Reduce Sound Levels In Less Than A Minute

Okay, I will admit, the title may be a tad bit leading.  The fact is, it can be done.  I speak to customers almost daily who are struggling with the noise levels produced from open pipe blowoffs.  With Noise Induced Hearing Loss (NIHL) a significant problem among manufacturing workers, reducing the noise form compressed air can be a simple solution and contribute toward reducing overall noise exposure levels. Many of these calls and emails revolve around reducing these exact noise levels, sometimes the open pipes have existing threads on them to install the solution immediately.

To reduce these noise levels, we need to simply reduce the amount of energy that is being expelled through the pipe. How do we do this you might ask?  The use of an air nozzle will reduce the energy being dispersed from an open pipe.  This will result in lower air consumption as well as lower sound levels while actually increasing velocity as the pipe will maintain higher operating pressures. Be cautious about the air nozzle you choose, however, they are not all created equal. EXAIR’s engineered air nozzles are among the quietest and most efficient air nozzles available.

Family of Nozzles

What size pipes can we fit nozzles to?  That’s a great question.  We have nozzles that range from a 4mm straight thread all the way up to 1-1/4″ NPT thread.  This also includes nearly any size in between especially the standard compressed air piping sizes.  For instance, a 1/4″ Sched. 40 pipe that has 1/4″ MNPT threads on it can easily produce over a 100 dBA noise level from 3 feet away.  This can easily be reduced to below 80 dBA from 3′ away by utilizing one of our model 1100 Super Air Nozzles.  All it takes is a deep well socket and ratchet with some thread sealant.

This doesn’t just lower the sound level though, it reduces the amount of compressed air expelled through that open pipe by creating a restriction on the exit point.  This permits the compressed air to reach a higher line pressure causing a higher exit velocity and due to the engineering within the nozzle, this will also eliminate dangerous dead-end pressure and complies with OSHA standard 29 CFR 1910.242(b).

Easy Install

All in all, a 30-second install can make an operator’s work station considerably quieter and potentially remove the need for hearing protection.  If you would like to discuss how to lower noise levels in your facility, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

How to Install A Super Air Knife – From the Basic to the Creative

Occasionally, a caller will ask if we offer installation services for our products. They’re usually very pleased to learn that there’s not all that much to it.

Any of our Super Air Knives can use our Model 9060 Universal Air Knife Mounting Systems (shown below; one on a 12″, and four on a 108″ length) for easy installation and precise aiming.

The 9060 Universal Air Knife Mounting Systems are perfect for simple, fast installation and positioning.

Shorter lengths, like the Model 110006 6″ Aluminum Super Air Knife (below, left,) can be adequately supported by air supply piping.  We don’t recommend that with longer lengths (due to overhung load concerns) but even a Model 110018 18″ Aluminum Super Air Knife (below, middle,) can be supported by the supply pipe in a vertical position.  We even stock our 3″ Aluminum Super Air Knives with Stay Set Hoses & Magnetic Bases (below, right.)

Just a few more popular ways to install a Super Air Knife.

The Super Air Knife also has a series of 1/4″-20 tapped holes, 2″ apart, along the bottom of the body.  These are often used for installation & mounting as well, and we’ve seen some creative methods, for sure:

Yes, that’s a door hinge. No, it wasn’t my idea, but I kind of wish it was.

EXAIR Super Air Knives come in lengths from 3 inches to 9 feet long.  We stock them in aluminum, 303SS, 316SS, and PVDF.  If you need a custom length or material, though, we do those too.  We can even talk about the best way to mount it.  Call me.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Video Blog: Split Ring Design of the Super Air Wipe Eases Installation

This video showcases just how easy it is to install a Super Air Wipe or a Standard Air Wipe onto an extrusion line.  The split ring design makes it possible to install or remove from the line without having to thread the product, all within a minute or less.

If you would like to discuss your application, or any point of use compressed air application, please contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Accessories and the Value Added

The word “accessory” can come with some baggage… it’s become synonymous with “add-on” and “up-sell,” and cost-mindful consumers may see them as just another way for a slick salesperson to make an extra buck. And frankly, they wouldn’t have that reputation if there wasn’t some truth to it.  The server at your favorite restaurant will offer appetizers, or recommend side dishes to go with your entree. If you go to buy a new car, you’ll get a pitch for a variety of aftermarket add-ons.  The paint counter folks at the hardware store always tell me what specific brush and/or rollers I should use with the paint I’m buying…and it’s never the 10-pack of economy brushes that costs less than the single, premium quality brush they recommend.  In all of these cases, these employees are trained, constantly encouraged, and hopefully rewarded on the success of these “up-sell” strategies.

