The video below is a brief introduction to the EXAIR Efficiency Lab, a free service provided by EXAIR for customers within the USA and Canada.
If you have a single point blowoff that does not have an engineered nozzle, or if you have a wider format blowoff, manifold or home-made drilled pipe, contact an Application Engineer with EXAIR and let us help you to reduce your energy waste. Following are some examples of product where we have helped to save some serious air and reduced noise levels which heightens employee comfort.
That’s right folks, we’ve gone and done it again. When a customer calls for custom product because their environment calls for it or due to dimensional requirements, EXAIR has the ability and flexibility to meet those needs!
This time around it was a customer with specific material requirements due to their environment. I had a customer contact me recently that was using an aluminum Super Air Knife near a high voltage operation and was getting ground interference due to the aluminum air knife. They asked if it was possible to make them a custom knife out of PEEK plastic. After some light discussions about the form of the knife and what other materials are safe for their environment we settled on a 30% glass filled PEEK plastic for the knife, brass bolts and pipe plugs, with a PTFE shim installed. The form factor of the knife would follow the same shape as our PVDF Super Air Knives that are available from stock. The customer could not use PVDF due to high temperature and potential off-gassing in the process.
The results are shown below.
Whether you are looking for a one off product that is tailor made to your application or want to have a simple feature like hardware material changed in a stock EXAIR product that you are incorporating into thousands of machines, we have the solution for you.
A brief video showcasing the full EXAIR Swivel fittings offering. Each of the 9 Swivel Fitting models offers a 25° from center line adjustment for a total of 50° full range of adjustment. The Swivel fittings are an ideal accessory for a variety of EXAIR products. For more product details see our product page. For any questions or fitment suggestions contact an Application Engineer.
Just released, we are now stocking four different pipe sizes of Sanitary Flange 316 Stainless Steel Line Vacs. We are offering these in the following sizes, 1-1/2″, 2″, 2-1/2″, and 3″ Sanitary Flange. The performance is the same as our Stainless Steel Line Vacs, but now it is even easier to install in sanitary flanged piping systems. No need to get adapters or have specialty shops weld flanges on.
The new Line Vacs are available for purchase on their own or in a kit which includes the Line Vac, a mounting bracket for the Line Vac, pressure regulator and filter separator. The only parts you provide are the clamps, gaskets and compressed air supply.
These are the latest four additions to our already extensive line of in-line pneumatic conveyors. If we do not offer a stock Line Vac that will fit your needs, we also offer custom Line Vacs to fit virtually any need you may have, just contact us and we will help you determine what will work!
In case it goes unnoticed, EXAIR focuses on engineered compressed air point of use products to ensure that our customers are utilizing their costly utility as efficiently as possible. The main benefits to purchasing EXAIR products are the support you receive from us at EXAIR, the quality of the product, the savings in compressed air, and the increase in safety. Another added benefit is a large number of utility companies are offering rebates on the purchase of engineered nozzles, just like the Super Air Nozzles that EXAIR offers.
Many energy providers offer these energy rebates for commercial or industrial users. Here in the Cincinnati area, Duke Energy offers rebates on items such as lighting, air compressors, engineered air nozzles, heaters / dryers for extrusion machines, energy management systems, variable frequency drives, data center equipment, even food service equipment, custom incentives, and many other items.
For each engineered compressed air nozzle that is installed, in order to meet the rebate requirements they must flow less than or equal to given flow rates in SCFM at 80 psig inlet pressure. The pipe sizes, flow rates, and EXAIR equivalents are shown below.
EXAIR Engineered Air Nozzle Part Number
EXAIR Flow Rate @ 80 psig
#1102/#1103 – 1/8 NPT
#1100/#1101 – 1/4 NPT
All are 1/8 NPT
2.5, 4.9, 8.3 SCFM
#1003 – 3/8 NPT
By just replacing the nozzles the customer saved 2.7 SCFM per nozzle.If we take an example such as the EXAIR Case Study shown below for 1/4″ copper tube that was being used as an open ended blow off. The copper tubes were consuming 19.6 SCFM at 100 psig inlet pressure, there were 10 machines with one line per machine operating 40 hours, 52 weeks per year. The customer retrofitted the open pipes with a model 1100 Super air nozzle and was able to reduce the air consumption by 2.7 SCFM per nozzle. If they were to purchase these nozzles this year, current list price for a model 1100 Super Air Nozzle is $36.00 USD, then apply for the energy rebate offered by Duke Energy and receive $20.00 per nozzle replaced. The total savings and return on investment is shown below.
10 nozzles x 2.7 SCFM = 27 SCFM x 60 minutes per hour x 8 hours per day x 5 days per week x 52 weeks per year = 3,369,600 SCF of compressed air saved per year.
3,369,600 / 1,000 SCF x $.25 = $842.40 USD savings in compressed air per year.
Cost Savings per week = $16.20 USD
Total purchase cost is $36.00 x 10 nozzles = $360.00 USD
Energy Rebate = @20.00 per nozzle x 10 nozzles = $200.00 USD in rebates.
$360.00 USD purchase price – $200.00 USD energy rebate = $160.00 USD final purchase cost.
Return on investment at a savings of $16.20 USD per week is
$160.00 / $16.20 = Less than 10 weeks pay back!
By applying for the energy rebate this customer could reduce the ROI of this air savings project from just over 22 weeks (which is still very good) to less than 10 weeks.
If you would like to learn more about whether there are Industrial energy rebates available in your area, contact an Application Engineer and let us know where you are located and who your energy provider is.
We will help you determine the correct engineered solution to save your compressed air as well as help you to apply for eligible energy rebates in your area.
Today, I would like to discuss a question that comes up time and time again over the years. “What happens when I put water through a Super Air Knife?” That raised another question from myself of what about a Super Air Wipe?
The answer is quite simple, it will come out, just not as good as compressed air does. The engineering and design for Super Air Knives were all based around compressed air use. With any good product of course comes the question in time, how else can we use this? A number of applications for the Super Air Knife is blowing moisture off a part that has been applied through a series of wash/rinse nozzles. What if the knife could apply the liquid and then a second knife could remove the liquid. Below are some images from testing that was done on a Stainless Steel Super Air Knife at various gap sizes and various pressures. The “best” performance visually was from operating the air knife with .004″ gap and approximately a 17 PSIG inlet pressure (this is for a 12″ Super Air Knife).
As you can see in the photos, the water does flow fairly well immediately out of the knife, and becomes more turbulent as it gets further away from the knife. The stream actually begins to break up and thus the effective distance of the knife may be reduced when using it to flow liquids. This is not going to perform like a pressure washer, the maximum distance for the stream of liquid before it completely fell off was around 10′ from the discharge point. If this were to be used to remove loose debris or to cover a part in water to help cool the part the stream would be more than enough to perform.
As noted above the operating pressure was fairly low, and the gap was at a .004″ thickness. I recently tested a 1″ Stainless Steel Super Air Wipe as well. The shim gap was once again set to .004″ thick to permit a better flow and a low pressure, approximately 10-12 psig inlet pressure. As you can see the flow of water is not as smooth as the air flow out of a Super Air Wipe but if a light rinsing process was needed, or a water cooling process, this would work well.
So the answer to the main question at hand is yes, a Super Air Knife and Super Air Wipe will both operate with a pressurized liquid source under the correct circumstances. While they do not operate exactly like they do with compressed air, the results still prove useful in certain applications.
EXAIR is a company that is built around saving, sustainability, and doing the right thing. Our products focus on saving compressed air, reducing sound levels, and improving the safe operation of compressed air blow offs. EXAIR is also focused on ways to give back to our community and better our team. Over the past year EXAIR, through an employee sponsorship program, has given back to over 30 charities. This program is open to all EXAIR employees and enables us to select a charity event that we wish to participate in and EXAIR will sponsor our participation. Fortunately, many events have a charitable arm associated with them and we have a great deal of events to choose. This leads to us, the employees, being able to contribute to charities we want to, but also gets us out and doing these events and staying active.
Over the past year EXAIR has sponsored employees in over 30 different charity backed events. This list continues to grow every year and this does not include the charities that we have always supported through direct donations or volunteering, for instance.
The picture below is of our 7 person team for the Tough Mudder in Kentucky for 2016, out of the 7, 6 are employees that were all sponsored and chose to support Wounded Warrior through running the Tough Mudder for the 2nd year in a row, first time in Kentucky, and third Tough Mudder for a few of us.
For myself, the best part of working for a company that not only gives to charities but encourages their employees to get out and participate within our communities, is knowing and experiencing these events together. To give an idea we had five separate departments represented at just this event.