EXAIR’s Chip Trapper Improves Material Recovery for Recycling

I recently worked with our Peruvian Distributor to help one of their customers solve an issue they were having with material recovery after a polishing operation. The company manufactures security locks for doors. During the manufacturing, one of the processes involves polishing the parts to a nice finish to ensure proper fit and provide a nice appearance for the finished product. Coolant is used to keep the temperature down during the polishing process. This coolant is then contaminated with leftover bronze debris that the company recycles.

The problem was that the process to filter the leftover bronze from the coolant was done by hand. This process, taking almost one hour to complete, was too time consuming and they were not able to recover 100% of the material. In looking for a better way to perform this process, they came across the EXAIR Chip Trapper.

The Chip Trapper was able to allow them to empty the entire coolant sump in less than 90 seconds. The bronze material contained within the coolant was trapped by the 5 micron filter bag inside of the drum, while the coolant passed through. They could then pump the clean coolant back into the drum and recycle the bronze trapped in the filter bag. Not only were they able to dramatically reduce the time it took to complete the process, but it also resulted in a much more effective method of reclaiming the material. No longer were they stuck with an inferior process and more time could be freed up to be spent on production.

Using either a standard or High Lift Reversible Drum Vac to provide the vacuum source, the Chip Trapper is capable of filling or emptying a 55 gallon drum in less than two minutes. It is able to pick up both the liquid coolant as well as any chips or shavings that are suspended in the coolant. The liquid is forced through a filter bag inside of the drum which contains any solid materials while allowing the coolant to filter out into the drum. Switching the knob on the Reversible Drum Vac and the directional flow valve to empty will allow the clean coolant to be pumped back out of the drum and reused.

chiptrapperfamily

After implementing the Chip Trapper in our own shop, we were able to increase the life of the coolant by 6x. In addition to the increased coolant life, a process that used to take up to 2 hours per machine now takes less than 10 minutes. The Chip Trapper quickly and easily pays for itself.

The Chip Trapper is available in either 30, 55, and 110 gallon systems. It’ll also come with (2) 5 micron filter bags, other filter bags are also available ranging from 1 micron up to 200 micron filtration. Using a simple detergent, the filter bags can be washed out, cleaned, and reused multiple times. With no motors or impellers to clog or wear out, as well as no electricity requirement or shock hazard, the Chip Trapper comes with our standard 5-year Built to Last Warranty. Do yourself (and your machine operators) a favor and get a Chip Trapper on order today. They’re in stock, ready to ship and start saving you time and money!

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

EXAIR Pneumatic Liquid Vacuums

EXAIR‘s line of Industrial Housekeeping Products consist of liquid and dry vacuums that utilize compressed air to operate. They do not have electric motors which most ‘all purpose’ vacuums rely on.  In industrial settings with harsh conditions and rugged use, EXAIR’s Industrial Housekeeping Products are ideally suited for the everyday wear and tear. 

Reversible Drum Vac with spill recovery kit!
EXAIR liquid type vacuums, like the Reversible Drum Vac, the High Lift Reversible Drum Vac, and the Chip Trappers are reliable, versatile and easy to use. Installing onto an any closed head, 30, 55, or 110 gallon drum creates a high powered vacuum.  It can fill a 55 gallon drum in less than 2 minutes.  Then, with the turn of a knob, the the same pump quickly empties the drum. Useful for refilling coolant sumps, vacuuming floor spills, or transferring contaminated liquids to filtration tanks in minutes.  Flow rate can be controlled with the knob. 
EXAIR Reversible Drum Vacs
The Chip Trapper has an internal filtration system to separate the chips from the coolant, allowing for disposal of the solids, and for pumping of the clean coolant back into the sump.
EXAIR Chip Trapper
When you look at the vacuums, you’ll notice there is not an electrical cord.  Because the EXAIR Industrial Housekeeping Products utilize compressed air for operation, they do not have the same issues with wear, breakdown and failures as electrical type vacuums. There are no moving parts in the vacuum units to wear out or break.  They are maintenance free, just supply clean, dry air, and they will operate for a long time. For the the liquid type systems, there is a built in pressure/vacuum relief device and auto safety shut-off to prevent overfilling.

There are no motors and bearings to wear out and no impellers to clog.  The Chip Vac is 50% quieter than a comparable electric vacuum.  Safety is a top priority, and the use of the unit on wet floors and spills is not an issue when electricity is not involved.

If you would like to talk about Industrial Housekeeping products or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS

EXAIR’s Heavy Duty HEPA Vac

March brings with it the first day of spring. I don’t know about you, but boy am I ready for some warmer temperatures!! Naturally, spring is the time of year that we roll up our sleeves and do some of the deep-cleaning we’ve been putting off all winter. Lucky for you, EXAIR has an entire line of Industrial Housekeeping Products that’ll get your shop cleaned up for spring. With no moving parts to wear out and no electrical requirement, these products are Built to Last. For applications requiring you to vacuum very fine or dusty materials, look no further than EXAIR’s Heavy Duty HEPA Vac.

HEPA Vacuum

Electrically powered vacuums or shop vacs are not designed to be operated in a rugged industrial environment. Filters clog, motors wear out, and you find yourself frequently replacing them. EXAIR’s Heavy Duty HEPA Vac has NO moving parts to wear out, doesn’t require maintenance, and needs nothing but a source of compressed air to operate. A static resistant hose also prevents painful shocks when working with dry, dusty materials.

The vacuum generator is constructed of a hardened steel alloy designed to be resistant to abrasion and delivers a powerful vacuum level of -60” H2O at 80 PSIG. The lever lock drum lid fits any open top 30, 55, or 110 gallon drum. Moving the system from one drum to another can be done quickly, allowing you to keep different materials separate for recycling. Recycling companies will pay a premium for pre-sorted materials, allowing you to get more out of your otherwise scrap material. It can be used with any open head steel, fiber, or plastic drum in good condition (ANSI Standard #MH2-2004).

If you don’t have a spare drum available, not to worry! EXAIR also sells a Premium Heavy Duty HEPA Vac System that will include either a 30, 55, or 110 gallon drum and dolly.

hepahowani

The HEPA Vac works by injecting compressed air at 80-100 PSIG through the air inlet (1) and into an annular plenum chamber (2). It is then injected into the throat through precisely directed nozzles (3). These jets of air create a vacuum at the intake (4) which draws in material through the generator itself (5), directing it into the bottom of the drum. The airflow is passed first through a pre-filter to trap larger particles, and then through the 0.3 micron HEPA filter, trapping any airborne particles. It is then exhausted through the vent in the top of the drum lid (6).

You wouldn’t use a hammer to try and drive in a screw, so don’t try and force a shop vac or electric vacuum to deal with these harsh materials. Get yourself the right tool for the job and give an EXAIR Vac a try. With a 5 Year Built to Last Warranty, there really is no comparison. Act fast, between now and May 31, 2020 we’ll include a FREE Model 6492 Vac-u-Gun System to any US and Canadian order.

Tyler Daniel
EXAIR Corporation
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

EXAIR Chip Vac Systems: Overview

 

When it comes to industrial vacuums, wouldn’t it be nice to have a durable, long lasting vacuum that is quiet? There is such an industrial vacuum that has all these qualities; the EXAIR Chip Vac System. This vacuum system has no moving parts, no motors to fail, or bearings to wear. They only need compressed air to operate. The Chip Vac Systems are very durable to clean surfaces, floors, and fixtures within industries like machining centers, saw mills, lathes and other areas. They can pick up solid materials like aluminum chips, wood chips, and plastic fragments. The vacuum pumps can generate a strong vacuum level measuring -36.8” H2O (-9 KPa) at 80 PSIG (5.5 Bar). To accommodate the multiple types of industrial applications, EXAIR offers the Chip Vac Systems with different options and drum sizes.

The unique design of the Chip Vac incorporates a modified lid that will fit on an open top 55-gallon, 30-gallon, or 110-gallon drum (209L, 114L, or 418L respectively). A 0.1-micron filter bag mounts in the center of the lid to allow the excess air to escape and to contain the contamination inside the drum. The large surface area of the filter bag allows for extended use before replacement while the high-efficiency filtration will keep the fine particles from re-entraining back into the environment. Under the drum lid, EXAIR adds a silencing hose which reduces the noise level and directs the contamination toward the bottom of the drum. With this feature, the noise level is only 77 dBA at 80 PSIG (5.5 bar). Measure that against any electric shop vac!!!

Model 6193 System

The Chip Vac Systems come in three different options to best fit your application. The standard option has a drum lid as described above and a latching ring to attach to the drum. It also comes with 10-foot (3m) vacuum hose, an aluminum chip wand, a hose hanger, a manual valve, (2) extension wands and an assortment of plastic tools. This option is available for the three different drum sizes as noted above. For example, model 6193 will fit a 55-gallon drum (209L) size, model 6193-30 will fit a 30-gallon drum (114L) size, and model 6193-110 will fit a 110-gallon drum (418L) size.

Deluxe Chip Vacs

The second option is the Deluxe Chip Vac System. This option will include all the items in the standard option above plus a drum dolly and a tool holder. The drum dolly helps to move your drums to different locations. The tool holder has magnets to attach to a steel drum and to hold all the plastic tools. The Deluxe system is a great option for making your system mobile for other areas in your plant. This option is also available in the three main drum sizes like above. For example, model 6293 is for the 55-gallon drum (209L), model 6293-30 is for the 30-gallon drum (114L) and model 6293-110 is for the 110-gallon drum (418L).

If you do not have any drums in your facility, do not worry. EXAIR offers steel drums in our Premium Chip Vac Systems. The Premium package has the items in the standard option plus a variety of upgrades. It will come with a heavy-duty steel drum for all sizes. The upgrades include the heavy duty aluminum tools and an anti-static vacuum hose. The upgraded aluminum tools include a floor tool, crevice tool, skimmer tool with detachable brush, and a two-piece double bend wand. We also add a 20 foot (6.1meter) compressed air hose with quick connect fittings. The Premium package will still come with the drum dolly and tool holder. These can be ordered by using the model 6393 for the 55-gallon drum (209L) size, model 6393-30 for the 30-gallon drum (114L) size, and model 6393-110 for the 110-gallon drum (418L size).

Mini Chip Vac

EXAIR manufactures another type of industrial vacuum within this family; the Mini-Chip Vac System. This system is a self-contained unit that uses a 5-gallon drum which is very compact and easy to use in tight areas. We stock two packages, model 6193-5 and model 6293-5. The model 6193-5 comes standard with a 5-gallon drum with lid and lock-ring, 10-foot (3m) vacuum hose, the 0.1-micron bag filter, an aluminum chip wand, a manual valve, (2) extension wands and an assortment of plastic tools. The model 6293-5 adds a drum dolly to the package to make it mobile with wheels. Even with its small footprint, the Mini Chip Vac is very powerful and quiet. So, noise will not be a nuisance when operating next to the vacuum.

If you get tired of throwing away your electric vacuums with burned up motors or loud “dying” noises, you should try the EXAIR Chip Vac System. They will definitely extend the useful life, make it much quieter to use, and vacuum solid materials quickly. For U.S. and Canadian customers, we offer a 30-day unconditional guarantee to try these units. And as a bonus for end users, you will be able to receive a free Vac-u-Gun as a promotion from now until May 2020 with a qualified purchase. How can you not try them out? If you need help to determine which Chip Vac System would best suit your application, you can contact an Application Engineer at EXAIR.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb