Which Air Nozzle Is Right For Me?

Well, the obvious answer is, of course, an engineered air nozzle…you’re likely aware of this, or you wouldn’t be reading posts on the EXAIR Corporation blog.  We have no issue with narrowing that down a bit, and saying that the answer is an EXAIR air nozzle.  I bet you knew that was coming as well.  So let’s assume that, because of the cost of compressed air, the potential hazards of its unregulated discharge, and the flat-out racket it can make (unless you do something about it,) you’re looking for something efficient, safe, and quiet.

Now that we’re on the same page, let’s unpack that question.  The nature of the application will let us know the airflow pattern & characteristics (mainly flow & force) that we need.

For example, if you need just a pinpoint of airflow, our Atto Super Air Nozzle blows a 1/2″ diameter pattern at a distance of 3″.  Get a little closer than that, and it’s as tight as you want it to be.  Now, it’s only generating a force of 2oz (at 12″ away) but keep in mind that’s all concentrated in a small fraction of an inch diameter.  Which is plenty for most applications that need that precise of an airflow.

Atto Super Air Nozzle

If you DO need a little more flow & force, our Pico and Nano Super Air Nozzles offer incremental increases in performance.  The pattern starts to widen out, but that’s a function of the increased flow expanding in to atmospheric pressure…it has to go somewhere, you know.  But, again, the closer you get, the more focused the flow is to the centerline of the nozzle.

On the other end of the spectrum are EXAIR’s High Force Air Nozzles.  These are particularly useful for stubborn blowoff applications – a foundry blowing slag off hot strip as it cools, for example.  Our largest of these, a 1-1/4 NPT model, generates 23 lbs of force…that’s over 25 times the power of our standard Super Air Nozzle.

 

With 23 lbs of hard hitting force, this 1-1/4 NPT Super Air Nozzle is perfect for the most extreme blow off and cleaning jobs.

Speaking of the standard Super Air Nozzle, it’s the most popular answer to the Big Question.  It’s suitable for a wide range of blowoff, drying, and cooling applications, like the kinds of jobs an awful lot of folks use open end blowoff devices on.  Open ended tubes blow out a great amount of air, but they’re wasteful and noisy, and OSHA says you can’t use them unless you regulate the pressure to 30psig…where they’re not even going to be all that effective.

Choose from (top left to bottom right) 316SS, Zinc Aluminum, or PEEK Thermoplastic…whatever you need to stand up to the rigors of your environment.

If you’ve got a 1/4″ copper tube, for example, it’ll use 33 SCFM when supplied with compressed air at 80psig.  It’ll for sure get the job done (albeit expensively, when you think of all that compressed air consumption,) but it’ll be loud (likely well over 100 dBA) and again, OSHA says you can’t use it at that pressure.  So, you can dial it down to 30psig, where it’ll be marginally effective, but it’s still going to use more air than the Model 1100 1/4 NPT Super Air Nozzle does at 80psig supply pressure.  The hard hitting force of the Model 1100, under those conditions, will make all the difference in the world.  As will its sound level of only 74 dBA.  Not to mention, it’s fully compliant with OSHA 1910.242(b).  Oh…and you can even install it directly on the end of your existing tube with a simple compression fitting.

One of our customers installed Model 1100 Super Air Nozzles on all their lathe blowoff copper tubes, and saved almost $900 a year in compressed air costs.

We’ve also got engineered Air Nozzles smaller than the 1100 (all the way down to the aforementioned Atto Super Air Nozzle) and a good selection of larger ones, including Cluster Air Nozzles that hold tighter airflow patterns than similar performing single Super Air Nozzles.  They’re available in materials ranging from Zinc-Aluminum alloy, bare aluminum, brass, 303SS, 316SS, or PEEK thermoplastic polymer to meet the requirements of most any area of installation, no matter how typical or aggressive.

