If you need to operate at a different pressure because you require less or more force or simply operate at a different line pressure, this formula will allow you to determine the volume of air being consumed by any device.
Lets first consider the volume of the 1100 Super Air Nozzle at a higher than published pressure. As shown in the formula and calculations it is simply the ratio of gauge pressure + atmospheric divided by the published pressure + atmospheric and then multiply the dividend by the published volume. So as we do the math we solve for 17.69 SCFM @ 105 PSIG from a device that was shown consume 14 SCFM @ 80 PSIG.
Now lets consider the volume at a lower than published pressure. As shown it is simply the ratio of gauge pressure + atmospheric divided by the published pressure + atmospheric and then multiply the dividend by the published volume. So as we do the math we solve for 11.04 SCFM @ 60 PSIG from a device that was shown to consume 14 SCFM @ 80 PSIG.
When you are looking for expert advice on safe, quiet and efficient point of use compressed air products give us a call. Experience the EXAIR difference first hand and receive the great customer service, products and attention you deserve! We would enjoy hearing from you.
The other day I received a call from the Corporate Director of a manufacturing company with multiple locations across the country. He had grown frustrated with the service and quality he was receiving from his current Air Gun & Nozzle supplier. He explained that he was unable to buy the individual components to make repairs to the air guns and described the overall quality as “disposable”.
I asked him for model air gun he had been purchasing so that I could make an accurate comparison and recommendation for the equivalent or better EXAIR offering. As I researched this competitive air gun I was surprised to find out that the specifications were vague at best. What I mean by that is EXAIR clearly publishes air consumption @ 80 PSI, force which is specified @ 12″ from the nozzle and the sound level in dBA @ 3′ from the nozzle.
The customer reported an average noise reduction of over 15 dBA which looks considerable, however it is a greater gain than the number would indicate. An increase of 10 dB is required before sound is perceived to be twice as loud, therefore EXAIR lowered the perceived sound by over 150%!
When you are looking for OSHA safe, quiet and efficient point of use compressed air products give us a call. Experience the EXAIR difference first hand and receive the great customer service, products and attention you deserve! We would enjoy hearing from you.
Hearing loss due to high noise levels is a common problem in many industrial facilities. Without the use of proper PPE, hearing loss can occur quickly. This is a serious concern as hearing loss is permanent and once the damage is done there’s no way to reverse it. Due to this risk, OSHA strictly enforces standard 29 CFR-1910.95(a).
This directive discusses the effects of noise and limits exposure based on the dBA. The table below indicates the maximum allowable exposure time to different noise levels. Sound levels that exceed these levels should first be addressed by proper engineering controls such as isolating the source of the sound from personnel or replacing the cause of the sound with something like an engineered compressed air nozzle. When such controls aren’t feasible, proper PPE must be worn to protect the operator.
Hearing loss can occur in as little as 30 minutes when exposed to sound levels 110 dBA or greater. Operators have a tendency not to use PPE as directed, if an OSHA inspector comes to your facility and notices that the sound levels exceed the maximum allowable level without protection hefty fines will be soon to follow. In this example from the United States Department of Labor, a company was fined a total of $143,000 for failing to protect their employees.
In order to identify the places or processes in your facility that are causing the problems, you’ll need a tool to measure the sound level. EXAIR’s easy to use Digital Sound Level Meter allows you to measure and monitor the sound level pressure in a wide variety of industrial environments. The source of the loud noise can then be identified and isolated so that corrective action can be taken. For compressed air related noise, EXAIR manufactures a wide variety of engineered compressed air products that can reduce the sound level dramatically. In many cases, EXAIR products are capable of reducing noise levels by as much as 10 dBA. Since the dBA scale is logarithmic, this equates to cutting the sound level in half!
If there’s processes within your facility that are above these limits and you’d like to eliminate relying on proper PPE, give an Application Engineer a call. We’ll help walk you through the selection process and make sure that when the OSHA inspector comes knocking you’re prepared!
What do you think of when someone says “air nozzle?” Is it a crimp or a “crush” on the end of a piece of tubing? Is it a device that attaches to the end of a pipe or a hose? If so, does it have engineered features that focus the stream, amplify the flow (through entrainment, perhaps,) reduce the noise level, or provide an element of safety?
If so…you’re right. Any of the above descriptions, strictly speaking, qualify as an “air nozzle,” in fact, just a plain open-ended pipe or tube meets the criteria. As long as it serves to discharge a stream of air towards a target, it’s an air nozzle.
Even the devices with those efficient, quiet, and safe engineered features come in a variety of styles, types, and models. Consider EXAIR’s product line of Air Nozzles and Jets…we have seventy-two distinct models, in a range of sizes, materials of construction, and performance. That’s a LOT to choose from, and it doesn’t even take into account the products that can be fitted with different shims that, technically, make them a wholly different nozzle, performance-wise. Which brings us, dear reader, to the focus of today’s blog: the Flat Super Air Nozzle.
Flat nozzles are not unique to EXAIR…there are dozens of others on the market in a variety of sizes and materials. What IS unique about EXAIR’s Flat Super Air Nozzles is their performance…
Efficiency: When a competitor’s flat nozzle was replaced with a Model 1122 2″ Flat Super Air Nozzle, consumption was reduced from 31 SCFM to 21.8 SCFM. Since the nozzle was operated 24/7, this resulted in a savings in compressed air cost of $3.31 per day…meaning the nozzle paid for itself in under three weeks.
Durability: Both our 1″ and 2″ Flat Super Air Nozzles are available in rugged Zinc Aluminum alloy, or heat & corrosion resistant Type 316 Stainless Steel.
Versatility: A 0.015″ thick shim is installed in the Flat Super Air Nozzles. These provide optimal performance in a wide variety of typical industrial and commercial blow off applications. We also offer High Power versions, with a 0.025″ thick shim, for additional flow and force. You can also experiment with other shims, from 0.005″ to 0.030″ in thickness, for customized applications. These shims are all 316SS, and are available in sets, or individually. The patented design of these shims, in fact, is key to their high efficiency, as explained in this video:
Ingenuity: While this EXAIR characteristic is not specific to the Flat Super Air Nozzles, our most recent ingenious development features them: the Super Air Scraper. By combining a scraping blade with the 2″ Flat Super Air Nozzle, we’ve turned our very popular Soft Grip Safety Air Gun into the perfect tool for easy removal of sticky or stubborn debris from most any flat surface.
EXAIR Flat Super Air Nozzles are Intelligent Compressed Air Products with a 15 year history of successfully solving all kinds of air blowing applications. To find out more about how they can work for you, give me a call.
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EXAIR’s highly engineered and efficient Back Blow Nozzle’s provide a powerful 360° airflow through an array of holes to remove coolant, chips or debris. Back Blow Nozzle’s are the perfect solution for cleaning out the inside of any pipe, tube, hose or channels.
I recently worked with a customer at a company that manufactures steel sheets. They grind, polish, and then shot blast the steel sheets. As the material exits the shot blasting chamber, some of the media still sticks to the steel and is carrying over into additional processes. To mitigate this, they installed a 1” pipe with drilled holes at the exit of the conveyor to remove the excess media and keep it contained inside of the machine. While this worked, it was using a substantial amount of compressed air which was resulting in a pressure drop across the rest of the facility when this machine was in operation.
Although their current method was doing the job for them, they couldn’t live with the increased compressed air consumption. After searching the internet, they came across the EXAIR website and were interested in learning about other blowoff methods. Typically for an application involving a wide sheet of moving material we’d look towards one of our Super Air Knives, available from stock in lengths from 3”-108”. But, in this case there was some friction between the shot blasting media and the stainless steel sheet that required brute force. They needed something that was going to give them an increased amount of force, but still reduce their overall consumption.
I recommended our HP1125 High Power 2” Flat Nozzle. With a .025” thick shim installed, the HP1125 nozzle will produce 2.2 lbs of force when operated at 80 psig. This was more than enough to remove the shot blasting media. They’re also much quieter than an open blowoff, producing a sound level of just 83 dBA. While this wasn’t a motivating factor for them, the reduction in noise was definitely welcomed. They placed some on order and replaced the 1/4″ open holes with (10) Model HP1125 2” Flat Super Air Nozzles.
For comparison, (10) 1/4″ holes will consume 690 SCFM at 80 PSIG while (10) of the HP1125 comes in at just 370 SCFM. By simply installing the HP1125 (which conveniently also has a 1/4 NPT air inlet), they reduced their compressed air consumption by a whopping 46%!! By reducing air consumption they eliminated the system pressure drop, they were also able to increase the force as the compressor was able to maintain the 80 PSIG pressure at the header pipe. This also alleviated the pressure drops experienced elsewhere in the plant.
At EXAIR we have a wide-range of different products suited to a number of different blowoff applications. From 4mm nozzles producing just 2 ozs of force, all the way up to our largest nozzle capable of delivering 23 lbs of force and everything in between. No matter the application, EXAIR has something capable of taking care of the job. Odds are it’ll be safer, quieter, and more efficient!
The word “accessory” can come with some baggage… it’s become synonymous with “add-on” and “up-sell,” and cost-mindful consumers may see them as just another way for a slick salesperson to make an extra buck. And frankly, they wouldn’t have that reputation if there wasn’t some truth to it. The server at your favorite restaurant will offer appetizers, or recommend side dishes to go with your entree. If you go to buy a new car, you’ll get a pitch for a variety of aftermarket add-ons. The paint counter folks at the hardware store always tell me what specific brush and/or rollers I should use with the paint I’m buying…and it’s never the 10-pack of economy brushes that costs less than the single, premium quality brush they recommend. In all of these cases, these employees are trained, constantly encouraged, and hopefully rewarded on the success of these “up-sell” strategies.
Of course, my boys and I can devour even the largest plate of chili cheese nachos long before the rest of meal comes out. My wife absolutely loves the remote starter function that the dealership installed on the new car she bought last year. And, if you’ve ever painted a well-lit room, you know the difference between a $1 paint brush and a $10 paint brush. So if my server gets a little bigger tip, my car dealer salesperson gets a little more commission, or the paint counter folks get a bonus, then it’s a win-win, as far as I’m concerned.
EXAIR carries a variety of accessories for our Intelligent Compressed Air Products. Some aid in mounting & installation:
Others make it easy to ensure adequate supply conditions:
The performance of many EXAIR Intelligent Compressed Air Products can be altered by replacing the shim:
In addition to these product-specific accessories, EXAIR carries a complete line of:
*Filter Separators to remove water, dirt, and rust from your compressed air system. Our Automatic Drain Filter Separators have a 5 micron particulate element, and a centrifugal vane to remove moisture.
*Oil Removal Filters with coalescing elements that remove any trace of oil, and also provide additional particulate filtration to 0.03 microns.
*Pressure Regulators, so you can “dial in” the performance you need, so you don’t overpower the application, or waste compressed air. They come in sizes from 1/4 NPT to 1-1/4 NPT, and are rated for flows up to 700 SCFM. A pressure gauge provides accurate indication of outlet pressure, and the adjustment cap can be removed to prevent tampering.
*Silencing Mufflers to reduce work area noise from compressed air exhausting from pneumatic cylinders, valves, etc. There are several styles to choose from, depending on your needs:
Sintered Bronze Mufflers are simple in design, with minimal back pressure restriction, and come in sizes from #10-32 thread to 1-1/2 NPT.
Straight-Through Mufflers offer noise reduction up to 20 dB, and come in sizes from 1/4 NPT (up to 22 SCFM) to 3/4 NPT (up to 73 SCFM.)
Heavy Duty Mufflers have an internal stainless steel screen that not only protects the exhausting components from environmental contamination, but also keeps air system contaminants from being ejected at high speed into the work area.
Reclassifying Mufflers are an upgrade to the Sintered Bronze Mufflers and provide the highest level of noise reduction – up to 35 dB. They also trap oil mist, eliminating breathing hazards to personnel.
*12 ft Coiled Hoses (1/4″ or 3/8″ ID) and Compressed Air Hose (3/8″ or 1/2″ ID; up to 50ft lengths) can be provided with any Intelligent Compressed Air Product. We also have a full supply of fittings (tees, elbows, nipples, couplers, reducers, etc.) and adapters to fit our Super Air Nozzles to your existing air guns or blow off devices.
*Receiver Tanks are used to store a ready supply of compressed air. If you have an intermittent demand of sufficient size, it can cause a pressure transient in your system, which can drag down the ability to supply other points of use. Installed near the point of intermittent demand, they prevent pressure & volume fluctuations, keeping the operators at all points of use happy. Model 9500-60 Receiver Tank has a capacity of 60 gallons, is rated to 200psig, and meets ASME pressure vessel code.
In closing, let me offer the following advice that’s served me well over the years:
*Be mindful of the valued added by the accessories & add-ons you’re presented during a purchase of capital equipment…or anything else, really. Don’t buy something you don’t need, but if you need it…well…it’s OK to buy it.
*Don’t skimp on quality. Odds are, if an accessory is offered by the manufacturer of the product, it’s going to work well for you. They should be able to tell you if it will or won’t if you discuss your needs with them. I know I will if you call me to discuss a compressed air product application.
*Get the big plate of nachos, especially if you’re dining with teenagers.
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