EXAIR Heavy Duty Safety Air Gun Reduces Noise Level and Saves Air!

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Inside of the customer’s fin press

Just this week I’ve been working with an aerospace manufacturer that had some concerns about a cleaning operation on one of their fin press machines used for a stamping process. After each operation, they need to blow out the dies to remove any residual oil and debris. They were currently using a ¼” open copper tubing operating at 90 psi. Their reason for contacting EXAIR was due to a recent OSHA compliance training that their production manager had attended. He learned about OSHA 1910.242(b), a directive that we’ve written about many times in the past, that states compressed air devices used for blowoff must maintain a dead-end pressure less than 30 psi. Additionally, the sound levels were far too high to adhere to OSHA directive 29 CFR 1910.95(a). This was a major concern for them and a common theme that we hear from many of our customers. As this manufacturer is clearly aware, fines associated with failing to comply to OSHA directives can be quite costly. Their failure to adhere to this and a few other directives led to a total penalty of $33,800.00.

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EXAIR’s Heavy Duty Safety Air Gun with Chip Shield

After some discussion about the different types of solutions that EXAIR has to offer, we settled on the Model 1310-18-CS. At a sound level of just 74 dBA when operated at 80 psi, we were able to drastically improve upon the sound levels that he was previously experiencing. This was a very welcomed solution by his operators, as they were now able to clean out the dies without having to wear any hearing protection. The Chip Shield also added some additional protection so that no debris could come back towards the operator. In addition to addressing his sound level concerns, we were also able to save a substantial amount of compressed air. The 1310-18-CS will consume just 14 SCFM of compressed air at 80 psi. A ¼” pipe operated at this pressure will consume approximately 69 SCFM. This is an 80% reduction in compressed air usage for just one operation!!

If you have an application where sound level needs to be reduced or you’re looking to improve upon employee safety, EXAIR has the solution. Give us a call today to find out how we can implement a solution to keep OSHA inspectors at bay.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

Not All Compressed Air Guns Are The Same

If you work in an industrial plant or manufacturing environment, chances are you use some type of compressed air gun for cleaning parts, work areas, etc. Many air guns purchased through large industrial suppliers are a common choice due to the cost of the gun but as the saying goes – “you get what you pay for”. These types of guns may be cheap to purchase but they are also made cheap and have parts that can break easily, like the trigger or nozzle. In many cases, the nozzles on these guns are also in violation of OSHA requirements, producing dangerous discharge pressures and loud noise levels, which can lead to costly fines or potentially deadly injuries.

EXAIR offers 5 different styles of Safety Air Guns that not only eliminate these concerns, but also provide a more efficient operation, which can reduce energy costs. All of our Safety Air Guns are fitted with our engineered Air Nozzles  which meet OSHA Standard 1910.242(b) for 30 PSI dead end pressure, as they provide a relief or safe path for the air to exit if the nozzle were to be blocked or pressed against an operator’s body so the exiting air pressure will never reach 30 PSIG. They are also engineered to entrain surrounding air across the profile of the nozzle, which produces a smoother airflow, ultimately reducing wind shear, resulting in much lower sound levels, meeting OSHA Standard 29 CFR 1910.95(a).

 

 

The Precision Safety Air Gun body is made of a durable high impact, glass reinforced nylon, providing for a lightweight, ergonomic operation. These guns feature a curved extension, ideal for delivering a powerful stream of air in hard to reach areas, like clearing debris from drilled holes. All of the nozzles used with these units are either 316ss construction for durable, corrosion resistance or PEEK plastic for non-marring applications. The air inlet is 1/4 FNPT and there is a convenient hanger available for safe storage.

 

 

 

Our NEW VariBlast Compact Safety Air Guns are ideal for light to medium duty processes, featuring a variable flow trigger to achieve different force levels ranging from 2.0 ounces up to 1 pound, depending on the nozzle. The body is cast aluminum and there are (2) 1/4 FNPT air inlets available, 1 on the bottom and 1 on the back of the gun, as well as a storage hanger, for easy installation. Nozzles are available in zinc aluminum alloy, 303ss, 316ss and PEEK plastic. These guns are available with aluminum extensions from 6″ up to 72″.

 

 

The Soft Grip Safety Air Guns are commonly used in long-term use applications as they feature a comfortable grip and long trigger which helps to reduce hand and finger fatigue. The cast aluminum construction is well suited for more rugged environments and again, features a hanger hook. These guns can be fitted with aluminum, stainless steel or PEEK plastic to meet the demands of a variety of applications and are available with 6″ – 72″ aluminum extensions for extra reach or Flexible Stay Set Hoses , allowing the user to aim the airflow to a specific target area. The air inlets for these guns are going to be 1/4 FNPT.

 

 

 

EXAIR’s Heavy Duty Safety Air Guns deliver higher force and flows than other air guns, as these units feature a 3/8 FNPT air inlet, which maximizes the compressed air flow to the engineered Super Air Nozzle. Like the Soft Grip, the durable cast aluminum body is designed for use in tough industrial processes, and the ergonomic and comfortable trigger are ideal for hours of use. Aluminum extension are available, again in lengths from 6″ up to 72″, but feature a larger diameter for optimal flow and superior durability.

 

The Precision, VariBlast, Soft Grip and Heavy Duty Safety Air Guns are ALL available with an optional, polycarbonate Chip Shield to protect personnel from flying chips and debris, further meeting OSHA Standard 1910.242(b) for the safe use of compressed air.

 

Lastly we offer our Super Blast Safety Air Guns. The Super Blast Safety Air Guns are ideal for wide area blowoff, cooling or drying a part, as well as long distances. They feature a comfortable foam grip and spring loaded valve that will shut off the airflow if the gun is dropped. These units use our larger Super Air Nozzles and Super Air Nozzle Clusters, providing forces levels from 3.2 lbs. up to 23 lbs. Depending on which nozzle is fitted on the assembly, air inlets will range from 3/8 FNPT up to 1-1/4 FNPT. Aluminum extensions are available in 36″ or 72″ lengths.

 

 

For help selecting the best product to fit your particular application, please contact one of our application engineers for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

PrACTice Like A Champion

If you follow our blog, you know that over the past 2 years I have posted a few blogs related to coaching my oldest son’s youth football team. Well it’s that time of year again as we enter our 3rd season with the team. Each year, the athletic boosters put together a “Spirit Wear” package for the players, parents and coaches to purchase that typically includes a t-shirt, with some type of motivational message, and matching shorts. Last year the slogan was “Out Work, Out Hustle, Out Hit”, and in all honesty, I really didn’t like it all that much. This year’s shirts have the motto “PrACTice Like A Champion” which plays right into the mentality our coaching staff tries to instill in our young players.

The head coach and I attended a youth football coaching clinic over the winter that was put on by our local NFL team, the Cincinnati Bengals, to further develop skills to help our players. During the clinic, one particular NFL positions coach used the term I.M.P.A.C.T. as an acronym for “I Might Provide A Critical Thought, Teaching or Technique”. This message really hit home for us with not only how we communicate with our players but also how we interact with each other, referees, parents, opposing coaches and players, etc. We are dealing with 8-9 year old kids who are very impressionable so how they see their leaders (coaches) act can play a large role in their own behavior.

Over and over we remind the kids during practice and in games that win or lose, we are going to respect the game and play it the right way. Too many times you see professional and sometimes collegiate athletic teams disrespect their respective sport by cheating or playing “dirty” to try and gain a competitive edge. Heck, during some of our own peewee games we’ve had opposing players get frustrated and try to take out key players or have coaches instruct their players to take a cheap shot after a play has been whistled dead. Now, I’m as competitive of a person as there is, but I will NEVER understand this type of mindset. These are young kids, playing a GAME. At the end of the day, you put your uniform on, line up and let the game play itself out – may the best team win. For our team, this year’s motto “PrACTice Like A Champion”, we hope is going to serve more purpose than just relating to our football program but rather as a way they go about each day.

While we don’t compete in sports at EXAIR, we do put in the “Practice” behind the scenes in being “Champions” to our industry. We are constantly working on developing new products to support our customer’s ever changing needs. For example, we recently released our NEW Catalog 31 which features several new products like our VariBlast Safety Air Guns, Sanitary Flanged Line Vac Air Operated Conveyors and our NEW Gen4 Static Eliminators.

Click on the photo to order a FREE copy of our NEW Catalog 31

If you need assistance with selecting any of these new products or to “tackle” a particular application, contact one of our team members and let us put our championship mindset to work for you.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

 

EXAIR Safety Air Gun Promotion

From August 1st to September 30th, 2017, EXAIR will be giving away a 1” Flat Super Air Nozzle with a purchase of a Precision, Soft Grip, or Heavy Duty Safety Air Gun.  We are promoting the importance of safety in the workplace with the EXAIR Safety Air Guns as well as the versatility of the different types of EXAIR nozzles.  This promotional item, model 1126 nozzle, has a patented shim to blows a 1” wide stream of air to clean surfaces quickly and efficiently; a $43.00 complimentary gift (click on the link below).

Promotional Nozzle with EXAIR Super Air Guns

Compressed air guns are one of the most commonly used pneumatic products in a manufacturing plant.  They are used at workstations to blow off debris and to clean parts and tools.  Because of the large quantities that are used in a plant; they are the most targeted by OSHA (Occupational Safety and Health Administration).  Majority of the common brands of air guns fail to comply with two common violations, rule 29CFR 1910.95(a) for loudness and rule 29CFR 1910.242(b) for dead-end pressure.  The reason is due to the nozzles that comes with the compressed air guns.  Fines can get very expensive, and you can alleviate these penalties by purchasing an EXAIR Safety Air Gun.  We are all responsible for safety; management, HSE department (Health and Safety Engineer), supervisors, and even the operators.  Your compressed air guns should be assessed in your facility to evaluate your safe work environment.

1310 Heavy Duty Safety Air Gun

With EXAIR Safety Air Guns, we supply an efficient, effective, and most important, safe air nozzle with all of our air guns.  They are CE Compliant and exceed the OSHA sound level and dead-end pressure requirements.  With substandard air guns, the operators would have to listen to loud noises all day and have to wear hearing protection.  As for the dead-end pressure; the EXAIR nozzles are engineered to not allow the operator to completely close the end against the hand or skin.  This is very important because if the pressure exceeds 30 PSIG, air can penetrate the skin and cause an air embolism.  Some manufacturers place a restriction inside the air gun to comply with this standard, sacrificing the effectiveness of the blowing force.  With our design, the compressed air is not able to be blocked; allowing the air to escape to atmosphere.  Even with the compressed air system set to 100 PSIG, the pressure against the skin will not exceed 30 PSIG.  Safety is a major concern for all of our customers and a priority for EXAIR in manufacturing our products.

1210-6-CS Soft Grip Safety Air Gun

As I mentioned above, the nozzles are one of the most significant parts in making a compressed air gun safe and OSHA compliant.  In combining our engineered nozzles with a quality air gun, this makes the EXAIR Safety Air Guns one of the best products on the market.  We currently have three different styles; the Precision, Soft Grip, and Heavy Duty.  These Safety Air Guns are ergonomically designed to fit comfortable in your hand; and they come with quality trigger mechanisms and a durable valve assembly.  The Precision Safety Air Gun is great for tight spaces and clearing out small holes.  The Soft Grip Safety Air Gun provides extra comfort for long extended uses, and the Heavy Duty Safety Air Gun is a rugged, heavy duty industrial air gun.  In combination with the EXAIR nozzles, the Safety Air Guns can offer another important attribute; we can save you money!!!  Compressed air is very expensive to make, and with our Safety Air Guns, we use less compressed air but still create a strong blowing force.  We do this by entraining the free ambient air into the air stream.  If you increase the mass of air to the target, it will give you a hard hitting force to remove debris from surfaces or to clean tools and holes.  The amplification ratio can be as much as 25 to 1.  That means that for every 1 part of compressed air, the EXAIR Nozzles will entrain 25 parts of ambient air.  So, the payback period for using an EXAIR Nozzle can be within weeks by the savings in the electrical cost.  With the EXAIR products, we were able to partner with Energy Star and power facilities.  For the amount of energy savings, some power companies offer rebates for using EXAIR products.   We can offer our services to see if your local power company is participating in these rebates.

