In 1972, the US Department of Labor’s Occupation Safety & Health Administration (OSHA) established Standard 29 CFR 1910.242(b) to reduce the outlet pressure to less than 30 psi, of an open pipe, nozzle, air gun, etc. when being used for cleaning. The intent of this directive was to prevent injury to operators. They determined that 30 psi was the pressure in which the skin could be broken if the device were dead-ended against the operator’s body, causing an injury known as an air embolism…the dead-ended force of the air, under pressure, breaks the skin and introduces air flow inside the body. This is a VERY dangerous condition which can quickly lead to serious injury, possible stroke or ultimately death.
While OSHA doesn’t recommend any type or manufacturer of device, they do provide two methods you can follow to gain compliance.
The first would be to reduce the operating pressure below 30 PSI, as shown in the below line drawing. This, of course, limits the strength and usefulness of the exhausting air flow before it reaches the nozzle and before it is used upon the application.
The other method indicates using a nozzle which includes a pressure reducer or a relief device which will reduce the air pressure to less than 30 psi if the nozzle is dead ended. All of EXAIR‘s products are engineered to meet or exceed this Standard. In the case of our Super Air Nozzles, the air exits through a series of jets, recessed behind an array of fins, so the outlet holes cannot be blocked directly, any potential obstruction of the outlet air holes results in the air having an alternative route to avoid injury to operators and personnel. This allows the full pressure (the highest energy) to reach the nozzle and the application.
Open air lines and homemade blow offs violate OSHA standard 1910.242(b) because of harmful dead end pressures. If you would like to discuss how EXAIR products can help you gain OSHA compliance to increase personnel safety and avoid costly fines, please give me a call, I’d be happy to help.
Even if you’re a casual reader of our blogs, you already know that EXAIR Application Engineers LOVE to preach efficiency in the use of compressed air…it’s our “bread and butter;” the very nature of our business. This year, we’re celebrating thirty-five years of leading the way in the development of efficient, safe, and quiet compressed air products. Our track record of success as a solutions provider across a diverse range of industrial and commercial applications is well documented in our blogs, as well as Knowledge Base and Case Study Libraries. We devote considerable resources (engineering, research & development, product testing, etc.) to making certain that EXAIR Intelligent Compressed Air Products cost less to operate, and perform better, than whatever you’re using right now.
Strange as it may seem, though, sometimes our products are EXTREMELY popular in cases where they INCREASE a facility’s consumption of compressed air…by replacing something that DOESN’T use compressed air at all:
*I’ve written before about how our Large Maximum Cold Temperature Vortex Tubes have replaced liquid nitrogen rigs in freeze sealing operations. Now, a Vortex Tube directs a portion of its air supply to (usually) unusable hot exhaust, in order to generate the usable flow of cold air. When compared to the costs of liquid nitrogen and the resources involved to get it where it needs to be, though, the cost of the compressed air needed to operate the Vortex Tube is indeed the practical solution.
*Line Vacs are probably THE prime example of the value of using compressed air where it wasn’t used before…replacing a “bucket and ladder” operation:
*Then there are the situations that just come down to time. In large spaces, our Super Blast Safety Air Guns can be used to “sweep” the floor in a fraction of the time it takes an operator with a push broom.
To make a long story just a little bit longer…if you’re using compressed air, you can use it better with EXAIR’s engineered compressed air products. And there are plenty of practical applications where you’re not using compressed air right now too. If you’d like to find out more about either one, give me a call.
Return on Investment, or ROI, is the ratio of profit over total investment. Many people use it to evaluate stocks, financial markets, capital equipment, etc. It is a quantitative way in determining the validity of an investment or project. Recently, there has been a big push by power companies for energy efficiency within the manufacturing sectors. EXAIR, in partnership with Energy Star, has been manufacturing safe and efficient products since 1983. An ROI will give a measurable value to communicate more thoroughly with your financial decision-makers.
Equation 1: ROI = (Total annual savings – Total Project Cost) / Project Cost * 100
In an earlier blog, I wrote about a project with a company in calculating compressed air savings; “EXAIR Super Air Nozzles: 38 Day ROI Saves Money”. In this blog, I determined the total compressed air savings and the payback period by switching to EXAIR Super Air Nozzles. The payback period is the amount of time it will take for the project to pay for itself; and for the above manufacturer, it was calculated at 38 days. To associate this to a Return on Investment, I will use that information from the blog to calculate the ROI. Equation 1 shows that for any positive ROI value means that the payback period is less than one year. The larger the ROI value, the quicker the investment that you made will start earning money for your company.
The first part of the equation, Total Annual Savings, is calculated by amount of compressed air savings when using EXAIR Super Air Nozzles in a blow-off application. When this customer switched from copper tubes, which uses an excessive amount of compressed air, to the model 1110SS Super Air Nozzles, the compressed air consumption dropped by 80%. Compressed air is considered a fourth utility in manufacturing plants because the amount of electricity to make compressed air is very large. At a rate of $0.08/KWh, each Super Air Nozzle saved this company $306.00 per year. As described in the blog, the facility used four nozzles per machine, and they had 25 machines in their facility. The total annual savings is calculated as follows:
Equation 2: Total Annual Savings = $306 * 4 * 25 = $30,600 per year.
The second part of the equation, Total Project Cost, is the cost of the nozzles plus the labor to install them onto the machines. The model 1110SS Super Air Nozzle has a price of $46.00 each. These engineered nozzles are designed to use less compressed air by entraining the “free” ambient air, making them very efficient for blow-off applications. The amount of time required to install four nozzles to each machine was 1 hour. This time included tapping, fixturing, and testing each setup. The labor rate that I will use in this example is $75.00 per hour (you can modify this to your current labor rate). The labor cost to install four nozzles is $75.00 per machine. The Total Project Cost can be calculated as follows:
With the Total Annual Cost and the Project Cost known, we can insert these values into Equation 1 to calculate the ROI:
ROI = (Total annual savings – Total Project Cost) / Project Cost * 100
ROI = ($30,600 – $6,475)/$6,475 * 100
ROI = 373%
When a decision maker sees this large of a value for a Return on Investment, it makes it very easy to proceed with an energy-saving project to install EXAIR Super Air Nozzles on their machines.
Besides cost savings, there are some additional things that EXAIR products can provide. It may be difficult to put a value on the savings, but these products can improve your process and save your company money. First, they can reduce repair or replacement costs on maintenance items for the air compressors. If you use less compressed air, then the running hours of the compressor is reduced. Second, some things that can be easily overlooked is safety. The Intelligent Compressed Air® products have a much lower sound level where expensive PPEs may not be required. Another safety feature is dead-end pressure in which the operator could risk health in using open pipe or substandard nozzles. Some other enhancements in using EXAIR products are improved system reliability, increased productivity, and reduced unscheduled downtimes (typically seen with broken plastic nozzles). These added benefits plus the short ROI can validate a energy-savings project in your facility.
Power companies see the great value in using efficient engineered products in compressed air systems as they currently offer rebates. If you need help to see if your local power company does offer rebates, EXAIR can research the programs for you. The rebates will reduce the cost of each nozzle as well as cut the overall project cost. EXAIR also offers an Efficiency Lab. We will compare your current blowing device with an EXAIR product to find any compressed air savings. It is simple to do. Just fill out the form, Efficiency Lab, and ship your product to us. We will test each product with calibrated equipment and report the results. The comprehensive report will include compressed air savings which can be used for the ROI calculations above. For the company above, they were able to save $30,600 a year with a ROI at 373%. If you would like to team up with EXAIR to establish annual savings, project improvements, and rebates, you can contact an Application Engineer to get started. We will be happy to work with you.
If you’ve ever cleaned around the house (and who hasn’t?), you’re probably familiar with atomized liquid spraying…it’s what happens when you squeeze the trigger on that bottle of cleaner that breaks down the stove top grease in the kitchen and the ring-around-the-tub in the bathroom.
There’s a variety of industrial and commercial applications that require an atomized liquid spray too…applications that are beyond the scope of an operator with a trigger-operated spray bottle. That’s where EXAIR Atomizing Spray Nozzles come in. We have three types: Internal Mix, External Mix, and Siphon Fed. Depending on what you want to spray, and how you want to spray it, one of these is likely going to work better than the others for you. Today, we’re going to examine the Internal Mix Atomizing Spray Nozzles.
Better mist: Because the liquid & air come together inside the air cap, this results in very fine atomization.
Range of adjustment: Regulating either the liquid or air pressure supply will change the flow rate AND the flow pattern, giving each individual nozzle a wide performance band. The needle valve can “fine tune” the flow and pattern with even greater precision.
Area of coverage: With five patterns (Narrow or Wide Angle Round, Flat Fan, Deflected Flat Fan, and 360° Hollow Circular) and 72 distinct models to choose from, you can get spray patterns from 2″ (1/8 NPT Narrow Round Model AN8010SS) to 13 feet (1/2 NPT 360° Hollow Circular Model AT5010SS.)
Flow rate: Again, because of the many models available, you can get from 0.6 gallons/hour (Model AN8010SS again) to 264 gallons/hour (1/2 NPT Wide Angle Round Model AW5030SS.)
No-Drip option: The standard Models have a needle valve, which, as mentioned above, gives you the ability to make minute changes to the flow rate & pattern. If the application calls for rapid on/off control, or the chance of an errant drip after flow is not stopped might be a problem, the needle valve can be replaced with a No-Drip assembly. This positively shuts off liquid flow, at the exit of the liquid cap, when air pressure is secured.
Easy installation: All of our Atomizing Spray Nozzles have female NPT (1/8, 1/4, or 1/2) ports. The 1/8 and 1/4 NPT models can be adequately supported – and positioned – with a Stay Set Hose, and all models (even the 1/2 NPT) can be used with an appropriately sized Swivel Fitting. If you want to use your own tubes or hoses, we’ve got “clip-in” style Mounting Brackets.
