You Don’t Need to Spend Thousands to Optimize Your Compressed Air System

There is no denying it, saving compressed air is a process.  This process often involves some type of energy audit or at the very least an evaluation of something going wrong with production and a way to improve it.  Many programs, consultants, and sales reps will devise a solution for the problem.

Often times the solution is to create a more efficient supply side of the compressed air system. The supply side is essentially everything within the compressor room or located in close proximity to the actual air compressor. While optimizing the supply side can amount to savings, many of these solutions and services can involve great expense, or capital expenditure processes.  These processes can often lead to delays and continued waste until the solution is in place.  What if there was a way to lower compressed air usage, save energy, solve some demand issues on the compressed air system and save some money while the capital expenditure process goes through for the larger scale project.

These solutions are a simple call, chat, email or even fax away. Our Application Engineers are fully equipped to help determine what points of your compressed air demand side can be optimized. The process generally starts with our Six Steps To Compressed Air Optimization.

6 Steps from Catalog

Once the points of use are evaluated the Application Engineer can give an engineered solution to provide some relief to the strain on your compressed air supply side.  For instance, an open copper pipe blow off that is commonly seen within production environments can easily be replaced with a Super Air Nozzle on the end of a Stay Set Hose that will still bend and hold position like the copper pipe does while also saving compressed air, reducing noise level, and putting some capacity back into the supply side of the compressed air system.

engineered nozzle blow offs
Engineered solutions (like EXAIR Intelligent Compressed Air Products) are the efficient, quiet, and safe choice.

One of the key parts to the solutions that we offer here at EXAIR is they all ship same day on orders received by 3 PM ET that are shipping within the USA. To top that off the cost is generally hundreds, rather than thousands (or tens of thousands) of dollars. Well under any level of a capital expenditure and can generally come in as a maintenance purchase or purchased quickly through the supply cribs.  Then, to take this one step further, when the EXAIR solution shows up within days and gets installed EXAIR offers for you to send in the blow off that was replaced and receive a free report on what level of compressed air savings and performance increases you will be seeing and provide a simple ROI for that blow off (though we would also encourage a comparison before a purchase just so you have additional peace of mind).

This amounts to saving compressed air and understanding how much air is being saved, adding capacity back into your supply side which will reduce strain on the air compressor, give the ability to increase production while the capital expenditure for the end solution of controls and higher efficiency on the supply side is approved to then save even more compressed air and energy.

The point is this, savings and efficiency doesn’t have to involve a capital expenditure, if that is the end game for your project that is great! Let EXAIR provide you a solution that you can have in house by the next business day to save money NOW and then put that savings towards another project. No matter the method, it all starts with a call, chat, email or fax.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Friction Loss – Pressure Drops – Fitting Restrictions – Why Compressed Air Plumbing Matters

Over the weekend I was working on a car in my driveway and I needed a large volume of air at the far end of the car to try and unplug a clogged sunroof drain line.  Rather than trying to move the car while it was mostly taken apart, I just hooked up another air line extension and started to go to the drain.   Even knowing what I know as an EXAIR Application Engineer about lengths of tubing, air restriction, and fitting restrictions, I went ahead with the quick and easy “fix”.

An example of pressure drop from a compressed air quick disconnect.

I grabbed another 30′ – 3/8″ i.d. air line with 1/4″ quick disconnects (see why this is wrong with this blog) on both end, rather than getting out the 50′ long 1/2″ i.d. air line that I have with proper fittings that then reduce down to a 1/4″NPT at the end to tie into most of my air tools. By doing so I ended up hooking up a Safety Air Gun which then gave a very light puff of air into the tube and the clog in the line went nowhere.  As a matter of fact, it was almost like it laughed because the tubing vibrated as if the clog said, “Pfft I am going nowhere.”

I then, stepped back and evaluated what I had done in a rush to try and get a job done rather than taking the extra five minutes to get the proper air line to do the job.   I then spent 10 minutes putting that hose up and getting out the correct hose.  Then, with a whoosh and a thud the clog was launched into my yard from the clogged drain port and I finished the repairs.

If only I had watched Russ Bowman’s spectacular video on Proper Compressed Air Supply Plumbing the day before. Rather than wasting time with the quick “fix” that cost me more time and didn’t fix anything I should have taken a little more time up front to verify I had properly sized my lines for the job at hand.

