EXAIR Product Overview: Mufflers

Noise, we all hate it to some extent. From the hustle and bustle of crowed streets to the whine of a jet engine noise has plagued the world for eons leaving people to search for a way to escape into a moment of peace and quiet. The majority of people that I know pack their massive over sized backpacks and head deep into the mountains for days on end to escape the noise sometimes traveling for 10+ miles at a time. But how can we help eliminate this monstrosity that we have created in our manufacturing environments? The answer is mufflers, and no I don’t mean your car muffler (although they do the same thing) I mean compressed air mufflers. Compressed air can be a loud utility inside of a plant environment and exceed the OSHA guidelines for personnel noise exposure. But this noise can easily be mitigated with the use of Intelligent compressed air products and mufflers.

Big Sandy Lake Trail – Wind River Range State Park, WY

OSHA Standard 29 CFR 1910.95(a) outlines the total noise exposure to a particular noise level per day and dictates that noise exposure at or above 85 decibels require ear protection. By placing a muffler on the end of the pipe one can reduce the sound level significantly to the point it could be the difference between having to wear ear protection and not having to. With that being said EXAIR offers four different types of mufflers to choose from and they are Reclassifying, Sintered Bronze, Straight-Through, and Heavy Duty.

Reclassifying mufflers offer the best noise reduction at 35 dB and have the added benefit of removing oil mist from the air line. This means that the Reclassifying mufflers are ideal for pneumatic cylinders. Per OSHA Standard 29 CFR 1910.1000 worker shall not be exposed to more than 5mg/m3 of oil by volume in a 40-hour work week. The patented design of the removable element separates oil from the exhausted air and meets or exceeds the OSHA Standard.

Sintered Bronze Mufflers are an excellent low-cost solution which can be easily installed into your current existing ports. These mufflers also come in the largest variety of different sizes ranging from thread sizes of #10-32 to 1.5” NPT. Also, the Sintered Bronze Mufflers are specifically designed to provide the minimal amount of back pressure and restriction. The main difference between these mufflers and the reclassifying is that the Sintered Bronze Mufflers cannot collect oil out of the exhaust.

The quick pick chart for easily choosing which muffler you need

If the process air needs to be directly plumbed away from personnel, then the Straight-Through Muffler is the way to go. Straight-Through Mufflers are ideal for situations that require both a threaded inlet and exhaust. In most applications you will see the Straight-Through Muffler pair with our E-Vac vacuum generators or Vortex Tubes to provide noise reduction of the unit. All in all, the Straight-Through Muffler can reduce noise levels up to 20 dB.

Model 3913 Straight-Through Muffler

Lastly, the Heavy Duty Muffler provides a corrosion resistant aluminum outer shell with a stainless steel inner screen. This design allows the muffler to catch any contaminants such as rust from being ejected potentially causing harm or quality defects. Typically, this muffle will reduce noise levels up to 14 dB.

Model 3903 Heavy Duty Muffler

If you have any questions or want more information on EXAIR’s E-Vacs and their Accessories. Give us a call, we have a team of application engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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Efficiency Lab Leads To Big Savings

EXAIR Corporation manufactures quiet, safe, and efficient compressed air products for industry. We want our customers to get the most out of our products, and, in turn, their compressed air systems. To do that, we offer a unique service called the EXAIR Efficiency Lab. Here’s how it works:

  • An Application Engineer can arrange to have your existing compressed air device(s) sent in to our facility.
  • We’ll use our calibrated test equipment to measure the compressed air consumption, sound level, and force applied of those devices.
  • You’ll receive a detailed test report, along with our recommendations to implement an efficient, quiet, and safety compliant solution.
  • We’ll even send your tested device(s) back to you, at no charge, if you wish.

I recently had the pleasure of conducting just such a test on some air guns.  The caller was the Environmental Health & Safety Director for a plastics manufacturer.  The main concern was safety compliance…a recent audit had shown that some workstations were using handheld blowoff devices that did not comply with OSHA standard 1910.242(b), which limits dead end pressure of compressed air products used for cleaning to 30psi.

