The Professor’s Assistant Has Come a Long Way

Today, I’m writing one of my last regular blogs for EXAIR. Since the Professor has moved on to his higher calling, I have started working for EXAIR as a design engineer. In 2008 I was a design engineering co-op student for EXAIR. I didn’t know anything about air. I had to learn the difference between CFM (cubic feet per minute), SCFM (standard cubic feet per minute) and ACFM (actual cubic feet per minute). I had to learn that a 1/4 pipe does not measure 1/4″ anyway you measure. I found out the hard way to point the 1116 Super Air Nozzle toward the ground, because it will lift ceiling tiles in short order. EXAIR stuck with me as a co-op to allow me time to grow and learn. At the same time EXAIR continued to grow and expand as well. Once my co-op turns were over, I left EXAIR at the end of 2009. I finished my degree and got some experience outside the company. In 2013, I rejoined EXAIR as an Application Engineer.

I have been writing entries for the EXAIR blog for two years. Looking back through my most viewed posts, I see topics on Air Knivescomplying with OSHA, and Videos. I also see an accomplishment, Product of the Year Award Winner. Third on the list though is On the Job Training: Internships and Co-ops. I wrote this blog with “The Professor” in mind…

I had just learned that he was leaving EXAIR and it made me pause for a time to think about “The Professor”. He was the driving force behind the Co-op program here at EXAIR. In doing so he was sticking his neck out. I’m sure first on his mind was getting someone who could do his dirty work. No one wants to test Line Vacs in the summer. It is hot and messy work. “The Professor” wasn’t above getting dirty, but I think he wanted to be.

But in hiring a Co-op, he wasn’t just making his life easier. Everyone will attest I had a lot to learn. In the first year of working with “The Professor”, he spent as much time training me as I spent producing useable material. I like to think he ultimately got more out of me than he put it in, but training Co-ops is quite an investment in time.

In moving over to design engineering, I feel much more confident that I will be able to teach our new Co-ops a good way of doing their work. It is such a leg a up to have spent time in their shoes. “The Professor” ultimately never got to benefit from me working for him as a engineer. The work he put in training several Co-ops has been an excellent investment in the future, and I hope more companies follow his example.

Dave Woerner
Design Engineer/Application Engineer/Co-op


EXAIR Air Wipes Offer an Improvement Over Competition

Last week, I had a customer using a competitor’s air wipes to remove water from an extrusion. These were air wipes built from UHMW blocks or similar material with a hinge and some air holes drilled in it.  He had several extrusion lines, and on each of these lines he used several air wipes. The one positive of these air wipes is they used less air than EXAIR’s Air Wipes, so on paper they seem the better choice. In practice it took 5 of these Air Wipes to do the job of one EXAIR Super Air Wipe. In addition to being more effective, EXAIR Air Wipes were also less expensive and produced a lower noise level.

The customer had two sizes of air wipes. The smaller version was a 1/2″ Air Wipe which used 8.3 SCFM (times 2 = 16.6 SCFM) at 80 PSIG, but it produced a noise level of 85 dBA. EXAIR Super Air Wipe, model number 2400, requires 13.9 SCFM and produces a quiet noise level of 75 dBA at 80 PSIG inlet pressure. EXAIR’s air wipe is able to easily remove water from an extrusion in a single pass. The 360 degree uniform blast of air works to remove water evenly and quickly. We offer the Air Wipes in aluminum and stainless steel with a braided stainless steel air line to join the two halves of a clamshell design.  The EXAIR 1/2 Air Wipe produced a much better blow off while reducing noise level by 10 dBA.

Super Air Wipe
1/2″ Super Air Wipe

The larger version of the air wipe was a 2″ unit that used 15.3 SCFM (times 3 = 45.9 SCFM) of compressed air and created 80 dBA of noise at 80 PSIG of inlet pressure. The EXAIR 2″ Super Air Wipe, model 2402, used 29.5 SCFM and lowered the sound level to 77 dBA at 80 PSIG of inlet pressure.  The EXAIR Super Air Wipes also were significantly thinner than the competitive offering which allows them to fit in tighter spaces. The EXAIR 2″ Air Wipe is 1.125″ in depth, the competitor’s product was more than 4″ long. By reducing the amount of the space need on the line and reducing the number of Air Wipes needed EXAIR was able to supply a better Air Wipe for their extrusion process.