Interchangeability: The only difference between any model of the same-size Atomizing Spray Nozzle is the Liquid and/or Air Cap. If your application’s liquid spray requirements change, or vary, you don’t need to replace the whole nozzle; just one (or in some cases, both) of the caps.
In most “general” blowoff applications, the conical airflow pattern from a standard round shaped nozzle is ideal when trying to remove dust or light debris from the surface of a part or material. However in certain applications, a focused, laminar flow of air is required to produce the desired result, such as cleaning peanut butter from a fill nozzle or ejecting parts in a stamping operation.
EXAIR manufactures our 1″ Flat and 2″ Flat Super Air Nozzles, which provide a 1″ and 2″ (respectively) wide, forceful stream of high velocity, laminar airflow while consuming only a small amount of compressed air. Both the 1″ and the 2″ are available in Zinc Aluminum alloy, rated up to 250°F (121°C), or 316 Stainless Steel construction, rated up to 1,000°F (538°C)
Their unique design incorporates a specially designed, replaceable shim, to maintain a critical gap between the cap and body, resulting in the focused airflow. They are shipped from stock with a .015″ shim installed.
Using the optional shim kit, the shims can be changed out to .005”, .010” or .020”, which allow you to increase or decrease the force and flow by either opening or closing the gap, providing more or less force and flow to meet the demand of the application.
(Here’s a short video showing how easy it is to change out the shims)
We also offer our High Power versions of these nozzles which feature a thicker shim installed (0.025″) for applications requiring higher thrust and velocity.
If you have an application you would like to discuss or to see how the Flat Super Air Nozzles might improve your process, give me a call, I’d be happy to help.
Compressed air driven devices are always given a specification for the compressed air flow at a certain pressure. For example, an EXAIR model 1101 Super Air Nozzle has a specified flow of 14 SCFM at 80 PSIG. This means that when this nozzle is operated at 80 PSIG, it will require 14 SCFM of compressed air flow. But what if the force from the nozzle is too high when operated at 80 PSIG and a lower operating pressure is needed?
Thankfully, we can calculate the compressed air flow at a different pressure using the absolute pressure ratio. The absolute pressure ratio says that for any given change in absolute operating pressure, there will be a proportional change in the air consumption of a device. So, what is an absolute pressure?
Put simply, an absolute pressure is the value which you would measure on pressure gauge plus the atmospheric pressure (PSIA, or Pounds per Square Inch Atmospheric). So, our 80 PSIG operating pressure mentioned above is an absolute pressure of 94.5 PSI (80PSIG + 14.5 PSIA). Similarly, if we wanted to determine the compressed air flow at an operating pressure of 60 PSIG, our absolute pressure would be 74.5 PSI (60 PSIG + 14.5 PSIA).
The absolute pressure ratio is a ratio of the new absolute operating pressure (new PSIG + PSIA) compared to the known absolute operating pressure (known PSIG + PSIA). For example, when comparing an operating pressure of 60 PSIG to an operating pressure of 80 PSIG, we will end up with the following ratio:
This means that our absolute pressure ratio in this case is 0.7884. To determine the compressed air flow for the model 1101 Super Air Nozzle at 60 PSIG, we will take this ratio value and multiply it by the known flow value at 80 PSIG. This will yield the following:
Utilizing this formula allows us to truly compare a compressed air powered device at different operating pressures. If we did not use the absolute pressures when comparing compressed air devices at differing pressures, our values would be erroneously low, which could yield to improper compressed air system planning and performance. And, using the absolute pressure ratio allows anyone to make a true comparison of compressed air device performance. If specifications are given at different pressures, performance data can be misleading. But, by using the absolute pressure ratio we can make a more exact evaluation of device operation.
If you have a question about your compressed air device and/or how a change in pressure will impact compressed air flow, contact our Application Engineers. We’ll be happy to help.
I like some better than others, but I don’t believe I’ve ever had bad pizza. That’s why I was pretty excited when I got to talk to a caller from a popular pre-packaged pizza crust maker. When these crusts leave their oven, they spray a coating of seasoned oil on them. This not only flavors, but preserves the quality from the time they make & package them to the time I celebrate life with a tasty slice, right out of my oven.
They were using inexpensive liquid-only nozzles that led to an inconsistent application of the oil…sometimes too much; other times, too little. And, it was always spraying, even in between the individual crusts as they came down the conveyor, leading to wasted oil that had to be cleaned up later.
They were already familiar with our Super Air Nozzles, as they had several Model HP1125SS 2″ High Power Flat Super Air Nozzles in use for blowing off the packages prior to labeling, so the caller asked if we might have a solution for the oil too.
After considering the size of the crust and the distance at which they needed to install the nozzle, they decided to try a Model AF2010SS Internal Mix Flat Fan Pattern No-Drip Atomizing Spray Nozzle. This applies a consistent and even coating of oil, and, by feeding a signal from the oven controls into a solenoid valve in the compressed air supply line, they’ve eliminated the excess spray, leading to savings in material cost and cleanup time.
If you’d like to know more about how EXAIR Atomizing Spray Nozzles can save you time, mess, and liquid, give me a call.