After discussing their typical uses for these (and other) air guns, they sent in a couple for testing.  Here’s what we found out:

“Thumb guns” are especially popular for blowoff because of their compact size, ergonomic design. and low price.

The air gun with the 7″ straight extension (top) is a “textbook” example of non-compliance with OSHA standard 1910.242(b).  Because it has an open-end discharge with no relief path, this one could cause an air embolism if it were inadvertently dead-ended into the operator’s skin – a potentially fatal condition.  It also uses a considerable amount of compressed air, and is quite loud.  At 80psig supply pressure:

  • Compressed air consumption is 40.7 SCFM
  • Noise level is 95.5dBA
  • Force applied, at a distance of 12″, is 13oz

For comparison’s sake, EXAIR Model 1210-6 Soft Grip Safety Air Gun is fitted with our Super Air Nozzle, on the end of a 6″ rigid extension:

  • Compressed air consumption is 14 SCFM
  • Sound level is 74dBA
  • Force applied, at a distance of 12″, is 13oz…same as theirs.
Model 1210 Soft Grip Safety Air is fitted with an EXAIR Super Air Nozzle. We can also supply it with a Rigid Extension and Chip Shield (right).

The other one is OSHA compliant (it can’t be dead-ended…the cross-drilled hole provides a relief path, but it was still pretty inefficient and loud.  At our standard test pressure of 80psig:

  • Compressed air consumption is 30.8 SCFM
  • Noise level is 94.8dBA
  • Force applied, at a distance of 12″, is 16.9oz

Although the force generated by the Model 1210 Soft Grip Safety Air Gun isn’t quite as high as theirs, it’s still our recommendation here.  Oftentimes, the flow and velocity generated by the engineered Super Air Nozzle is more than capable of meeting the needs of the typical blow off applications these types of air guns are used in.

EXAIR Efficiency Lab testing proves that replacing these air guns with our Soft Grip Safety Air Guns (or at least replacing the tips with EXAIR Super Air Nozzles…we also have adapters for that) will result in compressed air savings of 66% and 55%, respectively, and lower sound levels to within OSHA standard 1910.95(a) limits:

All EXAIR Soft Grip Safety Air Guns comply with these limits for 8 hour exposure.

If you’d like to know more about the efficiency & safety (or lack thereof) of your current air blow off devices, give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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Air Nozzles and Air Jets: An Overview

One of the simplest solutions to lower your air consumption and noise level when it comes to compressed air is to switch your open tubes or pipes and liquid nozzles which are being used for air applications to an engineered compressed air nozzle. EXAIR’s Engineered Air Nozzles and Jets provide a simple solution for a wide variety blow off and compressed air applications and can solve a multitude of process problems efficiently. These applications can include simple blow offs, cooling, part ejection, and much more.

Super Air Nozzles:
Super Air Nozzles are one of the more versatile of all of EXAIR’s Engineered Air Nozzles. They come in many different sizes from a tiny size of M4 threads and 13 millimeters long to the largest with  1-1/4 NPT threads which has a 2″ hex and is almost 5″ long. These are usually used for standard blow off applications that replace open pipes to reduce your air consumption and noise. The force values vary from 2 ounces to 23 pounds of force. 

Another variation of the Super Air Nozzles is the Flat Super Air Nozzles; these nozzles create a small flat curtain of air at a high force to provide a wider blow off area for smaller NPT sized nozzles. The 1” and 2” Flat Super Air Nozzle also have replaceable shims that allow you to adjust the force coming out of the nozzle by increasing the amount of air that is used.   

EXAIR Air Nozzles

Back Blow Air Nozzles:
Back Blow Air Nozzles are designed in a way that blows that makes it easy to blow out the inside of pipes. The Back Blow Air Nozzles have holes around the outside diameter pointed back that creates a cone of air around the air inlet port. This makes it easy to dislodge clogs in pipes that you don’t want going back into the machine and for blowing out liquid and debris from the inside. They are also commonly used with EXAIR’s Chip Shield as to prevent any particles from flying back and hitting the user. Back Blow Air Nozzles come in three sizes: M4, ¼”, and 1” and can be used on inside diameters ranging from ¼” to 16”. 

EXAIR Back Blow Air Nozzles

Super Air Nozzle Clusters:
Super Air Nozzle Clusters use a number of the ¼” Super Air Nozzles to create one nozzle that has a wider cone and larger force. Clusters are usually used in wide area blow off but can also be used for part cooling and part reject as they do supply a wider area of force. Super Air Nozzle Clusters are sized by the number of nozzles in the cluster; the three sizes that we offer are 4-nozzle cluster (3/8” NPT inlet), 7-nozzle cluster (1/2” NPT inlet), and the 12-nozzle cluster (1” NPT inlet). 

EXAIR Super Air Nozzle Cluster

Air Jets:
Air Jets amplify the total volume of air into a high velocity stream of air. This makes it very useful for blowing off/drying applications and cooling applications due to the higher volume of air flowing through the unit. Air Jets come in two variations which are the High Velocity Air Jet and the Adjustable Air Jets. The High Velocity Air Jet uses a 0.015” shim that allows the air to escape the unit at a high velocity laminar flow to entrain the surrounding ambient air; this can be adjusted down using the shim kit which includes a 0.006” and 0.009” shims. The Adjustable Air Jet allows the user to easily adjust the air gap using the micrometer gap indicator. 

EXAIR Air Jets

If you have any questions about compressed air systems or want more information on any of EXAIR’s products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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What Makes EXAIR’s Super Air Knife so Efficient

EXAIR Super Air Knives have been designed to improve upon performance characteristics of our original Standard Air Knife design, which was already a very good performer itself. The Super Air Knife design improves air consumption and noise exposure levels. Since they use less air, they cost less to operate. Because they operate quieter, they can contribute to a quieter environment and increase safety for your personnel. 

Compressed air is such a common utility in manufacturing environments (and more) that many of us take it for granted and may not be the best stewards of its use.  EXAIR Super Air Knives are the most efficient compressed air knife on the market today and help us all to use our compressed air more wisely.

If you have homemade air knives, pipe with drilled holes or manifolds with multiple nozzles, you are in a position to play the hero and save your company compressed air and money. 

Implementing a design which uses the free air surrounding us all, is a significant feature making the Super Air Knife efficient. This is done by utilizing entrainment to move the surrounding ambient air and amplify the blast of compressed air.

Diagram showing how the Super Air Knife works

Air Entrainment is the phenomenon that occurs when air/gas under pressure is released from a device in such a way that a low pressure is generated in the immediate area of the gas discharge.  Gas from the surrounding environment is then pulled into the discharged air stream, increasing its volumetric flow rate. Using this principle, a Super Air Knife increases the air flow without increasing the amount of compressed air used.

This phenomenon is prevalent in many of EXAIR’s products but shines the brightest with EXAIR’s Super Air Knife. The Super Air Knife Sports the highest entrainment ratio out of all of the products with a whopping 40:1 ratio, this makes for a very efficient use of compressed air. With an air consumption of only 2.9 SCFM per inch of air curtain at 80 psig then the air knife would be moving 116 SCFM per inch of air curtain. That’s a lot of air!

Also the fact that entraining ambient air is just moving the ambient air with the energy within compressed air makes process is extremely quiet. This is because the outer layers of the total developed flow are lower in velocity, and serve as a sound-attenuating boundary layer.  The sound level of a Super Air Knife at any length is only 69dBA.  That’s about as loud as someone talking at normal speech 3’ away from you.

Entrainment demonstration using a Super Air Knife

If you have any questions about compressed air systems or want more information on any of EXAIR’s products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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