The Power of Optimization

When you take your car into the service shop for an oil change, you notice that they will check all the fluids, air filter, the belt, tire pressure, etc.  The reason that they do this is twofold.  They want to make sure that your car will not run into any potential safety problems and to get the maximum performance from your vehicle.

EXAIR has been in the forefront of selling efficient, safe, and effective products since 1983.  In that time, we wanted to become more than a manufacturer.  We wanted to also provide a way to improve your compressed air system.  We developed this into our Optimization product line.   By design, these products are also twofold.  First, it shows the importance of saving compressed air, improving safety and refining processes.  Second, it helps to improve the performance of your compressed air system to get the most out of it.   I am going to discuss a few points of each product below:

Electronic Flow Control

Electronic Flow Control:  The EFC is designed to save compressed air.  If there are any time gaps in a blowing or cooling application, then we should turn off the compressed air.  The EFC is a miniature timing PLC that uses a photoelectric sensor to turn off the compressed air.  By using less compressed air, you will be able to save a bunch of money.  This is why the light bulb in your refrigerator goes off when the door is closed (or does it?).

Digital Sound Level Meter

Digital Sound Level Meter:  This device is used for measuring sound level.  For safety reasons, OSHA sets a decibel ratings for work environments.  The Digital Sound Level Meter is calibrated to a NIST standard to accurately measure noise level.  If you have poor nozzles on your air guns or open pipes for blow-offs, you could be violating the OSHA standard 29CFR 1910.95(a), which will result in fines.  EXAIR products are designed to meet this standard.

Ultrasonic Leak Detector

Ultrasonic Leak Detector (ULD):   Many compressed air systems have leaks.  If they go unnoticed, this will affect the overall capacity of the compressed air system as well as costing a lot of money.  Leaks can account for one-third of your compressed air output.  The ULD can find these leaks to optimize your system and to improve the “health” of your compressor.

Digital Flowmeter

Digital Flowmeter (DFM):  If you can measure flow, then you can find many ways to optimize.  The DFM is able to show and record the amount of flow that you are using in your compressed air system.  You can also use the Digital Flowmeters to find leaks, diagnose pneumatic problems, and use the recorded information for preventative maintenance.  In comparing to an open pipes or competitive products, you can easily see the air savings with EXAIR products and easily determine the payback period (which is generally in weeks).  EXAIR does offer options that are wireless, serial, or USB type of recording, so, you can continuously monitor your compressed air system 24/7.

With the Optimization products, it can “service” your compressed air system; so that, you can get the most from it.  It can save you money, make your system safe, and keep things pneumatically maintained.  If you would like discuss one or more of these products, you can contact an EXAIR Application Engineer for more details.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

PEEK Super Air Nozzles Resist Corrosion; Won’t Scratch Sensitive Surfaces

Because they might be needed in some pretty aggressive environments, EXAIR offers many of our Intelligent Compressed Air Products in a variety of materials. One particular material of construction, however, has two distinct benefits. PEEK (Polyether Ether Ketone, for those of us who ruined the grading curve in CHEM102) plastic offers not only superior chemical corrosion resistance; it’s also non-marring. Since EXAIR introduced the first PEEK Super Air Nozzle in 2005, they’ve been specified all over the world; sometimes for their corrosion resistance; other times so they won’t mar or scratch sensitive surfaces…and every once in a while, for both.

I recently had the pleasure of discussing blow off applications with the production manager of a large anodizing & plating company. The chemicals used in these processes are extremely corrosive, and the equipment used in those areas has to be made of something that’ll handle it. PEEK plastic is just such a material. Also, once they’ve treated their customers’ parts, they need to handle them with care…they’re getting paid a premium to provide nice, shiny parts with a perfect finish. When they’re blowing them off, they need to use something that won’t scratch up the surface if the operator makes incidental contact with the blow off tip. Again, PEEK plastic is just such a material.  Since their existing blow offs were fitted to 1/8 NPT connections, they chose the Model 1102-PEEK Mini Super Air Nozzle.

EXAIR’s PEEK Super Air Nozzles can be mounted in place or on a Safety Air Gun, depending on your needs.

Corrosion resistant and non-marring…EXAIR offers our PEEK Super Air Nozzles in six sizes, from the Atto (M4x0.5 threads; 2.5 SCFM; 2 oz force applied) to our High Force Model 1104-PEEK (3/8 NPT threads; 35 SCFM; 1.9 lbs force applied) for an incredibly diverse range of applications.

If you’d like to discuss what material(s) of construction your application(s) require, give me a call.

Russ Bowman
Application Engineer
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Cabinet Cooler Systems Save The Day, Every Day

Summertime temperatures get hot. Protect your electronics with an EXAIR Cabinet Cooler System.

As you may have seen in our most recent E-NEWS Special Bulletin, or experienced in real life (depending on where you’re located,) most of the eastern United States is seeing a pretty significant heat wave for early summer…or, as we call it at EXAIR, “Cabinet Cooler Season.”  And this year is kicking it off with a bang, for sure.

On Tuesday, when the E-NEWS email went out, I was on the phone, processing an order for a Model 4340 NEMA 12, 2,800 Btu/hr, Thermostat Controlled Cabinet Cooler System, to ship overnight to a user who wanted to protect the new drive they were replacing because theirs overheated.  They were up and running before noon on Wednesday.

On Wednesday, four local customers placed “will call” orders for Cabinet Cooler Systems.  I had the pleasure of talking with one of them, who was installing one for the very first time.  As he was looking over the Installation & Operation Guide before he left our building, he just wanted to make sure that hooking it up was as simple as it sounded…and it is.  We pulled the parts from the box and went over exactly how each step is performed, and he left feeling confident that he’d have it installed pretty quickly.  Just in case, I also got his email address and sent him a link to our NEMA 4 Cabinet Cooler System Installation Video Blog:

I don’t know what the rest of the summer holds in store, but I know this: if you have concerns about protecting sensitive, critical, and/or expensive electrical & electronic enclosures, EXAIR Cabinet Cooler Systems are the solution you’re looking for.  Easy to install.  Maintenance free operation.  Durable, UL Listed, and CE Compliant.  If you’d like to discuss your application and get one for yourself, call me; let’s talk.

***Order an EXAIR Cabinet Cooler System before July 31, 2017, and get a FREE AC Sensor!***

Russ Bowman
Application Engineer
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EXAIR Won’t Keep You Waiting For Anything

Have you ever sent an email, or left a voice mail message for someone without knowing they were out of the office? It can be pretty frustrating to not hear back from someone, especially if your needs are urgent.

At EXAIR, we make sure this doesn’t happen:

*For starters, we don’t have an automated attendant…if you call EXAIR during normal business hours, you’re going to talk to a real live human being.

*What’s more, that real live human being is going to be one of our Customer Service Representatives, and they can answer any questions you might have about price and availability of any of our Engineered Compressed Air Products.

*If you need detailed technical information, they’ll transfer you to an Application Engineer…and they are always keenly aware of who’s available & who’s not.  You won’t get anyone’s voice mail unless you specifically ask for it, and if one of us is on vacation (and won’t be able to return your call for a number of days,) you’ll know that before you’re transferred to leave that message.

*Not only that, but we’ve got a system in place to monitor each other’s emails.  Which brings me to the success story that inspired this blog:

It’s vacation season, and another of us took off for some well deserved R&R with the family.  According to The System, I get to check those incoming emails while this co-worker is out.  And he (like the rest of us) gets a LOT of emails.  Some are new requests for application/performance data, and some are continuing conversations of the details of (sometimes) complex applications.  Like the project he was working on with a customer who wanted to use Air Knives to blow off a continuous strip of material exiting a wash/rinse vessel.  After a discussion of the details of the application, they had decided to try (2) Model 110003 3″ Aluminum Super Air Knives, one mounted on either side, to “strip the strip.”  And it worked perfectly.  They just wanted to run the details of this first installation by us before doing the other seven.  Part of my process was to go back through the chain of emails…while this looked pretty straight forward, the devil is indeed in the details, and I hate that guy.  But, try as I might (sorry; I’m an engineer,) I could not find fault, or room to improve, with the setup they designed…it was most pleasantly devil-free.

Compact, efficient and quiet, the EXAIR 3″ Super Air Knife is an ideal blow off solution for a variety of applications.

Anyway, with my agreement that their installation was indeed optimal (it’s exactly what I would have done too, for the record,) they placed an order for the (14) Super Air Knives to outfit the other (7) wash/rinse operations.

If we were keeping score, it would be coworker-2, Russ-14.  But we’re not.  Lest my record suffer when I “break for the Lake” in June.  By then, it’ll be Cabinet Cooler Season, and I almost hate to miss a week of that.  Almost.

Man, I don’t even take long pants with me to the Lake.

If you have questions about compressed air products or applications, we’ve got answers.  Live and in real time, every day.  Call us; let’s talk.

Russ Bowman
Application Engineer
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Reversible Drum Vac Empties Sumps For Demolition Company

A demolition company was looking for a way to remove the liquid from sumps and tanks in the industrial buildings they were contracted to provide their service upon. The liquids in question were mainly coolant and oil that had been left behind when the machinery was removed…anything that could be re-used was already gone; this was the “bitter dregs,” as it were.  Since these buildings are about to be demolished, electricity is rarely available.

They had a pumping system that ran off a diesel engine that they COULD take with them, but they ALWAYS had a large mobile air compressor for the pneumatic tools used in other processes in the demolition of the building. Since they had steel drums in abundance, the Reversible Drum Vac Systems sounded very attractive to them, so they got a Model 6295 Deluxe High Lift Reversible Drum Vac System for 55 Gallon Drum to try out.

The High Lift Reversible Drum Vac System converts a drum and dolly into a mobile pumping system.

Now, instead of committing an additional truck (and driver) to getting the diesel engine driven pumping system to the site, they simply move the Reversible Drum Vac pump unit from 55 gallon drum to 55 gallon drum as they’re filled. Once the drums are returned to their facility, they switch the the Reversible Drum Vac to the “empty drum” configuration, and use it to pump the liquid out into their recycling tanks, where they await collection and processing by their waste handling service.  Even when they have to use a number of drums, the High Lift Reversible Drum Vac Systems still streamline the process over the use of the diesel engine pumping system.

If you’d like to find out more about our Industrial Vacuums, or any of our compressed air operated products, give me a call.

Russ Bowman
Application Engineer
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Super Ion Air Knife Removes Debris In Vinyl Window And Door Manufacturing

I recently worked with a vinyl window and door manufacturer on a static issue they were experiencing during the manufacturing process. After the aluminum frames are cut to length they are placed into a holding fixture where the vinyl seals are placed in a channel inside the frame and clamped together. A machining tool then travels around the parts to trim and machine the excess material, creating dust and some small chips. They tried to vacuum the debris away but were still seeing some residual material cling to the surface due to static, which resulted in manual rework of the parts, slowing down the production cycle.

Vinyl window – similar to the window being produced by the customer

The customer was able to send a drawing of the holding fixture for reference and after reviewing the information, I recommended they use our 18″ Super Ion Air Knife Kit in this application. The Super Ion Air Knife provides a high velocity, laminar sheet of ionized air across the length of the knife. As the positive and negative ions neutralize the surface charge, the airflow is able to clean the part of the unwanted material so it can be more easily vacuumed away. Using the regulator included in the kit, they can reduce the supply pressure to control the outlet flow and velocity to an acceptable level that doesn’t disrupt the current process.

Super Ion Air Knives are available in standard lengths from 3″ up to 108″ and ship from stock.

If you have an application you would like to discuss or are considering an EXAIR product for your process, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Vinyl Slider Window with Grid image courtesy of Steve Anderson via Creative Commons License

 

Internal Mix Atomizing Spray Nozzle Used In Feed Additive Process

Last week I took a call from an agricultural customer looking to replace the spray nozzle used in their feed additive process. The soy oil/beeswax solution they are applying to the feed, is slightly viscous (close to 100 cP) which seems to be clogging the tight clearances inside the current nozzle, resulting in varying flow rates and an erratic spray pattern. They had tried to contact the current manufacturer several times for a solution but were unhappy with the lack of assistance they were receiving, not to mention the long lead times of 6-8 weeks for a replacement.

After further discussion, they confirmed they weren’t as concerned with the flow rate or spray pattern, as they were with the nozzle potentially getting clogged.  They were able to obtain some internal dimensions of the existing nozzle and after further review, I recommended they use our Model # AF1030SS Internal Mix Flat Pattern Atomizing Nozzle as a replacement. This nozzle has larger inside diameters which would reduce the potential for clogging. Our Internal Mix Atomizing Nozzles mix the liquid and air inside the air cap and produce the finest atomization. The flow rate can be changed by adjusting the control valve on the nozzle and/or by adjusting the liquid pressure. Internal Mix nozzles are capable of handling fluids up to 300 Centipoise. All of our Atomizing Nozzles are In STOCK, so delivery is never an issue.

Model AF1030SS Internal Mix Flat Fan Pattern Atomizing Nozzle

When considering an Atomizing Nozzle for an application, there are some general parameters that can be helpful in making the best selection.

  1. Do you have a pressurized liquid source?
  2. What is the fluid viscosity?
  3. What spray pattern best fits the process?
  4. How much flow (GPH/LPH) do I need?

If you have an application requiring a fine mist of atomized liquid spray, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

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