If you have an loud, wasteful, and likely unsafe blowoff, you owe it to yourself and everyone else who has to put up with it to consider a better solution.  Call me; let’s talk.

Russ Bowman
Application Engineer
EXAIR Corporation
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EXAIR Pneumatic Liquid Vacuums

EXAIR‘s line of Industrial Housekeeping Products consist of liquid and dry vacuums that utilize compressed air to operate. They do not have electric motors which most ‘all purpose’ vacuums rely on.  In industrial settings with harsh conditions and rugged use, EXAIR’s Industrial Housekeeping Products are ideally suited for the everyday wear and tear. 

Reversible Drum Vac with spill recovery kit!
EXAIR liquid type vacuums, like the Reversible Drum Vac, the High Lift Reversible Drum Vac, and the Chip Trappers are reliable, versatile and easy to use. Installing onto an any closed head, 30, 55, or 110 gallon drum creates a high powered vacuum.  It can fill a 55 gallon drum in less than 2 minutes.  Then, with the turn of a knob, the the same pump quickly empties the drum. Useful for refilling coolant sumps, vacuuming floor spills, or transferring contaminated liquids to filtration tanks in minutes.  Flow rate can be controlled with the knob. 
EXAIR Reversible Drum Vacs
The Chip Trapper has an internal filtration system to separate the chips from the coolant, allowing for disposal of the solids, and for pumping of the clean coolant back into the sump.
EXAIR Chip Trapper
When you look at the vacuums, you’ll notice there is not an electrical cord.  Because the EXAIR Industrial Housekeeping Products utilize compressed air for operation, they do not have the same issues with wear, breakdown and failures as electrical type vacuums. There are no moving parts in the vacuum units to wear out or break.  They are maintenance free, just supply clean, dry air, and they will operate for a long time. For the the liquid type systems, there is a built in pressure/vacuum relief device and auto safety shut-off to prevent overfilling.

There are no motors and bearings to wear out and no impellers to clog.  The Chip Vac is 50% quieter than a comparable electric vacuum.  Safety is a top priority, and the use of the unit on wet floors and spills is not an issue when electricity is not involved.

If you would like to talk about Industrial Housekeeping products 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.

Jordan Shouse
Application Engineer

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EXAIR’s Heavy Duty HEPA Vac

March brings with it the first day of spring. I don’t know about you, but boy am I ready for some warmer temperatures!! Naturally, spring is the time of year that we roll up our sleeves and do some of the deep-cleaning we’ve been putting off all winter. Lucky for you, EXAIR has an entire line of Industrial Housekeeping Products that’ll get your shop cleaned up for spring. With no moving parts to wear out and no electrical requirement, these products are Built to Last. For applications requiring you to vacuum very fine or dusty materials, look no further than EXAIR’s Heavy Duty HEPA Vac.

HEPA Vacuum

Electrically powered vacuums or shop vacs are not designed to be operated in a rugged industrial environment. Filters clog, motors wear out, and you find yourself frequently replacing them. EXAIR’s Heavy Duty HEPA Vac has NO moving parts to wear out, doesn’t require maintenance, and needs nothing but a source of compressed air to operate. A static resistant hose also prevents painful shocks when working with dry, dusty materials.

The vacuum generator is constructed of a hardened steel alloy designed to be resistant to abrasion and delivers a powerful vacuum level of -60” H2O at 80 PSIG. The lever lock drum lid fits any open top 30, 55, or 110 gallon drum. Moving the system from one drum to another can be done quickly, allowing you to keep different materials separate for recycling. Recycling companies will pay a premium for pre-sorted materials, allowing you to get more out of your otherwise scrap material. It can be used with any open head steel, fiber, or plastic drum in good condition (ANSI Standard #MH2-2004).