1408SS-CS Precision Safety Air Gun

A substandard blow-off gun is unsafe, loud, waste compressed air, and increase production times.  EXAIR Safety Air Guns can help improve these situations in all these areas.  They are OSHA compliant, very safe and very quiet.  They use less compressed air which saves you money.  And with a variety of different nozzles, they can better fit your application to decrease down time.  EXAIR offers a 30 day unconditional guarantee on our cataloged items to try.  You can see for yourself on how effective these compressed air guns can be.  If you need help to match the best Safety Air Gun to your application, you can contact an Application Engineer.  And during the next two months, take advantage of the free 1” Flat Super Air Nozzle  offer.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

OSHA Standard 1910.242(b) – Dead-End Pressure and Chip Guarding Explained

OSHA Standard 1910.242(b) discusses the use of compressed air for cleaning and blowoff. It states that the use of compressed air for cleaning purposes is prohibited if the dead-ended pressure exceeds 30 psig. This phrase means the downstream pressure of the air nozzle or gun, used for cleaning purposes, will remain at a pressure level below 30 psig for all static conditions. In the event that dead ending occurs, the static pressure at the main orifice shall not exceed 30 psi. If it does exceed this pressure, there is a very high potential for it to create an air embolism. An air embolism, left untreated, can quickly impede the flow of blood throughout the body. This can lead to stroke, heart attack, and sometimes death. Take a look at the animation below to see how an air embolism can affect the body.

With this in mind, there are only two options for staying within compliance of this standard. Either install an engineered solution that will reduce the air pressure to less than 30 psig if dead-ended, or regulate the pressure below 30 psig. For the vast majority of operations, regulating the input pressure below 30 psig is useless. The force and flow from the nozzle at this pressure is greatly reduced and likely not enough to be effective in most applications. All of EXAIR’s Safety Air Guns are designed so that the flow cannot be dead-ended. The fins on the Super Air Nozzles are not only useful in amplifying the force by drawing in ambient air, but they also prevent an operator from completely obstructing the airflow.

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The fins of the Super Air Nozzle allow air to escape and prevent dead-end pressure from exceeding 30 psig.

In addition to being concerned about dead-end pressure, OSHA 1910.242(b) also states that compressed air used for cleaning should include effective chip guarding. By this, they mean that some method or equipment must be installed that will prevent chips and particles from coming back into the eyes or skin of the operator. In addition to offering OSHA compliant nozzles and guns, EXAIR also has Chip Shields that can be installed onto any of our Safety Air Guns. The polycarbonate shields protect the operator from any flying debris while performing a drying or blowoff operation. Simply add a “-CS” to the end of any Safety Air Gun Model number to have a Chip Shield installed on the gun.

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EXAIR’s Model 1210-PEEK-CS with Chip Shield

The Occupational Safety and Health Act of 1970 does not contain any provisions that allow for the approval or endorsement of equipment. Alteration or the misapplication of what was once a safe piece of equipment would create a dangerous scenario that is out of the control of the original manufacturer. Any nozzles or guns marketed as “OSHA approved” should immediately throw up a red flag. Identifying and implementing a safe, OSHA compliant solution rests in the hands of the manufacturer themselves. If you’ve got questions about compressed air safety or have an existing blowoff in place that does not adhere to this OSHA directive, give us a call. We’ll be sure to recommend a solution that will keep your operators and wallets safe!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

 

EXAIR Air Guns Increase Safety And Reduce Air Use

Many times we receive calls from customers that fall right in line with our focus here at EXAIR  – providing Intelligent Compressed Air Products that improve overall safety for operators and plant personnel in industrial operations as well as reduce compressed air usage, ultimately lowering energy costs. Such was the case last week when I received an inquiry from a customer who was looking for a handheld device that could easily attach to their existing air hose to replace the loud and inefficient homemade air nozzles they are currently using to blow off steel chips and coolant from their saws and drills. Their current set up includes a combination of smashed air guns, similar to the one shown below, some small open tubes and cheap plastic nozzles. The blowoffs were working but their operators were starting to complain about excessive noise during operation and notice the compressor in the area was running continuously during the cleaning cycle. Their first proposed solution was to lower the supply pressure which did lower the sound level and air usage somewhat, but now the exiting airflow wasn’t powerful enough to clear the debris. After doing an internet search they decided to reach out to EXAIR for assistance.

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Crushed guns create high pitch wind shear and provide no relief path for the air to exit safely

All of the Safety Air Guns we offer utilize our Air Nozzles which are engineered to meet or exceed OSHA Standard CFR 29 – 1910.95(a) for allowable noise exposure levels. As the Standard reads, when employees are subjected to sounds in excess of 90 dBA, some type of engineered controls should be used to lower the sound to a permissible level. Prolonged exposure to excessive noise can result in serious health issues, like tinnitus or a constant ringing of the ears, as well as stress and reduced productivity. In addition, our engineered Air Nozzles cannot be dead ended, meeting OSHA Standard 1910.242(b). With the design of our Air Nozzles, there is always a safe path for the air to exit so the outlet pressure will not reach 30 PSIG if the nozzle exhaust were to be blocked or pressed against the skin.  Due to this design, our units are safe to operate at higher pressure, resulting in a high velocity, forceful airflow.

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Model 1210 – Soft Grip Safety Air Gun

For this application, I recommended the customer use our Model # 1210 Soft Grip Safety Air Gun. This particular unit incorporates our Model # 1100 Super Air Nozzle which produces a low sound level of 74 dBA, well within the OSHA guidelines, and consumes only 14 SCFM @ 80 PSIG while having the necessary power to solve their application.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Finding What You Want – A Black Friday Blog

In the United States, today is the day that we traditionally call “Black Friday” – the retail industry’s unofficial “start of Christmas gift shopping season” – where stores made a habit of opening up early with deep discounts on select items. Here’s the deal: these are SELECT items (that THEY select) and the hopes are, you’ll buy more stuff (that may or may not be on sale) while you’re there. If you know exactly what you want, it can be a good deal for you. If you don’t, it can be a good deal…for the store.

Although we don’t have Black Friday sales events (in fact, we – and I believe most others in the industry, are closed today,) it still makes good sense to know what you’re looking for before you start shopping.  Let’s consider something basic, like an air gun.

Left-right: Precision, Soft Grip w/Stay Set Hose, Heavy Duty w/Rigid Extension, & Super Blast Safety Air Guns. With so many to choose from, we've got the one you're looking for.

Left-right: Precision, Soft Grip w/Stay Set Hose, Heavy Duty w/Rigid Extension, & Super Blast Safety Air Guns. With so many to choose from, we’ve got the one you’re looking for.

Price: this can be a real two-edged sword…not much is cheaper than a commercial grade air gun that you can buy at just about any hardware store. But, they can use upwards of 50 SCFM.  By comparison, our Model 1210 Soft Grip Safety Air Gun uses only 14 SCFM (@80psig supply pressure.)  And in any typical industrial blow off application, it’ll do the exact same thing, and cost WAY less to operate.  Use this calculator to find out.

Sound level:  you won’t find a quieter blow off product on the market.  At 80psig, the 1210 Safety Air Gun is only running at 74dBA.  Others can be well over 100dBA…that’s up to 3 times as loud, and well in excess of OSHA’s limits published in Standard 29CFR1910.95(a).

Safety: OSHA also limits the dead-end pressure of compressed air blow off devices used for cleaning purposes, to 30psig.  Unless it’s fitted, or designed, with a relief feature, you can’t supply it with any more than 30psig compressed air…which won’t really do a lot, when you think about the jobs you want to use an air gun for.  Ours can’t be dead ended, so you can supply them with 80-100psig for strong performance AND safety…by design.

Durability: You get what you pay for.  Normally, I would say “’nuff said,” but for further proof of this, I submit this blog, from the archives, on our Durable, Safe, and Efficient Safety Air Guns.  ‘Nuff said (now, anyway.)

If you’d like to talk about your compressed air product application, and how an EXAIR Intelligent Compressed Air Product might be the solution you’re looking for, give me a call.

Russ Bowman
Application Engineer
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