EXAIR 2" Super Air Wipe
EXAIR 2″ Super Air Wipe

Dave Woerner
Application Engineer

When Two Arms Aren’t Enough

This morning I was chatting with my colleague Russ Bowman about taking care of kids. I was complaining about having to try and chop vegetables while holding a 1 year old in my other arm. Russ shared some perspective with me. He always took pride in what he could get done with an infant or toddler in one arm. While I was complaining, he pushed me to see what I could really get done. I thought cutting squash was pushing it. He informed me that I lack either imagination or perseverance in my dad skills. I wish his wife (or mine) had been around because, I’m pretty sure they would offer “perspective” to both of us about how much you can get done with infant in your arms. Which would be fine, Russ and I know our better halves are better than us… Thank Goodness. Otherwise, the kids would not stand a chance.
The discussion reminded me of EXAIR’s foot pedal. It is like an extra hand to control your air supply. I had a customer this week that was punching 4 mm diameter plastic circles from a part. The 4 mm diameter plastic chips built up on the machine which would lead to a housekeeping nightmare. The customer installed a 3/8″ Line Vac, model 6078, to evacuate the plastic chips after each punch. The Line Vac worked great to evacuate the chips, but running it constantly required 5.6 SCFM of compressed air. To get the job done, the Line Vac only needed to run five seconds after each punch operation, and the punch operated three times every minute. Controlling the air supply to the Line Vac to only turn on when the Line Vac was needed would save 4.2 SCFM of compressed air.

line vac drill press
Picture Model 6080 Line Vac removing chips from a drill press.

Unfortunately, the operation required two hands. One hand to position the plastic blank, one hand to actuate the punch. This meant controlling the Line Vac would need a third hand. With a foot pedal, model number 9040, though, the operator could gain additional control to operate the Line Vac only when needed. This saved 4.2 SCFM of compressed air. The foot pedal would pay for itself in 124 days. On a 3/8″ Line Vac that may not seem like much, but a foot pedal controlling a 2″ Line Vac would save 33.75 SCFM and the payback time would be 15 days.*

*Assuming 24 hour day and 250 working days per year.

A foot pedal is an excellent option, when you need that third arm. Check one out today at

Dave Woerner
Application Engineer


Intelligent Compressed Air Products: Pulling In Free Air

Home of Intelligent Compressed Air Products
EXAIR is the home of Intelligent Compressed Air Products.

What is an Intelligent Compressed Air product? What makes it intelligent? Compressed air is typically a manufacturing facility’s most expensive utility. A standard cost is $0.25 per 1,000 Standard Cubic Feet (SCF) produced. Any pipe, manifold, or fitting can be modified to blow compressed air, but these homemade blow offs will be very noisy, waste a tremendous amount of compressed air and create an OSHA violation. In contrast EXAIR’s intelligent compressed air are engineered solution are quiet, use a minimal amount of compressed air and comply with OSHA safety standards.

Let’s take EXAIR Model 1100 Super Air Nozzle as an example. Connecting it to a 1/4 NPT fitting, will produce 13 ounces of force on a target when mounted twelve inches away, and use 14 SCFM of compressed air. To produce so much force using that little air, the Super Air Nozzle must be precisely designed and manufactured to maximize the entrainment of ambient air.

With the air nozzle we use compressed air to induce a primary air flow. This primary air flow is a high velocity jet of air that create low pressure area around the primary airflow entraining the ambient or free air. These air streams combine past the tip of the nozzle creating a powerful blast of air. The Super Air Nozzle can entrain air up to a ratio of 25 parts of ambient air moved for every 1 part of compressed air.  All of our Super Air Nozzle create this level of air entrainment.

EXAIR Super Air Nozzle entrains ambient air up to a 25:1 ratio

In addition to entraining a significant amount of air, the Super Air Nozzle also reduces the noise level. Most homemade nozzles are not well constructed so, the hole(s) that allow the air to escape may have sharp jagged edge which will induce noise or turbulence. Even commercial nozzles with cross drill holes create a tremendous amount of wind shear which leads to an ear splitting compressed air squeal. The smooth design of the Super Air Nozzle creates a laminar flow of air that reduces the noise of the nozzle to 74 dBA. For reference a 1/4″ open tube can easily create noise levels over 100 dBA. Using a compressed air nozzle, can greatly reduce the amount of noise in and around your shop.

Finally, EXAIR Super Air Nozzle complies with OSHA standard 29 CFR 1910.242, which requires that all nozzles that use compressed air over 30 PSIG must provide a point of relief in case the nozzle is dead ended. EXAIR Super Air Nozzle uses multiple orifices that are recessed, so that the air always has a path of escape. Many homemade nozzles do not have any provision to protect from dead ending, which means they do not comply with the OSHA standard.

EXAIR Super Air Nozzles are an important upgrade from a homemade nozzle and many times an upgrade for a commercial nozzle, because they entrain ambient air, reduce noise level, and comply with OSHA regulation.

Dave Woerner
Application Engineer

EXAIR Cabinet Cooler Systems Stabilize Relative Humidity

EXAIR Cabinet Cooler Systems are able to cool your electrical panels using only clean, dry compressed air. Other systems such as cooling fans or heat exchangers use ambient air full of dust and humidity. The temperature of ambient air also fluctuates with the seasons and will be very warm in the summer months, which degrades their ability to cool as the temperature rises. One of the myths about compressed air cooling is that humidity from the compressed air source will enter the cabinet. A water/dirt filter separator will prevent condensate from entering the cabinet and since relative humidity is carried away with the hot air exhaust, relative humidity will stabilize to 45%. This video shows how quickly EXAIR’s Cabinet Cooler Systems will have an effect on relative humidity.

Dave Woerner
Application Engineer

Reliability – EXAIR Cabinet Cooler Systems Have It

Today, I’m working on a informal video for you our lovely readers, and the video editing software can be quite cumbersome on the old CPU. I’m reminded of the old joke about Bill Gates and GM. Bill Gates says, “If Microsoft built a car it would cost $25 and get 1,000 miles to a gallon.” The executive of GM reads this in the paper and issues the following Press statement. “If GM developed technology like Microsoft, the car would crash twice a day.” All I have to say to either company is now I drive to work with a bad tire sensor in my car and every time I try and edit a video, I see a blue screen and need to reboot.

*Fine Print: I drive a car made in Korea and edit video with a software company other than Microsoft. The joke is just a joke not a reflection on either Microsoft or GM.

Today I wish I had a product that worked great everyday that I needed it. A product that require very little maintenance and I could count on to work right the first time every time. Something time tested, easy to install and innovative. I know of a product with these criteria – A Cabinet Cooler System – which is used to keep the internal temperature of your electrical cabinets at an optimal working temperature when dealing with components which heat the inside or when seasonal temperature increases cause additional internal heat buildup.

Cabinet Cooler Family
Cabinet Cooler Family (From Left To Right Small NEMA 12 Cabinet Cooler, Large NEMA 12 Cabinet Cooler, or Large NEMA 4X Cabinet Cooler)

A Cabinet Cooler is Vortex Tube based cooling product that runs on compressed air. The Cabinet Cooler Systems can cool up to 5,600 BTU/Hr. It has no moving parts to wear out. It will lower your compressed air temperature by 50 degrees F. The cabinet cooler also creates a positive pressure on the cabinet to prevent dust from entering the cabinet. We have varieties of NEMA 12 units to resist dust and oil intrusion and NEMA 4 units that resist, water, dust and oil intrusion. NEMA 4X units combat corrosion, water, dust and oil. The Cabinet Cooler Systems are versatile compressed air coolers that will work in harsh conditions.

The alternative to cabinet coolers have a variety of problems. During the heat of the summer fans are only able to pull in hot, humid, and dirty air. The hot plant air does not have the same cooling ability as cool winter air. In a dirty environment the fans must be filtered to prevent dust and dirt building up inside the cabinet preventing heat transfer. The motors on fans will need to be replaced. Air Conditioners have don’t rely on the ambient air temperature, but dust and dirt are pulled into their filters which can clog and lead to costly maintenance or replacement. Cabinet Coolers have no moving parts and don’t really on ambient temperature, so they are a much better system for hot, industrial environments.

EXAIR offers an online sizing guide for your convenience. Fill one out today, so you can avoid costly repairs on your electronic equipment.

Dave Woerner
Application Engineer

Escape to the Hills

I’m leaving for a short three day vacation this week in Hocking Hills. This is my biannual family reunion of my Great Grandfather’s family the Trouts. This will be our 7th or 8th trip down there, and I still have yet to go hiking at Old Man’s Cave, the local tourist attraction. I have always stuck closer to the pool and the golf course and away from the trail. Russ Bowman puts me to shame. He heads up there every year with his boys to go hiking and camping, and we tend to stay at a cabin which is more like a hotel with some wood paneling. To each their own.

For my parent’s generation the reunion is a chance to catch up with cousins that they spent summers with growing up. For my generation, it is a chance to meet and reconnect with our second cousins that we normally would only see at weddings and funerals. The three day reunion allows a longer more free flowing opportunity to see who people are. It is a different perceptive to get to know people that have a lot of history in common, but you only see once in a while. Most of the weekend is amazingly unscheduled, so you can come and go as you please.

This will be different for me. I’m taking my son who was born last August to meet his third cousins. It is different for a couple reasons. First, now I don’t just have to worry how I behave at the family reunion. I have to make sure my son doesn’t head-butt the other babies like he has been known to do at day care. Second, my family gets to see him grow up and learn stories about me when I was his age through the eyes of the people that were there and knew me best. I hope they stay away from a few stories until he is older, but probably not.

Getting together with the family reminds me of working here at EXAIR. As we witnessed with the Professor’s departure, and Dear Joe’s departure we see that some people might chose to not come into work everyday anymore, but they are always a member of our community. As time passes we are constantly reminded of their impact. With the Professor’s message we constantly drive to safe customers compressed air energy, and Joe always reminded us that we are here for the customer first, and if you can, help them in any way you should.

But, of course, the messages from those two individuals are the result of EXAIR’s company culture, our product’s ability to solve customer problems, and EXAIR’s commitment to customer service.

Contact an Application Engineer today to join our family of customers.

Dave Woerner
Application Engineer