Need an Upgrade? EXAIR has options.

Occasionally we field calls from customers who are currently using an EXAIR product but are looking to “upgrade” to something that might provide just a little bit “extra”. Such was the case recently when I was working with a customer who was currently using our Reversible Drum Vac to clean out their coolant tanks on their milling machines. The RDV was working great in the application but in an effort to gain more floor space, they were now going to store their coolant drums on their mezzanine, located around 10′ above the machining area so they needed something with more power to lift the heavy liquid coolant up to the mezzanine. I promptly suggested our High Lift Reversible Drum Vac. The High Lift Reversible Drum Vac provides up to 15′ of vacuum lift and mounts through the same, 3/4″ NPT threaded hole in the drum lid as their current unit. By purchasing a new High Lift pump unit only, and a 20′ vacuum hose, this customer avoided purchasing a completely new system (they  or other unfamiliar product. They simply replaced the pump unit into the 3/4 NPT bung of the existing drum, and swapped out the hose to meet their existing needs of higher lift.

HLRDV

The High Lift Reversible Drum Vac is designed to fit 30, 55 and 110 gallon, closed head steel drums.

This is just one example how EXAIR continues to offer new products to meet increasing customer demands. In fact, several other products have also been recently expanded or developed to demonstrate this commitment. Here is a short list showcasing some of our newer offerings.

The Chip Trapper System which filters suspended solids in liquid and traps them in a reusable filter bag inside the drum, is also offered in a High Lift version as well, providing the extra vacuum (180″ water column) discussed above, for elevated tanks or below grade sumps.

high-lift-chip-trapper

High Lift Chip Trapper System

We now offer our Heavy Duty Line Vac Air Operated Conveyors in 2.5″ and 3″ sizes with either smooth or NPT threaded ends. The HD Line Vac is constructed of a proprietary hardened alloy construction for superior abrasion resistance and is capable of moving dry material, higher and farther distances.

Heavy Duty Line Vac: Hardened Alloy Construction and High Performance

Heavy Duty Line Vac: Hardened Alloy Construction and High Performance

Our 1/2″ NPT Atomizing Nozzles provide higher flow rates, up to 303 GPH,  with varying spray patterns. Also available with our N0-Drip feature to positively stop the liquid flow when the compressed air supply is shut off.

ef5010ss

EF5010SS 1/2″ NPT External Mix Narrow Angle Flat Fan Pattern Atomizing Nozzle with flows up to 303 GPH.

no-drip

No-Drip Atomizing Nozzle eliminate liquid waste.

The High Velocity Air Jet and Adjustable Air Jet are now available in 303 Stainless Steel for application requiring superior construction where brass may not be suitable.

6013ss

Model # 6013SS Stainless Steel High Velocity Air Jet

 

Stainless Steel Adjustable Air Jet

Model # 6019SS Stainless Steel Adjustable Air Jet

Lastly, we now offer our HD HEPA Vac in a 30 gallon capacity for smaller area, lower scale cleanup for dusty environments.

Heavy Duty HEPA Vac Family

Heavy Duty HEPA Vac Family

All of these products are shipped from stock and can ship same day with orders received by 3:00 PM EST. If you are looking to upgrade your current EXAIR product or with help selecting the best solution, please give me a call, I’d be happy to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Engineering Makes The Difference In Spraying Application

The Paint Line Engineering Manager for a major agricultural & industrial equipment manufacturer wanted to improve the efficiency of their paint lines. They had “halo” systems through which large parts passed for primer & paint coatings, which were equipped with inexpensive liquid-only spray nozzles:

Liquid-only spray nozzles lack the control and efficiency of engineered solutions like EXAIR's Atomizing Spray Nozzles

Liquid-only nozzles lack the control and efficiency of engineered solutions like EXAIR’s Atomizing Spray Nozzles

You can get a whole handful of these and it’ll still cost you less than one of our Atomizing Spray Nozzles will.  If you don’t have any particular concerns about efficiency, spray pattern adjustment, droplet size or flow control (and a lot of applications don’t require this, and that’s fine,) then these will work GREAT for you.  And again, they’re abundant and cheap.

