce noise levels.  This would include; and not limited to; Super Air Nozzles, Safety Air Guns, Super Air Knives, and Mufflers.  If you wish to discuss further the safety improvements that EXAIR can provide, you can contact an Application Engineer.  We will be happy to help. 

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

Note 1: https://www.cdc.gov/niosh/topics/ohl/manufacturing.html