If you would like to discuss compressed air plumbing, appropriate line sizes, or insufficient flow on your compressed air system, please contact an EXAIR Application Engineer.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Video Blog: How To Clean & Replace Emitter Points for the Ion Air Gun & Ion Air Jet

This video will give a thorough walk-through on how to clean the emitter point on EXAIR Ion Air Jets model 8194 and Ion Air Guns model 8193.  This is the same procedure for replacing a damaged emitter point.  This procedure is for new style Static Eliminators with integrated grounded terminals, released on February 1, 2016.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

Excellent Customer Service Is The Only Way To Live

I have recently had a few dealings with other companies recently which has left me with two reactions: 1) How they are still in business? and 2) They really have their customer service running well.  The first company was, of course, a large conglomerate that provides our home internet service. The second company was a web-based company providing clothes dryer repair parts.

bad-customer-service

So the first company, it is a local supplier of internet service.   I called to try and upgrade my service to higher speeds and see when I could get it changed.   I have had their service for over 8 years and haven’t had a whole lot of issues with them, everything has been pretty good.   That is until I tried to use their live chat feature on the website where I was told one price for the service, I then questioned why that price didn’t match the one on their site and was told in order to get that price I would need to call a certain number and speak with a representative.   I thanked the person and made the call.  It took me about 15 minutes or so to get to an actual human and then ended up the price still wasn’t the same and got a little run around on features, so I decided I would look at competitive service.

I spoke to their competitor in my area, which was very straightforward with pricing and answered every question I had directly and gave me a very speedy installation date of the next day, but were about 5 dollars more expensive.  So I called my current provider back and got yet another different price but did finally get some straight answers… and then we got to the installation date – 3 weeks out.   I asked if the fact I was a long-standing customer that was upgrading mattered and found out that is actually hurt my installation date.   Since I was merely an upgrade it was extremely low ranking, but if I signed up for additional services then I would get someone to install it within 3 days. When I expressed my concern for this practice I was greeted with silence and sorry that is just how it is followed by when would you like me to schedule this.

So, needless to say, I contacted their competitor, laid everything out and got the service installed the next day, today I call to cancel my existing service and will hopefully never have to look back.   The moral of the story here is, even though I was a long-standing customer the provider saw no merit in that and actually ranked me even lower than a new account.   They were very cumbersome in how they answered questions which left me feeling uncomfortable and I couldn’t get even the same bad answer from the three different people I spoke with.   Ultimately I left them as a customer and am glad to be with another provider.

As for the second instance, I needed to fix the clothes dryer because it was making some funny noises.   So I took a few pieces off, moved stuff around, didn’t see a whole lot wrong and put it back together.   It started making the noise again so I gave it “The Fonz” treatment (hit it hard) and all was good.   The next time I went to dry something my wife then accused me of not starting the dryer because everything was still wet.   I took a look into it yet again and this time I took the dryer all the way apart thanks to an informal video from the manufacturer. The problem seemed to be some bad preventative maintenance on my part and hair/lint wrapping around a roller guide which cause the  roller to stop and the drum to start going slower, as well as a lot of burnt crud around the heating element. So then the parts search began.   I found a company online whose site was easy to navigate, had lots of pictures, even used their live chat which I got quick responses from, and even found videos of how to fix the exact problem I was having.  So I ordered the parts late at night on Monday, their site showed in stock and shipping the next day.   Tuesday I end up getting a confirmation that the parts will be shipped.  Wednesday I received the parts as well as a follow-up e-mail confirming that the parts had been delivered.

20140720_214053

The moral of this interaction as a customer is that I experienced what I hope our customers at EXAIR experience everyday.   All the information I needed was in one place and easy to find,  all the parts were in stock, I got quick responses that were truthful, and in the end even after I ordered the part  I still got great customer service.  Needless to say I have bookmarked their site and will be returning.

Here at EXAIR, you don’t get greeted by a robot when you call during business hours, you get greeted by a human.  We do our best to ensure all information you need is accessible from our site, as well as back that support up with our Application Engineering staff being available by phone, e-mail, chat, fax, visits to EXAIR, and even mail if need be.   Then if you decide to order something from us, if it is standard stock, we ship it same day as long as we get the order by 3 PM EST and are shipping within the United States.  Then, we offer helpful videos, as well as support after you have made your purchase.  On top of all that, we stand behind our products with a 30 day guarantee and a 5 year built to last warranty.

30 Day Guarantee

So no matter how small a project you have, or if you are having any issues with your existing supplier for compressed air products, contact us and see if you notice a difference.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF