EXAIR not only has products that will reduce your air consumption, cost and noise levels but also has the tools to help you calculate the annual savings and Return on Investment (ROI). Sometimes you have the materials in house to make your own pneumatic tools so you get that piece of pipe in the maintenance crib, drill several holes and connect your compressed air. It works, your team is proud of the solution and everyone moves on to the next fire, right?
Several projects later you notice that your compressed air usage seems very high so a team is assembled and challenged with a cost savings program geared towards compressed air savings. EXAIR is the company that can help. We have Intelligent Compressed Air Products, Free Expert Technical Help and savings calculators that can be used to show the savings in your reports and presentations. EXAIR’s cost savings calculator will simplify the savings for each process you study and help your efforts in purchase justifications.
We have several examples of helping our customers save money such as this blog by one of our talented Application Engineers. You will realize more than cost savings as you should also see significant sound reductions and safety improvements as all of our products meet or exceed OSHA standard 29 CFR 1910.95 (a) which outlines allowable noise exposure for personnel and OSHA standard 29 CFR1910.242 (b) Dead End Pressure requirements.
When you begin compressed air cost savings program and have questions as to where to start, how to calculate and how to prepare your justifications please give EXAIR a call and talk with one of our many talented Application Engineers. EXAIR’s Intelligent Compressed Air products and Application Engineers will support all your efforts to decrease compressed air usage, reduce sound levels and increase the safety of your environment.
EXAIR has a wide variety of Safety Air Guns for safe and comfortable use in all industrial environments. Each Style uses an engineered Air Nozzle that provides superior performance by entraining large volumes of surrounding air. Safe operation is assured along with low air consumption and noise levels.
The newest addition to EXAIR’s Safety Air Gun selection is the VariBlast® Precision Safety Air Guns! They are extremely lightweight and have a focused blast of air that provides remarkable cleaning capability. Designed with a variable flow trigger, the air flow is easily adjustable and able to produce a range of different force values. It comes equipped with a small diameter nozzle and a stock extension that easily fits into tight spaces and delivers a pinpoint, but powerful blast. Two other extension lengths are available at 12” and 20”!
Check out this Product Video for more Information!
EXAIR has a wide variety of Air Nozzles with all of them meeting or exceeding OSHA Maximum Allowable Noise Exposure OSHA Standard 29 CFR 1910.95 (a) and Dead End Pressure Standard 29 CFR 1910-.242 (b). EXAIR takes pride in engineering products that help improve the safety of your environment.
Our Back blow nozzles are no exception as these nozzles are designed to clean the inside of pipe, tube, hose or channel. The Back Blow Nozzle is designed with a series of holes providing a 360 degree of force of air flow clearing out coolant, chips or debris left behind from your manufacturing process. The nozzle prevents buildup of debris from moving deeper into a pipe or out the other end, causing safety hazard(s). Because debris is moving towards the operator it is recommended that the operator wear personal protective equipment. The Back Blow Nozzles come in 3 sizes for your custom use.
Model 1004SS is the smallest with M4 x 0.5 male thread. It delivers a effective high performance and recommended for diameters ranging from 1/4″ (6.3mm) up to 1″ (25.4mm). This nozzle has a SCFM rating at 4.5 at 80 PSIG and a sound level of 75 dBA.
Model 1006SS has a 1/4″ FNPT thread. It also has an effective high performance with recommended ranges from 7/8″ (22mm) up to 4″ (102mm) diameters. This nozzle has a SCFM rating at 22 at 80 PSIG and a sound level of 80 dBA.
Model 1008SS being the largest with 1FNPT thread. This nozzle is capable of of being used in diameters ranging from 2″ (51 mm) up to 16″ (406mm). This nozzle has a SCFM rating at 80 at 80 PSIG and a sound level of 80 dBA.
These nozzles are specifically designed for clearing debris and will most like need an extension and Chip Shield. EXAIR can help you with your selection, design, quote and order. If you need our help please contact any of our Application Engineers are and eager and ready to help.
The EXAIR Flat Super Air Nozzles are manufactured to blow a wide forceful stream of air. Their patented design creates a high velocity, laminar air stream with minimal air consumption and low noise. They come in two widths; 1” (25mm) and 2” (51mm). EXAIR offers a standard Flat Super Air Nozzle and a High Force Flat Super Air Nozzle in two different materials, zinc-aluminum alloy and 316 stainless steel. And with a metal construction, breakage is not a concern and performance are not sacrificed even in the harshest of environments.
The unique patented shims inside the EXAIR Flat Super Air Nozzles will give you three improvements to the design and function. First, they come in different thickness to create a wide range of forces. In conjunction with a regulator, you can “dial” in the correct amount of force from a breeze to a blast without overusing your air compressor. The patented design also allows an even flow across the entire width of the air nozzle. Lastly, they help to entrain the free ambient air; so that less compressed air is required. The high efficiency design will save you money. The EXAIR Flat Super Air Nozzles are effective in uniform blowing with safety and efficiency in mind.
To expand more on force adjustments with the Flat Super Air Nozzles, EXAIR has an easy way to change the shim to better suit your application. You can increase or decrease the force of the nozzle by just removing two screws and changing the thickness of the shim inside. EXAIR offers a variety pack called a Shim Set to give you a wide range of forces with the nozzles. For the standard Flat Super Air Nozzle, they come stock with a 0.015” (0.38mm) shim for both the 1” and 2” sizes. The corresponding Shim Sets will include a 0.005” (0.13mm), 0.010” (0.25mm), and 0.020” (0.51mm) shim. The High Force Flat Super Air Nozzles will come standard with a 0.025” (0.64mm) shim; and the Shim Set will include a 0.020” (0.51mm) and 0.030” (0.76mm) thick shim. This is a unique feature as most competitive flat nozzles do not allow you to do this. The chart below corresponds the appropriate Shim Set to the Flat Super Air Nozzle.
Not only are they safe, and easily adjustable they can help save compressed air vs using a open ended pipe!
For example, let’s look at the average operating costs for a single 1/4″ open copper tube. (If you don’t know you current energy costs, a reasonable average to use is $ 0.25 per every 1,000 SCF used, based on $ 0.08/kWh.
A single 1/4″ open copper tube consumes 33 SCFM @ 80 PSIG and costs roughly $ 0.50 per hour to operate. (33 SCF x 60 minutes x $ 0.25 / 1,000 = $ 0.50). For an 8 hour shift, the total cost would be $ 4.00 ($ 0.50 x 8 hours = $ 4.00).
If we were to replace the 1/4″ open copper tube with our Model # 1122 2″ Flat Super Air Nozzle with 1/4″ FNPT inlet, the air consumption would be reduced to 21.8 SCFM @ 80 PSIG. This may not seem like much of an air usage reduction, but when you look at the monetary, total cost of ownership for purchasing and operating the nozzle, the savings can quickly add up.
The operating cost for a 2″ Flat Super Air Nozzle with 1/4″ FNPT inlet is $ 0.33 per hour (21.8 SCF x 60 minutes x $ 0.25 / 1,000 = $ .033) or $ 2.64 per 8 hour shift ($ 0.33 x 8 hours = $ 2.64).
We can now compare the operational cost between the 2 devices:
1/4″ open copper tube operating costs: $ 0.50 per hour $ 4.00 per day (8 hours)
2″ Flat Super Air Nozzle operating costs: $ 0.33 per hour $ 2.64 per day (8 hours)
Cost Savings: $ 4.00 / day (open copper tube) – $ 2.64 / day (2″ Flat Super Air Nozzle) = $ 1.36 savings per day
The Model # 1122 2″ Flat Super Air Nozzle has a list price $ 67.00 USD.
ROI or Return On Investment calculation: $ 67.00 (Cost) / $ 1.36 (savings per day) = 49.26 days.
The 2″ Flat Super Air Nozzle would pay for itself in just over 49 days in operation. This is the savings for replacing just ONE 1/4″ open copper tube with an engineered solution! In most industrial plants, there could be several of these which presents even more opportunities to reduce the overall operational costs.
Our focus here at EXAIR is to improve the overall efficiency of industrial compressed air operating processes and point of use compressed air operated products. If you are looking to reduce compressed air usage in your facility, contact an application engineer and let us help you optimize your current system.