Save Compressed Air with the EXAIR Electronic Flow Control

The best way to save compressed air is to simply turn it off when it’s not being used. This might seem pretty simple, but there may be processes in your facility where this couldn’t be achieved by just turning a valve. In applications where product is traveling along a conveyor, and must be dried, cooled, or blown off, there is likely some spacing in between the parts. It isn’t necessary to keep the blowoff running constantly if there’s periods of intermittent spacing. To help reduce the overall load on the air compressor, implementing a solution to shut the air off in between each part can have a dramatic impact. EXAIR’s Electronic Flow Control, or EFC, is designed to improve efficiency by reducing overall compressed air usage. It utilizes a photoelectric sensor that detects when the part is present. When it’s not, it triggers a solenoid valve to close and shut off the compressed air supply.

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EXAIR EFC

One way to use the Electronic Flow Control would be for Turning a Atomizing Spray nozzle on to coat your product.  For example see the photo below where you could use the EFC to sense the pants coming down the line. Then turn the air supply on to spray a bleach solution to get the weathered look you are after. Once the pants pass the EFC will turn the nozzle off, replacing a manual operation awhile saving compressed air and your liquid solution!

Another use would be to tell when a hopper that is being filled by a Line Vac is empty or over filled.  You can adjust the sensor and the control module to sense that the hopper is empty and it will turn the compressed air on to the Line Vac to then feed the hopper.  Then set the timer module so it will run for the length of time it takes to fill the hopper.  The other way would be to place the sensor at the top of the hopper and have it sense when the pile of media has reached the full level.

The EFC models available from stock can accommodate flows up to 350 SCFM. For applications requiring more compressed air, EFCs with dual solenoids are also available. If you have an application in one or more of your processes where intermittent compressed air use could help save you money, give us a call. We’d be happy to take a look at the application and help determine just how quickly the EFC could start paying YOU

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS

Candy Producer Saves $4600 in Compressed Air with EXAIR’s EFC

A few months ago, I took a phone call from a manufacturing engineer who worked at a large candy production facility here in the United States. Extra chocolate was dripping out of the candy molds onto the conveyor belt below.  Within a few hours the belt was dirty enough they would have to stop the line and clean the residual chocolate off the belt. 

The best solution I found was a 72” 316 Stainless Steel Super Air Knife. It worked great when powered at 60 psig inlet pressure. The laminar flow of the Super Air Knife was perfectly suited for this application.  The knife was mounted between the mold and the belt to help solidify and blowoff the excess drips of chocolate. There was one drawback, the Super Air Knife was not needed to blow the belt continuously and the continuous demand was not desirable during peak production.

The simple solution for this was the EXAIR Electronic Flow Control, the EFC minimizes compressed air use by turning off the air when a sensor is triggered. Since there was a 4.5-minute time gap between each mold set this was a great solution. When the photoelectric eye saw a mold, it then told the solenoid valve to open and supply the knife with compressed air for 30 seconds while the mold was open and the excess chocolate would be dripping. See the Savings calculations below;

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Without using the EFC

(* Using $ 0.25 per 1000 SCFM used)

  • 72” Super Ion Air Knife = 165.6 SCFM @ 60 PSIG
  • 165.6 SCFM x 60 minutes x $ 0.25 / 1000 SCFM = $ 2.48 per hour
  • $ 2.48 per hour x 8 hours = $ 19.84 per 8-hour day
  • $ 19.84 x 5 days = $ 99.20 per work week
  • $ 99.20 per week x 52 weeks =$5,158.40 per work year without the EFC control

 

With the EFC installed (turning the compressed air off for 4 minutes 30 seconds with a 30 second on time = 6 minutes/hour compressed air usage)

  • 165.6 SCFM x 6 minute x $ 0.25 / 1000 SCFM = $ 0.25 per hour
  • $ 0.25 per hour x 8 hours = $ 2.00 per 8-hour day
  • $ 2.00 x 5 days = $ 10.00 per work week
  • $ 10.00 per week x 52 weeks = $520.00 per work year with the EFC control 

$ 5,158.40 per year (w/o EFC) – $ 520.00 per year (w/ EFC) = $4,638.40 projected savings per year by incorporating the EFC.

EFC287x250

This example illustrates, clearly, why choosing the EFC is a good idea. It has the ability to keep compressed air costs to a minimum and saves compressed air for use within other processes around the plant. With this type of compressed air savings, the unit would pay for itself in less than 3 months.

If you would like to see how we might be able to improve your process or provide a solution for valuable savings, please contact one of our Application Engineers.

Jordan Shouse
Application Engineer
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EXAIR Leads the Way with Standards and Certifications

For over 34 years, EXAIR has been the industry leader in providing Intelligent Compressed Air Products to the industrial marketplace. While much of our focus is to ensure our products are engineered to provide optimal performance, we are also dedicated to manufacturing products that meet a wide range of standards and directives to promote safety in relation to plant personnel.

 

For instance, all of our compressed air operated products meet or exceed OSHA Standards 29 CFR 1910.242(b), requiring that the outlet pressure of an open pipe, nozzle, air gun, etc., when used for cleaning purposes, must remain below 30 PSI when dead-ended against the skin, as well as Standard 29 CFR 1910.95(a) as a way to protect workers from job related injuries related to dangerous sound levels of 90 dBA and higher.

 

 


Many of our products are also CE Compliant, meeting the mandatory requirements for products intended to be sold in the European Economic Area or “EEA”. For example our Electronic Flow Control and Electronic Temperature Control (ETC) meet the EU (European Union) Low Voltage Directive 2006/95/EC.

 

 

EXAIR electrically powered devices, like our Static Eliminators and Digital Flowmeters for example, comply with the “Restriction of Hazardous Substances” or RoHS Directive 2011/65/EU, including the amendment outlined in the European Commission decision L 214/65.

 

 

We are also committed to providing material that supports the conflict mineral free rule to help aid in the relief of illegal trade of exotic materials, like tungsten, gold, tin and tantalum in the DRC region. Using the CMRT 4.20 template, we document our supply resources to ensure we provide conflict free products, as outlined in Section 1502 of the Dodd-Frank Wall Street Reform and Consumer Protection Act.

 

Lastly, the European Union introduced the REACH program – Registration, Evaluation, Authorization and Restriction of Chemicals, as a method to register chemical substances being imported into the EU to protect people and the environment, per Regulation (EC) No 1907/2006 Title I, Article 3.  Also noted in the program, Title II, Article 7, they state that any product with a substance intended to be released under normal operating conditions, must be registered for quantities totaling more than 1 metric ton per year. Since EXAIR products do not intentionally release or contain any such substances, registration to meet the program is not required.

 

If you have any questions about any of these Standards or Directives or about which EXAIR products comply, please feel free to contact an application engineer for assistance. We’d be happy to help!

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

EXAIR No-drip Atomizing Nozzles – Finalist for Flow Control Magazine Innovation Award

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EXAIR No Drip Atomizing Nozzle

In this summer of 2016, we are nearing the beginning of one of the largest sporting events on the planet, The 2016 Summer Olympics. At the heart of this celebration will be sporting events of all kinds. And in the tradition of the Olympics there is always a gold, silver and bronze winner to award the top three athletes in each event.

EXAIR is participating in a competition as well. It isn’t one of a sporting nature, but rather, one of ingenuity and innovation. Flow Control Magazine holds an annual competition for innovations in new products available in industry and we have entered the No Drip Atomizing Nozzle into the competition.

In general, Atomizing Nozzles are used for the application of high value fluids within industrial processes. In some cases where the Atomizing Nozzles are mounted above the target, residual fluid that is left inside the nozzle body can drip out when de-energized and cause un-wanted blemishes on the target surface.

EXAIR No Drip Atomizing Nozzles allow for external adjustment of compressed air and liquid inputs to adjust the liquid spray flow rate as well as droplet size for a wide range of applications. That’s pretty common amongst atomizing nozzles in general. So what is so innovative about the No-Drip Atomizing Nozzles?

We have found a way to control the on/off function of the atomizing spray which supports the no-drip feature as well as the atomizing flow with only one compressed air supply. Most other manufacturers require a nozzle that has a separate control for the small valve within the nozzle and another for the airflow that atomizes the fluid coming through. It is this innovation that dramatically improves the simplicity with which these nozzles can be installed into an application and controlled through typical air automation techniques. It was innovative enough that the US Patent Office granted EXAIR a patent on the design (Patent # 9156045). So, we’ve made the No-Drip Atomizing Nozzle available with 3 different spray patterns and 14 different liquid volume options to suit a wide variety of application need. Operating pressures can fall anywhere between 30 – 250 PSIG to atomize fluids up to 300 centipoise.

If you agree with the US Patent Office on the innovation and think that EXAIR’s No Drip Atomizing Nozzles should be a winner in this competition, we would appreciate your official vote.

Please vote for the EXAIR No Drip Atomizing Nozzles at this link to the Flow Control Magazine’s Innovation Awards page.

Thank you!

Neal Raker, International Sales Manager nealraker@exair.com

@EXAIR_NR