That wasn’t the case here – turns out, good quality paint is expensive, and every drop wasted adds up.  Getting a fine, even coating on parts of different sizes & shapes, every time, requires precision control of the flow pattern.  And design of an automated system benefits from a wide selection of options to choose from.

Enter the EXAIR line of Atomizing Spray Nozzles.  With (90) models to choose from, we can cover (literally) darn near any spraying application you can come up with.  If you know what flow rate and/or spray pattern you’re looking for (like a Paint Line Engineering Manager would,) then selection is quick & easy.  Paint consumption is down, quality is up…and the reliability of the new system means they’re spending less time and resources on cleaning & maintenance. For the record, the halo system ended up looking like this:

EXAIR Atomizing Spray Nozzles provide efficient, reliable coating.

EXAIR Atomizing Spray Nozzles provide efficient, reliable coating.

If you’d like to find out more about how engineered products, like EXAIR’s Atomizing Spray Nozzles, can make a difference to your operations…and your bottom line…give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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EXAIR Atomizing Nozzles in a Forging Plant

A steel forging plant was using a releasing agent in their process. This particular operation was to make a blank gear.  It started with a heated ingot that was placed in a two-part dual stamp die.  The front section of the die creates the hub of the gear, and the back section would finish the outer diameter of the gear.  The operator would use tongs to grab the hot part and place it in the front and back portion of the die.  Each time the press would cycle, a release agent would be sprayed onto the die so that the parts would not stick.  As you can see in the picture below, they had six liquid spray nozzles modified to spray the entire surface.  Two of the spray nozzles were blowing the release agent to the top portion of the die, and four spray nozzles would spray the entire bottom portion of the die.  Every time the press would cycle, the release agent would be sprayed.

Forging press with liquid spraying nozzles

Forging press with liquid spraying nozzles

At a rate of making a part every six seconds, much release agent was being sprayed. This lubrication for forging was not inexpensive, and it was adding cost to their operation.  They called EXAIR to see if we could help in this matter.

 

The EXAIR Atomizing Nozzles use compressed air to help “shear” the liquid into a very fine mist. The smaller the liquid particle size, the more surface area is created.  This is very beneficial in saving liquid material without reducing the required performance.  This customer purchased two Internal Mix Narrow Angle Round Pattern Atomizing Nozzles, model AN1040SS to replace the six liquid nozzles that he was using.  With a stainless steel construction as standard, it makes the Atomizing Nozzle very corrosion resistant and able to handle 400 deg. F (204 deg. C) temperatures.  With the narrow angle round spray pattern, they could position the Atomizing Nozzles to cover the entire top and bottom of the die (reference the photo below).  With the liquid adjustment valve, they could dial in just the right amount of release agent to keep the process running smoothly.  After the first week in modifying their operation with EXAIR Atomizing Nozzles, they noticed that they were using only half the amount of releasing agent.  This helped to cut cost in their operation, increasing their profit margin.

Forging press with EXAIR Atomizing Nozzles

Forging press with EXAIR Atomizing Nozzles

We can spray liquids very economically and efficiently. We have different types of spray patterns for three different styles.  We have the Internal Mix style for low viscosity fluids as purchased by the above customer; the External Mix for high viscosity fluids, and the Siphon Fed for unpressurized liquid systems requiring gravity or siphoning.  We can atomize liquids up to a rate of 5 gallons per minute (19 liters per minute).  If you believe that you are going through too much liquid in your process, you can contact an Application Engineer to see if we have the correct Atomizing Nozzle for you.

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

360° Hollow Circular Atomizing Nozzle Ideal For Treating Ductwork

There are many times we field calls from customers that fall directly in line with the intended use of one of our products. Such would be the case last week when a customer called looking for  a more reliable way to spray a light coating of rust inhibitor on the inside of a small section of ductwork roughly 9″ in diameter.  They were currently using a liquid only spray nozzle but were having trouble controlling the output flow, as well as the actual spray pattern. They were wasting a lot of the inhibitor as it was starting to “pool” in the bottom of the ductwork which would ultimately leak out onto the production floor and operator’s work area when the parts were prepared for shipment, also creating an unsafe work environment.

Model # AT1010SS Internal Mix 360° Hollow Circular Pattern Atomizing Nozzle

 

After discussing the application with the customer, I recommended our Model # AT1010SS Internal Mix 360° Hollow Circular Pattern Atomizing Nozzle. The circular spray pattern is the ideal solution when trying to coat the inside of a duct with rust preventative. The nozzle produces an even spray pattern up to 53″ in diameter with flows as much as 14.7 gallons per hour of liquid, depending on air and liquid supply pressures. Our Atomizing Nozzles also feature an adjustment valve to provide control of the flow rate as well. The 303ss construction is able to withstand corrosive environments and temperatures up to 400°F (204°C).

EXAIR offers a wide variety of Atomizing Nozzles that can be used to coat, rinse or cool a surface. They are also commonly used for dust suppression due to the wide coverage area they produce. For help selecting the correct Model # for your application, give us a call.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

EXAIR No-drip Atomizing Nozzles – Finalist for Flow Control Magazine Innovation Award

SF2010ss559

EXAIR No Drip Atomizing Nozzle

In this summer of 2016, we are nearing the beginning of one of the largest sporting events on the planet, The 2016 Summer Olympics. At the heart of this celebration will be sporting events of all kinds. And in the tradition of the Olympics there is always a gold, silver and bronze winner to award the top three athletes in each event.

EXAIR is participating in a competition as well. It isn’t one of a sporting nature, but rather, one of ingenuity and innovation. Flow Control Magazine holds an annual competition for innovations in new products available in industry and we have entered the No Drip Atomizing Nozzle into the competition.

In general, Atomizing Nozzles are used for the application of high value fluids within industrial processes. In some cases where the Atomizing Nozzles are mounted above the target, residual fluid that is left inside the nozzle body can drip out when de-energized and cause un-wanted blemishes on the target surface.

EXAIR No Drip Atomizing Nozzles allow for external adjustment of compressed air and liquid inputs to adjust the liquid spray flow rate as well as droplet size for a wide range of applications. That’s pretty common amongst atomizing nozzles in general. So what is so innovative about the No-Drip Atomizing Nozzles?

We have found a way to control the on/off function of the atomizing spray which supports the no-drip feature as well as the atomizing flow with only one compressed air supply. Most other manufacturers require a nozzle that has a separate control for the small valve within the nozzle and another for the airflow that atomizes the fluid coming through. It is this innovation that dramatically improves the simplicity with which these nozzles can be installed into an application and controlled through typical air automation techniques. It was innovative enough that the US Patent Office granted EXAIR a patent on the design (Patent # 9156045). So, we’ve made the No-Drip Atomizing Nozzle available with 3 different spray patterns and 14 different liquid volume options to suit a wide variety of application need. Operating pressures can fall anywhere between 30 – 250 PSIG to atomize fluids up to 300 centipoise.

If you agree with the US Patent Office on the innovation and think that EXAIR’s No Drip Atomizing Nozzles should be a winner in this competition, we would appreciate your official vote.

Please vote for the EXAIR No Drip Atomizing Nozzles at this link to the Flow Control Magazine’s Innovation Awards page.

Thank you!

Neal Raker, International Sales Manager nealraker@exair.com

@EXAIR_NR

Atomizing Nozzle Used in Copper Forming Applications

Lan

EXAIR Atomizing Nozzle, Narrow, Round Spray Pattern

 

Copper and its alloys are used in a variety of products from consumer goods like musical instruments, drawer and door pulls, wind chimes, electrical contacts and many other, similar parts that you do not see on more complicated pieces of equipment such as HVAC systems.

Comparatively speaking, copper is quite a malleable metal. That’s what makes it so useful for manufacturing processes such as expanding, reducing, flaring, beading and other similar processes that don’t necessarily involve a cutting or grinding action on the material, but rather a tool that comes into contact with the material to impart a specific shape that makes the made part beneficial to some other product or process.

And so, in the metal forming process, you generally have a hardened alloy tool that comes into contact with the soft copper (or brass) to impart one of the above mentioned effects to the material. With the metal forming process, you have friction that needs to be reduced substantially to aid in the forming process while maintaining the tool integrity and keeping heat generation to a minimum. There are a variety of oil-based lubricants that companies who specialize in this kind of processing, will use to lubricate the raw part prior to forming.

This is the point within the process where EXAIR Atomizing Nozzles can play a significant role in application of the lubrication. By atomizing the lubricant, the customer can have a controlled, even application of the lubricant to the tooling and/or material surface prior to putting the material through the forming operation. By applying a controlled layer of atomized lubricant, the customer can apply the lubricant in a sparingly manner to conserve on how much is used for each part formed. They get the benefit of the lubrication without over-doing it and wasting excess volume of lube applied. This, in turn, allows for a cleaner and safer processing area as well as measurable cost savings for the lubricant as well.

For lower viscosity lubricants (< 300 cP) that require only a light application of material, we have model AN1010SS which can provide a Narrow, Round spray pattern to coat smaller parts. If the part is larger or perhaps starts out as a sheet, we do also have model AW1030SS which can provide a Flat, Wide Angle spray pattern. If the lubricant has a viscosity that is higher than 300 cP, we also have a series of External Mix Atomizing Nozzles with similar spray flow patterns that can be selected for high precision adjustment of the liquid flow and droplet size to suit any need.

If you are in the metal forming industry and you are concerned with application of lubricants in your applications, we be glad to help you pick an Atomizing Nozzle to suit your needs. Contact us to discuss your application.

Neal Raker, International Sales Manager
nealraker@exair.com
@EXAIR_NR

A Lot Can Happen In Five Years

Five years ago, I wrote a blog about my (then) 11 year old son’s first-ever week away from home at Boy Scout Summer Camp. He’s departing again this weekend, but his troop has decided to venture “out of Council” this year, to Camp Howard W. Wall…it’s on the south coast of the island of St. Croix, in the US Virgin Islands.

They met last week to cover the final (and finer) details of international travel, flight schedules, logistics, etc., and activities…Camp Friedlander has a “blob:”

But Camp Wall has an OCEAN:

Just to put the distance into perspective...

Just to put the distance into perspective…

I’ve been thinking a LOT about the changes I’ve seen in the wide-eyed kid I dropped off at a camp that I drive past twice a day, and the smirking teenager that I’m driving to the airport on Sunday morning. And those changes are providing perspective on not only how fast those five years have passed, but how much can happen in that span.

In 2011, I was a wide-eyed “Dread Newbie” at EXAIR.  One of my very first meetings with the rest of the gang was to be trained on our brand new Atomizing Spray Nozzles…we only had three styles to choose from, but two of them came in four distinct models, and one came in FIVE. They were ALL Internal Mix, because hey, who doesn’t like the maximum range of adjustability that comes with being able to vary your flow rate and spray pattern size by adjusting liquid AND air supply pressures?

OK; it turns out that was just the beginning…within the year, our Engineering Department had developed:

External Mix – three styles, thirteen distinct models, to allow for independent adjustment of flow rate (by liquid pressure) and spray pattern (by air pressure.)

Siphon Fed – two styles, seven distinct models, that could be siphon OR gravity fed, for situations where it’s not practical to pressurize the liquid supply.

And, four years after that, looking back, it seems like THAT was just the beginning…we now have:

*Two sizes – the original 1/4 NPT and the new(er) 1/2 NPT.
*Sixteen styles – each available with our No-Drip option (so technically I guess we have thirty-two)
*Forty-five distinct models – we’ve got a flow rate/spray pattern combination for just about any application

And, like the rest of our catalog products, they’re all in stock, ready to ship today, on time, like we do 99.97% of the time…that’s actually one thing that HASN’T changed in the 17 years that we’ve been keeping track.

If you’d like to talk about Spray Nozzles…or any EXAIR products (old or new,) give me a call.

Russ Bowman
Application Engineer
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