Of course, my boys and I can devour even the largest plate of chili cheese nachos long before the rest of meal comes out.  My wife absolutely loves the remote starter function that the dealership installed on the new car she bought last year.  And, if you’ve ever painted a well-lit room, you know the difference between a $1 paint brush and a $10 paint brush.  So if my server gets a little bigger tip, my car dealer salesperson gets a little more commission, or the paint counter folks get a bonus, then it’s a win-win, as far as I’m concerned.

EXAIR carries a variety of accessories for our Intelligent Compressed Air Products.  Some aid in mounting & installation:

Clockwise from top: Universal Air Knife Mounting System, Stay Set Hoses, Cabinet Cooler Side Mount Kit, Mounting Brackets for Line Vac, Filter Separator, and Pressure Regulator, Swivel Fitting for Super Air Nozzle, Tool Holder for Industrial Vacuum Drums, Spray Nozzle Mounting Clip.

Others make it easy to ensure adequate supply conditions:

The performance of many EXAIR Intelligent Compressed Air Products can be altered by replacing the shim:

From left to right: Super Air Amplifier, Super Air Knife, 1″ Flat Super Air Nozzle, High Velocity Air Jets, and Air Wipe all feature replaceable shims to modify performance.

In addition to these product-specific accessories, EXAIR carries a complete line of:

Filter Separators are rated for air flow up to 400 SCFM; Oil Removal Filters, up to 310 SCFM.

*Filter Separators to remove water, dirt, and rust from your compressed air system.  Our Automatic Drain Filter Separators have a 5 micron particulate element, and a centrifugal vane to remove moisture.

*Oil Removal Filters with coalescing elements that remove any trace of oil, and also provide additional particulate filtration to 0.03 microns.

 

*Pressure Regulators, so you can “dial in” the performance you need, so you don’t overpower the application, or waste compressed air.  They come in sizes from 1/4 NPT to 1-1/4 NPT, and are rated for flows up to 700 SCFM.  A pressure gauge provides accurate indication of outlet pressure, and the adjustment cap can be removed to prevent tampering.

*Mounting Brackets and Modular Coupling Kits for our Filters and Regulators.  The latter are especially handy for easy, compact, and leak free installation.

*Silencing Mufflers to reduce work area noise from compressed air exhausting from pneumatic cylinders, valves, etc.  There are several styles to choose from, depending on your needs:

  • Sintered Bronze Mufflers are simple in design, with minimal back pressure restriction, and come in sizes from #10-32 thread to 1-1/2 NPT.
  • Straight-Through Mufflers offer noise reduction up to 20 dB, and come in sizes from 1/4 NPT (up to 22 SCFM) to 3/4 NPT (up to 73 SCFM.)
  • Heavy Duty Mufflers have an internal stainless steel screen that not only protects the exhausting components from environmental contamination, but also keeps air system contaminants from being ejected at high speed into the work area.
  • Reclassifying Mufflers are an upgrade to the Sintered Bronze Mufflers and provide the highest level of noise reduction – up to 35 dB.  They also trap oil mist, eliminating breathing hazards to personnel.

*We have manual ball valves (1/4 NPT to 1-1/4 NPT) and Solenoid Valves (120VAC, 240VAC or 24VDC) from 1/4 NPT to 1 NPT, and a Foot Valve, for hands-free operation.

*Swivel Fittings to securely install & aim many of our nozzles, from the Atto to the High Force 1 NPT Super Air Nozzles.  For a little more flexibility, Stay Set Hoses and Magnetic Bases can be used for Air Amplifiers, Super Air Nozzles, and even short Air Knives.

*12 ft Coiled Hoses (1/4″ or 3/8″ ID) and Compressed Air Hose (3/8″ or 1/2″ ID; up to 50ft lengths) can be provided with any Intelligent Compressed Air Product.  We also have a full supply of fittings (tees, elbows, nipples, couplers, reducers, etc.) and adapters to fit our Super Air Nozzles to your existing air guns or blow off devices.

*Receiver Tanks are used to store a ready supply of compressed air.  If you have an intermittent demand of sufficient size, it can cause a pressure transient in your system, which can drag down the ability to supply other points of use.  Installed near the point of intermittent demand, they prevent pressure & volume fluctuations, keeping the operators at all points of use happy.  Model 9500-60 Receiver Tank has a capacity of 60 gallons, is rated to 200psig, and meets ASME pressure vessel code.

In closing, let me offer the following advice that’s served me well over the years:

*Be mindful of the valued added by the accessories & add-ons you’re presented during a purchase of capital equipment…or anything else, really.  Don’t buy something you don’t need, but if you need it…well…it’s OK to buy it.

*Don’t skimp on quality.  Odds are, if an accessory is offered by the manufacturer of the product, it’s going to work well for you.  They should be able to tell you if it will or won’t if you discuss your needs with them.  I know I will if you call me to discuss a compressed air product application.

*Get the big plate of nachos, especially if you’re dining with teenagers.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook