If you’d like to know how efficient (or not,) quiet (or not,) and effective (or not) your current compressed air devices are, the EXAIR Efficiency Lab can help. For more details, we hope you’ll enjoy this short video.
I have a friend who participates in a process known as “extreme couponing.” She has multiple subscriptions to the Sunday edition of our major newspaper, and a couple of local papers that also have coupon inserts. When I see her at the grocery store, she’s got two 4″ binders full of baseball card holders, all stuffed with multiples of clipped coupons, organized by store aisle. The insane amount of money saved is a big factor in her being able to be a stay-at-home mother, which is something else she’s pretty good at.
Now, extreme couponing isn’t for everyone. Even beginners to the process can buy a year’s worth of paper towels for next to nothing. However, that may take up so much room in their house that they need to rent a storage facility for other belongings that folks like you and me simply keep in the garage or basement. It also takes a LOT of time and effort to do it right – as well as discipline. Saving half (or more) on a truckload of stuff you don’t need (or will never use) is a waste of money, time, and space. In fact, I know people who have abandoned extreme couponing for those very reasons…the “return on investment” just isn’t there.
That’s the deal in industry too. Anyone tasked with finding and exploiting efficiencies – or finding and eliminating inefficiencies – is going to be looking at return on investment. Like extreme couponing, though, it has to make sense in all aspects of the operation. For example:
*An OEM taking advantage of a quantity discount for components or subassemblies has to not only have the storage space available, but also has to consider the turnover rate…it costs money to keep product on the shelf.
*A machine shop considering a tooling upgrade has to compare the cost difference with the increased performance and/or lifespan of the “new and improved” product. A tool that costs 10% more but lasts twice as long is probably a good deal. A tool that costs twice as much but lasts 10% longer might not provide the “bang for the buck.”
*Any facility, before switching a service or utility provider, will “run the numbers” on promotional rates, contract terms, etc. before making a commitment.
Unlike extreme couponing, EXAIR makes it easy – and beneficial – to evaluate the return on investment:
*Our catalog (if you don’t have the latest, get it here) has complete performance & operational data on all of our products. This is great if you know what you want it to do.
*If you’re not quite sure, our catalog also has a good number of actual application write-ups for most of our Intelligent Compressed Air Products. You may be able to find something that’s similar to what you want to do, and further inform your selection from there.
*Once you’ve chosen a product, you can use the Calculator Library on our website to determine actual dollar cost savings associated with replacing a current compressed air powered device with an EXAIR product.
*No matter how detailed the discussion, and how confident a plan we may make, the age-old saying about how it “looked good on paper” proves itself every now and again. When this happens, all catalog products are covered by our 30 Day Unconditional Guarantee. If you’re not satisfied for any reason within 30 days of purchase, we’ll arrange return for full credit.
*Let’s assume that we’re pretty good at this (because we are) and it actually DOES work out (because it usually does) – we can calculate your new (and improved) operating costs and compare them with the cost of your previous devices. If you don’t have the instrumentation (flow meters, sound level meters, etc.,) this is a free service we provide in our Efficiency Lab. Send it in, and we’ll do a full performance test & issue a comprehensive report, all at no charge. And if you qualify for a Case Study, we can even save you some money on your next order. Contact me for more details if you’re interested.
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Many customers may not have the means to test the air consumption of their blowoff solutions. With compressed air being the most expensive utility in a manufacturing facility, it’s important to identify places where you can save money on your overall operating costs. EXAIR manufacturers a wide variety of products intended to help you reduce your compressed air usage. If you’re not able to accurately measure the consumption in your own shop, we invite you to send the products into EXAIR for testing. With EXAIR’s Award Winning Efficiency Lab, just simply contact an Application Engineer, box them up and send them to our warehouse in Cincinnati, Ohio.
Once we receive it, our engineers will complete some in-depth testing to determine the compressed air consumption, sound level, and force that your current solution provides. With this information, we’ll be able to compare it to an EXAIR Engineered Solution. This way we ensure that you receive the best, safest solution possible also capable of saving money through reduced air consumption and improved efficiency. We’ll send you back a comprehensive report that’ll help you to make the best decision for your company.
I’ve been recently working with a customer that sent in one of the nozzles they’re using across all their CNC machines. They wanted us to test it out and see if we’re able to offer them something that could reduce their overall compressed air usage. The nozzle was one of the cheap plastic varieties and was attached to a commonly used modular hose. This type of modular hose is not designed for operating under high pressures. These hoses are more suitable for liquid coolant or air that is at or below atmospheric pressure.
After testing, we found that at 80 psig the nozzle consumed 3.85 SCFM and produced a force of 1.92 oz. We also noticed that after 60 psig, the nozzle began to leak due to a poor seal where the nozzle met the brass hex. The EXAIR nozzle most suitable to replace this was the 1108SS. At just 2.5 SCFM at 80 psig, replacing the plastic nozzle with an engineered solution saves them 35% of their overall consumption for this blowoff. With close to 1000 of these nozzles in operation, that adds up quickly!!
In addition to increasing efficiency, replacing these nozzles also greatly increases overall worker safety. The sound level is reduced from 73 dBA to just 58 dBA and EXAIR’s nozzles also adhere to OSHA 1910.242(b). The plastic nozzles could be dead-ended, posing a hazard that can result in costly fines. These fines are assessed per infraction, so having multiple non-compliant nozzles can easily get very expensive if you’re subject to an unannounced visit by an OSHA inspector.
If you think you may have an opportunity to improve upon your existing blowoff methods, give us a call. We’ll be happy to take a closer look and have you send the product back to EXAIR for a quick trial in our Efficiency Lab. You’ll be glad you did!