If you don’t have a spare drum available, not to worry! EXAIR also sells a Premium Heavy Duty HEPA Vac System that will include either a 30, 55, or 110 gallon drum and dolly.

hepahowani

The HEPA Vac works by injecting compressed air at 80-100 PSIG through the air inlet (1) and into an annular plenum chamber (2). It is then injected into the throat through precisely directed nozzles (3). These jets of air create a vacuum at the intake (4) which draws in material through the generator itself (5), directing it into the bottom of the drum. The airflow is passed first through a pre-filter to trap larger particles, and then through the 0.3 micron HEPA filter, trapping any airborne particles. It is then exhausted through the vent in the top of the drum lid (6).

You wouldn’t use a hammer to try and drive in a screw, so don’t try and force a shop vac or electric vacuum to deal with these harsh materials. Get yourself the right tool for the job and give an EXAIR Vac a try. With a 5 Year Built to Last Warranty, there really is no comparison. Act fast, between now and May 31, 2020 we’ll include a FREE Model 6492 Vac-u-Gun System to any US and Canadian order.

Tyler Daniel
EXAIR Corporation
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Solving Static and Increasing Print Quality on Food Packaging

Gen4 Static Eliminators

A yogurt company printed bar codes on every cup that they produced. This was necessary for registering and tracing their product. After failing a bar code reader quality test, they started noticing some print issues during batch runs. They would have to stop their system, clean the inkjet printer head, and scrap product that would not register with the bar code reader.

This affects production rates, scrap rates, and overall cost. They stated that they threw away 30 to 40 cases per batch of yogurt due to this problem. They had an EXAIR catalog where they found a similar application within our Gen4 Static Eliminator product line. They contacted us to see if we could find a solution.

With non-conductive material like plastic, static is easily generated; especially during cooler weather. Static can be in a negative state or a positive state dependent on the material. For opposite charges, things are attracted to each other and will “stick” like magnets. For similar charges, they will repel each other. The higher the static charge, the stronger the force.

For the company above, the yogurt cups moved along a 7” (178mm) wide conveyor before they reached the bar code printer. This movement causes static to be generated on the surface of the cups. But, what about the inkjet printer? The function of the printer charges the ink droplets for direction and positioning. Since the ink droplets and the cup surfaces have the same charge, the droplets were being “pushed” back toward the printing head (reference photo below). Thus, the ink would dry on the surface and affect the quality of the bar code.

Bar Code Printer

When it comes to removing static, EXAIR is a leader in this market. We have a large product line of different types of Static Eliminators. Our design generates both positive and negative ions to remove any type of static charge. Since we only had to remove the static from the surface of the cup, I recommended a Gen4 Ionizing Bar. With a quick static decay rate, we can remove the static right before the bar code printer with only one Gen4 Ionizing Bar. For this application, I recommended the model 8003 3” Gen4 Ionizing Bar and a model 7960 Gen4 Power Supply. Together, it was very easy to mount and start using. EXAIR stocks lengths from 3” (76mm) up to 108” (2743mm), and we can ship a solution the same day. When you are losing 30 to 40 cases, time matters. And for this company, they received the items the next day to correct the misprints and short printing runs.

Gen4 Ionizing Bar w/ power supply

When problems occur, time can be of the essence. This is why EXAIR stocks our cataloged items for fast delivery.  For the company above, they had an EXAIR catalog which helped them to find a solution. If you would like to have an EXAIR catalog, you can click here to get one.   After they started using the Ionization Bar, the static was removed, the bar code was clean, and the operation ran smoothly. If static is causing issues for you, you can contact EXAIR and speak to one of our Application Engineers. We will be happy to assist you.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

EXAIR Remains Open for Business

To all of our customers and partners around the world-

As global and local concern about the current COVID-19 outbreak grows, we’re doing our best to keep everyone healthy and safe in the workplace while also minimizing the disruptions to our day-to-day operations.  At the same time, the landscape is changing almost by the day.  New public restrictions are put in place virtually every day.  The US is just entering the most crucial phase of this outbreak, if the lessons of other countries are any guide.  We know that many businesses, especially in Europe, are closed right now.  At the same time, our customers in Asia are beginning to come back online.

Yesterday, the state of Ohio issued an order requiring most residents to stay at home for the next 14 days and for most businesses to close during that time.  That order takes effect tonight, March 23rd.  After being able to read the order, EXAIR is exempt from it.  EXAIR is involved in nearly every industry listed by the Department of Homeland Security as critical industries, and those guidelines were part of the basis for the details of today’s order by the state of Ohio.  We know that is true through our many distributors worldwide as well.

Many industries that we support like food, pharmaceutical, medical equipment and related industries are absolutely critical right now.  If they need us, we need to be there for them.  The Governor’s press conference today stressed how important it was to everyone to keep supply chains moving, especially for critical industries.  EXAIR is part of that chain and will continue to do our part to the best of our collective abilities and we hope that our partners around the world can continue to do the same.

Please take care of yourselves, your families and each other.

Thank you for all you are doing.

Bryan Peters
EXAIR Corporation

EXAIR Vacuum Generators and Accessories

So, you’re looking at picking out a vacuum generator for your application but don’t know what accessories you need? Well here is a little overview of EXAIR’s E-Vac system’s accessories that you have to choose from. The E-Vac has a variety of uses from pulling a vacuum on a chamber to lifting Concreate cinder blocks. Here at EXAIR we offer everything that you may need to get started; this includes mufflers, vacuum cups, hose, and fittings.

Vacuum cups for E-Vac generators

Every time I hear someone talking about trying to pick something up the first line that comes to mind is “The claaaaaaw.”. But sometimes a claw or gripper isn’t the answer for the solution; using a variety of vacuum cups one can practically pick up almost anything. We offer four different kinds of vacuum cups to choose from stock; available are small and large Round, Oval, and Bellow styles. Round cups are more suited to being used on smooth, flat surfaces. Oval cups provide the most vacuum due to the larger surface area making them ideal for lifting heavy loads. The Bellows style is best suited for textured or uneven surfaces; the folds provide a collapsible area that allows the cup to compress and seal on the uneven surface.

EXAIR’s Standard and Straight Through Muffler

Next up is the mufflers; EXAIR’s mufflers do just that, they muffle down the sound generated by the E-Vac. There are two different types of mufflers that are available; these are the Standard and the straight through mufflers. The Standard muffler is designed to be attached to the discharge end of an in-line      E-Vac and has a closed end. These are best suited for applications that are free from dust and debris. The straight through muffler is open all the way through and are more suited to applications were dirt dust and debris is present. The straight through style also offers the best sound level reduction, up to 26 dBA.

Lastly the E-Vacs have an NPT threaded connection that will allow for a suitable connector to be properly installed. From here different connectors can be used to attach the various amounts of vacuum cups. The connectors provided are Push-In Connector Type Fittings of assorted styles available with our polyurethane tubing to make the installation and plumbing a cinch.

If you have any questions or want more information on EXAIR’s E-Vacs and their Accessories. Give us a call, we have a team of application engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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Advantages Of Compressed Air Operated Industrial Vacuums

Last week, I wrote about the benefits and advantages of the EXAIR Chip Trapper System. It’s just one workhorse in our stable of durable and reliable compressed air operated Industrial Housekeeping solutions.  All of our systems in this product line are compressed air operated, which means they offer several benefits that you don’t get with an electric powered vacuum:

  • Our air operated vacuums have no moving parts.  That means nothing to wear out & replace.
  • Electric motors burn out over time, and have to be replaced.  Not a problem with our products…if you supply them with clean air, they’ll run darn near indefinitely, maintenance free.
  • Using electric vacuums in wet areas can prevent a very real risk of electrocution.  This hazard does not apply to a compressed air hose, which is all it takes to run our products.
  • Long, stringy chips can get clogged in the impeller & rotating parts of a motor-driven vacuum.  Ours have no moving parts, which means nothing for detritus to get tangled up in.
Electric Vacuums are prone to clogging, wearing out, and motor failure.

Which EXAIR Industrial Housekeeping Product is right for you?  It depends on what you’ll be using it for.  Very generally speaking, here’s a brief overview of the product line:

Chip Vac Systems:

  • Pick up dry or wet chips and transfer them into a standard open top drum.
  • Available in four sizes: 5, 30, 55, or 110 gallon drums.
  • Turns your own 30, 55, or 110 gallon open top drum into a powerful vacuum system, in minutes, with a standard system.
  • Add portability and flexibility with a Deluxe System, which includes a drum dolly and a Tool Holder.
  • For a total Industrial Vacuum System, complete & ready to go right out of the box, the Premium Systems add a drum, a compressed air supply hose, an upgrade to Heavy Duty Aluminum Tools & a Static Resistant Vacuum Hose.
  • For smaller jobs or in tight quarters, the Mini Chip Vac System comes with a compact 5 gallon drum.  The Deluxe System adds a drum dolly for portability.

Heavy Duty Dry Vac Systems:

  • Function is similar to the Chip Vacs, but the vacuum itself is made of a hardened alloy, and offers higher vacuum power for dense and/or abrasive material cleanup.
  • Fits your existing 30, or 55 gallon drums for a quick & easy, basic high powered vacuum solution.
  • Deluxe Systems add Heavy Duty Tools & Tool Holder, and a Drum Dolly.
  • Premium Systems come with a 30, 55, or 110 Gallon Drum.

Heavy Duty HEPA Vac Systems:

  • All the power, durability, and convenience of the Heavy Duty Dry Vac Systems, but with a HEPA filter for contaminants such as mold, allergens, and other airborne irritants.
  • Fits your existing 30 or 55 gallon drums, or Deluxe & Premium Systems add the same accessories as the Heavy Duty Dry Vac Systems.
(Left to right) Chip Vac, Heavy Duty Dry Vac, Heavy Duty HEPA Vac

Reversible Drum Vac Systems:

  • These are our drum mounted vacuums for liquids.  They’ll fill or empty a 55 gallon drum in 90 seconds (tested with water.)
  • Fits an existing 30, 55, or 110 gallon closed top steel drum in good condition.
  • Deluxe Systems add a drum dolly, a Tool Holder and a set of plastic tools including a Spill Recovery Kit, for a multitude of cleanup needs.
  • Auto shutoff float prevents overfilling the drum.
  • Premium Systems add a 30, 55, or 110 gallon drum, Heavy Duty Aluminum Tools, and a compressed air supply hose.
  • High Lift Systems are available for higher viscosity (ups to 1400 cP) liquids, or when pumping from below grade (180″H2O suction lift.)
  • This same technology is incorporated into the Chip Trapper Systems, which (as detailed last week) trap incoming solids in a Filter Bag, allowing for instant pumping out of freshly filtered liquid.  They’re available with the High Lift capability as well.
Reversible Drum Vac, High Lift Reversible Drum Vac, Chip Trapper

Vac-u-Guns:

  • Handy and portable, the Vac-u-Gun is a lightweight handheld vacuum, blow gun, and transfer tool, all in one.
  • Collection System comes with a vacuum bag w/shoulder strap, extension wands, a crevice tool, skimmer tool, and round brush tool.
  • Transfer Systems come with the same tools, but include a 10ft hose instead of the vacuum bag.
  • All Purpose Systems come with the tools, the vacuum bag, and the 10ft hose.
  • Deep Hole Vac-u-Guns are fitted with a blow tube for stirring up fine debris from drilled holes, where it’s quickly and efficiently vacuumed away.

Regardless of your application, EXAIR has an Industrial Vacuum to fit.  Orders for qualifying systems through the end of May 2020 will include a free Vac-u-Gun.  If you’d like to discuss your Industrial Housekeeping needs, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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