Excellence Is Not An Act, But A Habit

“We Are What We Repeatedly Do. Excellence, then, is not an Act, But a Habit”

In my twitter feed I often see the aforementioned quote that is attributed to Aristotle. As this blog points out, the quote should really be attributed to Will Durant author of The Story of Philosophy, because it is his interpretation of what Aristotle would have said if he spoke English. While writing this blog I found out Aristotle didn’t really write the quote. In retrospect, clearly he didn’t write, if he did it might look something like this “Είμαστε Τι επανειλημμένα Do. Αριστείας, τότε, δεν είναι μια πράξη, αλλά μια συνήθεια”, but I digress.

Working with customers, resellers and catalog houses, I’m amazed at the different company cultures. Some customers will come to me six months before a project comes up to talk about the applications. They ask us for drawings, specifications, and certifications for the products that we recommend for their applications. They want to analyze all possible scenarios and plan for every eventuality.  These customers greatly appreciate our fully loaded knowledge base and availability of technical information.

Other customers call me for a quote and confirmation. They spent some time online, downloaded a CAD model and created a working plan, but before they pull the trigger, they want to run it by someone else. These customer greatly appreciate the fact that the phones are answered by human beings and we have a fully staffed Application Engineering department with engineers who are always eager to discuss applications and possibilities.

Finally, we have the customers, who I never spoke to before that need a product NOW and are willing to do anything to get. Shipping companies love these customers, because we have our products on the shelves ready to ship, but it will cost you air freight and a flux capacitor to get it there yesterday.

 

At EXAIR, our culture expects excellence. And no matter the kind of customer who contacts us, we know you are all trying to achieve it too – we are just trying to help. When our customer calls in to ask for something yesterday, we will already have it on the shelf ready to go. Unless it is a custom product, our production staff has already machined, built, and tested our product to our excellent standard.  I’m constantly amazed at the effort and continued excellence put out by customer service, engineering, marketing, and production. When the customer calls in to ask for product yesterday, 99.98% of the time I’m able to say that the shipment will be at the dock waiting for the shipping truck by 3:00 PM EST. We can typically do that without an extraordinary effort, because we practice excellent customer service everyday. It’s a habit we are not trying to quit.

Dave Woerner
Application Engineer
DaveWoerner@EXAIR.com
@EXAIR_DW

 

 

Video Blog: Adjusting a Vortex Tube

See how simple it is adjust the outlet temperature of an EXAIR Vortex Tube below zero degrees Fahrenheit.  Vortex Tubes  are a low cost, reliable maintenance free solution for many industrial spot cooling applications.

EXAIR Vortex Tubes are constructed of stainless steel to resist corrosion and oxidation for years of reliable, maintenance free operation. They are used to provide cooling for electronic controls, dry machining operations, cameras, sensors, CCTV, hot melt adhesives, soldering, brazing, gas sampling, heat seals, and environmental chambers.

There are many advantages when using Vortex tubes:

  • No moving parts
  • No electricity
  • No chemicals
  • Low cost
  • Maintenance free
  • Instant cold air
  • Easily adjusted for temperature

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

Troubleshooting 101: Super Air Knife

Yesterday, I was working with a customer on troubleshooting a Super Air Knife. He had brought the knife into EXAIR’s demo room so I was able to verify a few items very easily.  When trouble shooting air knives there are no moving parts, so it is very small list of items to check.

  1. Check the Air Supply

  2. Check the plumbing

  3. Check the inside of the Air Knife for debris

The customer had a 36″ Super Air Knife ,and he was seeing some weak spots in the air flow as well as a gradient in flow from one side of the knife to the other.  The first thing I did was to install a pipe tee with a pressure gauge in both ports on the bottom of the knife.  This would allow me to monitor the pressure we were supplying to the knife to calculate the air consumption and ensure the our piping was not starving the knife for air.

IMG_3735

Feeding the knife with equal pressure from both sides, is necessary for any air knife 24 inches or longer. The customer immediately noticed that the flow from the knife lost any sort of gradient, once it was fed in (2) locations. Still the air knife exhibited a spot in the flow where air velocity significantly decreased.  Since we were getting correct pressure and supplying enough air, we decided to remove the cap from the Super Air Knife.  Under the cap we found a variety of debris and one dreaded piece of PTFE plumbing tape. The plumbing tape was suppose to prevent air leaks throughout the compressed air system, but a piece had become lodged in the air gap of the Super Air Knife preventing air flow through a small portion of the Super Air Knife.  As you can see, once we followed a few simple steps to ensure proper installation of the Super Air Knife, it was quick and easy to narrow down what caused the lack of performance. This is yet another reason to make sure you have clean and dry compressed air, as well as use a point of use filter separator.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

Floating Plates With Compressed Air

Yesterday, I had the opportunity to work with a customer who was familiar with our product and was looking to roll out EXAIR’s Super Air Nozzle in various parts of the plant. Before purchasing our products, the customer was using (4) open 5/16″ aluminum tubing to move or “float” a 12 inches by 12 inches plate of aluminum. This plate is .187 inches thick and needed to be moved six inches against the wall of their conveyor. The (4) open tubes moved the plate, but the customer had some safety concerns. First, the open pipes violated the OSHA standard 1910.242(b) that any open pipe that can be dead ended must only be pressurized to 30 PSIG. Second, to move the plate successfully the shop pressure needed increase to 100 PSIG which increases the amount of load on the compressor and could lead to higher maintenance in the future. Finally, the noise level of open pipes was well over 110 dBA which was another OSHA violation.

1132ss

Considering all of these problems the customer contacted me, looking for an air nozzle to use instead of the open pipe. After a short discussion we decided to try (3) HP 1125 nozzles. Once the customer installed the air nozzles, they only used 2 of the air nozzles, and they were able to move the plate easily across the conveyor. This netted them several key results. The most noticeable at the plant was how quiet the operation became. Instead of dealing with noise levels in excess of 110 dBa (which is equivalent to the noise level of a turbo-fan aircraft at take off)  the HP1125 comes in at 83 dBA which is roughly the noise of a milling machine.  This was much more pleasant to the operator and any plant passersby.  The most important was the operation now complied with OSHA safety requirement of 1910.242(b).  Because of the width of the Flat Nozzle and the overhang of the cap, the nozzle can not be dead ended.  Since the unit can not be dead ended, pressure above 30 PSIG can be safely used.  Finally, the most economically result was that the air savings for the units.

The 5/16 tube had an ID of .183 and was 18″ long. When supplying it with 100 PSIG of compressed air, it will flow 22.8 SCFM of compressed air, so the customer was using 91.3 SCFM. The HP1125 nozzle uses 37 SCFM at 80 PSIG, so they were able to use 74 SCFM, which means each minute they were using 17.3 fewer cubic feet. At a cost of $0.25 per 1,000 Cubic feet, the HP1125 saved $0.26 per hour or $6.23 per day or $1,557 per year with 250 working days.

Replacing (4) open tubes with (2) HP1125 Flat Super saved $1,557 per year in compressed air savings, an OSHA violation, employees hearing, and lowered the system pressure from 100 psi to 80 psi.  Needless to say the customer was sold on the benefits on our products, and is looking for any more open pipes in his facility.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW