Combat Rising Energy Costs

It has been a long cold winter this year and I just got my utility bill in the mail. I almost fainted. Sad to say, I’m told that I should expect rising utility costs due to the increased cost of producing electricity.

Rising utility costs has a trickle down effect and no one is exempt. Manufacturers, retailers, farmers, food service, etc. all share the same duress. As the cost to do business increases, prices go up. It’s almost like I’m taking the hit twice.

A recent survey by the U.S. Department of Energy showed that for a typical industrial facility, approximately 10% of the electricity consumed is for generating compressed air. For some facilities, compressed air generation may account for 30% or more of the electricity consumed. Compressed air is an on-site generated utility. Very often, the cost of generation is not known; however, some companies use a value of 18-30 cents per 1,000 cubic feet of air.(ref. DOE)

bog200x181_e7daad

With that being said, EXAIR is your partner in compressed air energy savings. Our products are designed to use less compressed air for blow off, cooling, and non contact motion control. It is as simple as finding the leaks and making the repairs, controlling the air use, and upgrading to efficient engineered blow offs. Request your copy of our blow off guide [link]

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363
Web: www.exair.com
Twitter: EXAIR_JP

Blogheader_2014

Floating Plates With Compressed Air

Yesterday, I had the opportunity to work with a customer who was familiar with our product and was looking to roll out EXAIR’s Super Air Nozzle in various parts of the plant. Before purchasing our products, the customer was using (4) open 5/16″ aluminum tubing to move or “float” a 12 inches by 12 inches plate of aluminum. This plate is .187 inches thick and needed to be moved six inches against the wall of their conveyor. The (4) open tubes moved the plate, but the customer had some safety concerns. First, the open pipes violated the OSHA standard 1910.242(b) that any open pipe that can be dead ended must only be pressurized to 30 PSIG. Second, to move the plate successfully the shop pressure needed increase to 100 PSIG which increases the amount of load on the compressor and could lead to higher maintenance in the future. Finally, the noise level of open pipes was well over 110 dBA which was another OSHA violation.

1132ss

Considering all of these problems the customer contacted me, looking for an air nozzle to use instead of the open pipe. After a short discussion we decided to try (3) HP 1125 nozzles. Once the customer installed the air nozzles, they only used 2 of the air nozzles, and they were able to move the plate easily across the conveyor. This netted them several key results. The most noticeable at the plant was how quiet the operation became. Instead of dealing with noise levels in excess of 110 dBa (which is equivalent to the noise level of a turbo-fan aircraft at take off)  the HP1125 comes in at 83 dBA which is roughly the noise of a milling machine.  This was much more pleasant to the operator and any plant passersby.  The most important was the operation now complied with OSHA safety requirement of 1910.242(b).  Because of the width of the Flat Nozzle and the overhang of the cap, the nozzle can not be dead ended.  Since the unit can not be dead ended, pressure above 30 PSIG can be safely used.  Finally, the most economically result was that the air savings for the units.

The 5/16 tube had an ID of .183 and was 18″ long. When supplying it with 100 PSIG of compressed air, it will flow 22.8 SCFM of compressed air, so the customer was using 91.3 SCFM. The HP1125 nozzle uses 37 SCFM at 80 PSIG, so they were able to use 74 SCFM, which means each minute they were using 17.3 fewer cubic feet. At a cost of $0.25 per 1,000 Cubic feet, the HP1125 saved $0.26 per hour or $6.23 per day or $1,557 per year with 250 working days.

Replacing (4) open tubes with (2) HP1125 Flat Super saved $1,557 per year in compressed air savings, an OSHA violation, employees hearing, and lowered the system pressure from 100 psi to 80 psi.  Needless to say the customer was sold on the benefits on our products, and is looking for any more open pipes in his facility.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

Being Prepared

My sons went skiing with their Boy Scout troop this past weekend. It was the first time my youngest, who turns 12 next month, had been skiing, and he had a blast on the beginner’s slope and the tubing lanes. His 14 year old brother, however, is a grizzled veteran, having hit the slopes three whole times over the past three years. He’s quite athletic, though – this stuff just comes natural to him – so he and his friends spent most of their time on the “difficult” (marked by a blue square on the map) and “advanced intermediate” (blue square with a black diamond) courses. I don’t know much about skiing, but I do know that any slope represented with a black diamond is one that I do NOT belong on.

I mentioned his athleticism – right now, he’s in the middle of basketball season, his baseball team’s prospective pitchers and catchers are working out, and right after winter break, his football team began off-season weight training after school, three days a week. In the midst of all this, he still managed to find some muscles to get sore while skiing. Not as many as some of the other Scouts, though, considering the comments I heard at last night’s Troop meeting. They are all, however, looking forward to next year’s trip.

I tell you this, dear reader, because:
1. It reminded me of a conversation I once had with a customer, and,
2. It’s been a while since I wrote anything about Boy Scouts.

Now that #2 is out of my system, the customer wanted to discuss our Ultrasonic Leak Detector. He had recently purchased a Super Air Knife, and its performance made him think of where else he might be able to make improvements in his compressed air system. Since he had flow meters in place already (see The Six Steps To Optimizing Your Compressed Air System,) he turned to leak detection & repair. In other words, he wanted to find out where his system, much like my son’s hip & lateral abdominal muscles, was vulnerable.  Now that he’s finding out if he has any leaks to fix, he can move on to the next step of upgrading their operations with engineered compressed air products.

ultrasonic_2

And now that my son knows, very specifically and unforgettably, which muscle groups he needs to work on before the next ski trip, I hope he’ll consider some advance preparation next time. Even more than that, I hope that I’ll actually be able to join them then.

Russ Bowman
Application Engineer
russbowman@exair.com
Twitter: @EXAIR_RB

If Money Weren’t An Issue.

For every year I grow older I find it harder and harder to open my wallet for certain things.  I guess some would say “cheap” where I believe I have just learned from experience the things that I prefer to keep my money for.  However, if money weren’t an issue there is plenty I would love to indulge in.  For instance, a garage with enough “toys” to keep myself and any number of friends race needs met, or a driveway like the video below.

At this current point in my life, I won’t have to worry about the upkeep on either of those.  However, there is one thing I do have to worry about and that is the upkeep and cost of compressed air.   While some operators believe compressed air is free or that a single blowgun with no engineered solution really doesn’t cost that much, they are sadly mistaken.  It is because of this that EXAIR offers the most efficient way to use your compressed air in many point of use applications.

Take the real life example below.

It boils down to this:

Less Compressed Air Usage = Lower Operating Costs = More Profit = Race Track in Front Yard.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF