Calibration – Keep Your Meters True

EXAIR offers meters to measure the level of physical parameters such as sound and static. Each meter has sensitive electrical circuitry and a periodic calibration is recommended to ensure the meter readings are tried and true.

The model 9104 Digital Sound Level Meter is an easy to use instrument that measures and monitors the sound level pressure in a wide variety of industrial environments. The source of loud noises can be quickly identified so that corrective measures can be taken to keep sound levels at or below OSHA maximum allowable exposure limits.

The sound meter comes from the factory with an NIST (National Institute of Standards and Technology) certificate of accuracy and calibration.  As a good practice, EXAIR recommends a yearly calibration of the instrument, and we offer a service that calibrates the unit to the same NIST standards and provide a written report of the calibration.

The model 7905 Static Meter allows easy one-hand static measurements.  It is useful in both locating sources of high static charge and checking the reduction of static after treatment with an EXAIR Static Elimination product.  The unit is sensitive and responsive, and indicates the the surface polarity of objects up to +/- 20 kV when measured from 1″ away.

It is also recommended that the Static Meter be calibrated on a yearly basis.  EXAIR offers (3) levels of calibration service.  The first two provide calibration in accordance with MIL Standards using accepted procedures and standards traceable to NIST.  The third calibration service conforms to the same Mil Standard, as well as ISO/IEC standards.

Annual calibration service of your EXAIR Digital Sound and Static Meter, along with proper care and storage, will keep your meter performing tried and true for many years, providing accurate and useful measurements.

To initiate a calibration service, give us a call and an Application Engineer will issue an Returned Good number, and provide instructions on how to ship the meter to EXAIR.

If you have questions regarding calibration services for your meters or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_BB

EXAIR Super Air Knives Helps Keep Labels on the Bottles.

Super Air Knife Blower Air Knife

Sometimes you need more power.  I received a phone call from a bottling facility that was currently using a blower style type of air knives.  They increased their production rate from 220 bottles/min to 300 bottles/minute, and they started to see issues in the labeling process.  Their operation consisted of a wash cycle, rinse cycle, drying cycle, then labeling.  They determined that the bottles were not getting dry enough during the drying cycle before the labels were applied.  They had a VFD (Variable Frequency Drive) for the blower system, and they reached the maximum rate.  Still the bottles were not getting dry enough to allow the label to stick to the surface properly.  This meant that they would have to increase the size of their blower system.  With the capital cost of a blower system, they decided to call EXAIR to see if we could help them with the drying application.

Compressed air is the best way for establishing a strong blowing force.  Instead of air pressures in the range of inches of water, the compressed air system can generate over 40 times the amount of pressure than a typical blower system.  EXAIR products uses this power of the compressed air to give you a wide range of blowing forces for drying, cooling, or moving products.  For the above application, I recommended two model 110212 Super Air Knife kits.  The kit includes the Super Air Knife, a filter, a regulator, and a shim set.  They mounted one knife on each side of the bottles to blow off and remove the liquid after the rinse cycle.  Even at the increased bottle speeds, the EXAIR Super Air Knives had no issues in keeping the bottles dry.  With the regulator and the shim, it was easy for them to dial in the correct amount of force without using excess compressed air.  The labels remained glued and the bottling process ran smoothly.  Because the company was impressed by the Super Air Knives, they wanted to comment on the comparisons between the blower knife and the Super Air Knife.

  1. Cost:
    1. Blower System – The reason for contacting EXAIR. Blower-type air knives are an expensive set up.  They require a blower, ducting, and a knife.  To have any flexibility, a control panel with a VFD will be needed.
    2. Super Air Knife – It is a fraction of the cost. With their system, we were roughly 1/10 the cost; even with the kit.  No capital expense report would be needed for the two air knives.
  2. Installation:
    1. Blower System – They stated that it took them a week to install the entire system before they were able to operate. They had to run electrical wires, controls, ducting, and they even had to change the conveying system slightly to accommodate the blower size.
    2. Super Air Knife – They mounted the filter and the regulator on the conveyor, and ran tubing to the Super Air Knives. Even with a fabricator making a bracket to fit into their system, they had the system up and running is less than two hours.
  3. Size:
    1. Blower System – The foot print of the blower is large and it takes up floor space. The 3” ducting had to be ran to an oversized air knife.  With the congestion of the bottle system, it made it difficult to optimize the position and the blowing angle to adequately dry the bottles.
    2. Super Air Knife – With the compact design, the Super Air Knife packs a large force in a small package. It has a footprint of 1 ¾” X 1 ½” X 12” long.  The air knife only required a ¼” NPT compressed air line to supply the compressed air.  It opened up the floor space as well as the bottling area.
  4. Maintenance:
    1. Blower System – The blower filter had to be changed regularly, and system had to be checked. Being that the blower motor is a mechanical device, the bearings will wear and the motor will fail over time.  These items should be checked quarterly as a PM which increase the cost to run the system.
    2. Super Air Knife – No moving parts to wear out. The only maintenance would be to change the filter once a year.
  5. Versatility:
    1. Blower System – They did have a VFD to control the blowing force. But it was still very limited.  With a 36% increase in the bottle speed, they went beyond the maximum capacity of the blower.
    2. Super Air Knife – With a regulator and the shim set, the blowing force can be controlled easily from a breeze to a blast. With their application, the customer only required 40 psig with a standard 0.002” shim to clean and dry the bottles.  They had the option to adjust the regulator or change the shim to get the appropriate amount of blowing force.  So, with any changes in the bottling operations, the Super Air Knife could easily be adjusted.  Also, with the blowing force being optimal from a distance of 3” to 12” from the target, they had more flexibility in angle and distance to hit the moving target.
  6. Quiet:
    1. Blower System – With the blower and turbulent air flow, the units are very loud. It had a sound level near 93 dBA, and with the operators working around the system, they needed PPE to protect them from the high potential of noise induced hearing loss.
    2. Super Air Knife – These units are very quiet. At 40 PSIG, the sound level is only at 61 dBA.  (Even operating at a pressure of 100 PSIG, the sound level is only 72 dBA).  This was very nice for the operators to work around as it wasn’t a constant noise nuisance.

In using the compressed air, the Super Air Knives are engineered to be very efficient.  The design creates a 40:1 amplification ratio which means that for every 1 part of compressed air, 40 parts of the ambient air is entrained.  But, even with the use of compressed air, the customer still wanted to share the ease of installing, the effectiveness of blowing, and the improvements to their process.  With the 6 points noted above, the customer wished that they would have contacted EXAIR at the beginning.

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

Air Amplifiers – Vent, Exhaust, Cool, Dry, Clean – With No Moving Parts!

As an Application Engineer, one of the interesting aspects of working with customers on applications is the varied types of solutions an EXAIR product can provide.  The Air Amplifier family – Super Air Amplifier, Adjustable Air Amplifier, and the special High Temperature Air Amplifier can be used in a wide variety of process and applications.  Below highlights several of those from past experiences.

A defense contractor was performing maintenance service on a Navy ship, and the ventilation system had to be shut down.  To keep the personnel cool and safe, an auxiliary ventilation was to be supplied.  Rather than use a cumbersome blower assembly, which has to mounted on the top deck, and ducted down to the lower decks, they chose to utilize (2) 4″ Super Air Amplifiers.  They are very portable and can be set up in minutes.  This solution provided the necessary air flow, providing a safe environment for the maintenance crew.

Super Air Amplifier
EXAIR Air Amplifiers use a small amount of compressed air to create a tremendous amount of air flow.

A light bulb manufacturer needed a better solution for a cooling operation.  During manufacturing of a mercury lamp, the bulb must be cooled from 700°C to 600°C in just 15 seconds.  The current method, an open brass pipe, was working but the noise level was too high (95 dBA.) The goal was to maintain the 15 second cooling time, but reduce sound levels to 85 dBA.  By utilizing (2) of 3/4″ Adjustable Air Amplifiers, the customer was able to maintain the cooling rate, and reduce the noise level down to 80 dBA, a 15 dBA reduction.

adjustable Air Amplifier
Adjustable Air Amplifier

A garbage collector presented a problem that needed a solution.  The garbage was incinerated and when the furnaces were first started up, there tended to be issues with getting the flue to draft properly.  Using the High Temperature Air Amplifier, the high velocity air flow and draw provided the needed draft until the stack warmed up and the natural draft would be established.  Since the unit is capable of handling temperatures up to 700°F, it was able to withstand the heat of the process after the compressed air was turned off.

These and other Applications for the Air Amplifiers and all other EXAIR products can be found on the EXAIR website on the Products page, under the Related Info section toward the bottom of each page.

If you have questions regarding Air Amplifiers or any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_BB

EXAIR Accessories – We’ve Got you Covered

When you work with us here at EXAIR, we strive to have all the ancillary items that you might need to make your installation a success, without having to find components at the last minute or perhaps using the wrong sized components. Each specific product line such as Super Air Knives or Line Vac air operated conveyors have specific accessories such as mounting brackets or plumbing kits which EXAIR has made to simplify the installation of those particular products. We also carry generalized accessories which work across all of the product lines so you do not have to use multiple vendors or purchase orders.

Silencing Mufflers – Per OSHA Standard 1910.95(a), a worker must not be exposed to sounds levels above 90 dBA for any eight hour shift of a 40 hour work week.  EXAIR offers several types of mufflers including – Reclassifying, Sintered Bronze, Straight-Through and Heavy Duty.  For reducing the noise associated with an EXAIR E-Vac Generator, Vortex Tube, Cabinet Cooler System, or the exhaust air from cylinders, valves and other air powered equipment, we’ve got a muffler that will help to keep the noise level at an acceptable level.

Mufflers

Solenoid and Manual Valves – The easiest way to reduce compressed air usage and save on operating expense is to turn off the compressed air to a device when it isn’t needed. EXAIR carries a wide assortment of solenoid valves, with offerings in the NEMA 4/4X classification, and supply voltages of 24VDC, 120VAC, and 240VAC.  We also have manual ball valves from 1/4 NPT to 1-1/4 NPT and a foot operated valve, with 1/4 NPT connections.

Valves

Swivel Fittings, Stay Set Hoses and Magnetic Bases – To provide a great degree of flexibility for positioning an EXAIR Super Air Nozzle, Air Jets or Air Amplifiers, EXAIR offers several items.  The Swivel Fittings have 25 degree of movement from the center axis, providing a total of 50 degree of adjustability.  The position is locked in place and holds until adjustment is needed. For applications where frequent re-positioning of the air device is required, the Stay Set Hoses are ideal.  Simply mount the hose close to the application, bend it to the shape preferred, and because the hose has “memory”, it will not creep or bend.  Lastly, the Magnetic Bases are another option for flexible, movable installations.  The base has a on/off valve, and a powerful magnet to hold in any vertical or horizontal mounting arrangement.

Swivels, StaySets,MagBases2

 

Hoses – EXAIR can provide hoses for your application.  For the Line Vac air operated conveyor applications, we offer conveyance hose – a durable, clear reinforced PVC hose, in diameters of 3/8″ to 3″ ID, and lengths up to 50′. On the compressed air side, we can provide 12′ Coiled Hoses with 1/8, 1/4, and 3/8 NPT connections, and also 3/8″ and 1/2″ ID hose in lengths to 50′.

Hoses

Filter Separators, Oil Removal Filters and Pressure Regulators – Perhaps the most important accessories for use on a compressed air device are filters and regulators. Filtering the compressed air of dirt, debris, moisture and oil will help to prevent build up inside the EXAIR products, leading to longer service life, and less time spent cleaning, while providing optimum performance. Regulating the air pressure allows for tuning of the performance, using the proper amount of compressed air to obtain satisfactory results.

Filter and Regualtors

If you have questions regarding accessories for use with any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_BB

How To Solve A Problem with Compressed Air

In my (almost) six years as an EXAIR Application Engineer, I’ve learned a great many things about the capabilities of our products.  The way we do business sure does make it easy:

  • We readily share application information, as a team.  If you ask me a question, you’re asking all of us.  It does neither of us any good if I tell you something MIGHT work if one of my team knows it WON’T – or if someone knows what else DOES work.  If we can offer a solution, we will.
  • We’ll test your product, free of charge.  This is a popular way of finding out which Line Vac is best for conveying a particular product, for example.
  • If you’re considering a quiet, safe, and efficient EXAIR product as an upgrade, we’ll test your current product in our award winning Efficiency Lab, so you can compare accurate performance data and analyze the expected benefits…which can be dramatic.  Try us on that.
exair-testin
Line Vac conveyance rate testing (left;) Efficiency Lab testing (right.)

 

  • We’ll let YOU test our product, risk-free.  All catalog products come with a 30 Day Unconditional Guarantee.  We invite you to put it through its paces for up to a month.  If it’s not working out, we’ll arrange return for full credit.
  • We’ll do the math.  But first, a disclaimer: strictly comparing the force or flow of an engineered product to an open-end blow off won’t always tell the tale.  Our Intelligent Compressed Air Products are creating a laminar flow which won’t generate as high of a force/thrust as open-end blowing (which is turbulent by nature,) but is MUCH more conducive to efficiency and noise reduction, as well as similar (if not improved) performance.  But back to the math: if you know the metrics you need to meet for spot cooling (like a Vortex Tube, Adjustable Spot Cooler, Cold Gun, etc.) or for liquid spraying (the liquid flow rate and/or pattern size & shape from an Atomizing Spray Nozzle, for instance,) or the heat load that a Cabinet Cooler System can handle, we’ll do the calculations and specify the appropriate product.

Regardless of the application, if it can be solved with compressed air, it’s very likely that we have a great solution.  Call me to find out how we can help.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

EXAIR Air Nozzle Provides Non-Marring Solution For Rotary Die Cutting

Die Cutting is a highly efficient means to produce large volumes of uniquely shaped parts while creating a low volume of wasted materials. There are several different ways to produce die cut parts with one of the more common being Rotary Die Cutting. A Rotary Die Cutter typically incorporates the material passing between a roller die cutter and a heavy roller anvil to cut the specific shape  then passes the material down a conveyor or feed line while retrieving the waste material in another collection device.

I recently worked with a customer who was starting to see a large volume of scrap in their vinyl and rubber parts die cutting process as the die cut parts themselves were getting stuck onto the rolling die cutter and weren’t getting grabbed by the conveyor rollers. To try and get the parts to eject from the cutter they installed a few 1/4″ open copper tube air lines running across the roller but were concerned with amount of air they were wasting and the high pitch noise levels of close to 100 dBA. They were also seeing some damage to the parts they were able to get loosened from the die as some of the parts would make contact with the pipe, causing a “blemish” on the part, ultimately failing inspection.

I recommend the customer use our Model # 1100-PEEK Super Air Nozzle. The Model # 1100 consumes only 14 SCFM of compressed air (at 80 PSIG), much less than a 1/4″ open pipe, tested at close to 140 SCFM @ 80 PSIG. This nozzle produces a low sound level of only 74 dBA falling well within the allowable noise exposure levels set forth by OSHA. In addition, the PEEK plastic construction provides a non-marring solution in the event one of the parts did make contact with the nozzle.

1100-peek
1100-specs Model # 1100-PEEK Super Air Nozzle with Performance Specs

EXAIR offers a large selection of engineered air nozzles with varying airflow patterns, force, sound levels and materials of construction to meet a wide variety of application requirements. With help selecting the best solution or to discuss your particular application, please give us a call.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

EXAIR’s High Velocity and Adjustable Air Jets – Now Available in Stainless Steel

Newly released, the EXAIR High Velocity Air Jet and Adjustable Air Jet are now available in Type 303 Stainless Steel, providing greater durability, corrosion resistance and a higher maximum temperature rating of 400 °F.  Type 303 stainless steel has good resistance to mildly corrosive atmospheres along with good oxidation resistance at elevated temperatures, making the stainless steel Air Jet a great choice for blowoff or part drying in your harsh environment. Both types of Air Jets are also available in brass, for applications at 275°F and below, and when corrosion resistance is not as critical.

6013ss
Model 6013SS – High Velocity Air Jet

Air Jets utilize the Coanda Effect – wall attachment of a high velocity fluid – to produce air motion in their surroundings. As illustrated above, a small amount of compressed air to the inlet (large black arrow) is throttled through an internal ring nozzle above sonic velocity.  A vacuum is produced, resulting in large volumes of surrounding, or “free” air, being pulled in through the jet (blue arrows.)

air jet How Air Jets Work

Both the outlet and inlet can be ducted for remote positioning applications.

If the end is blocked, flow simply reverses at well below OSHA dead end pressure requirements, ensuring safe operation.

The High Velocity Air Jet comes standard with an .015″ shim, and a Shim Set is offered that includes .006″ and  .009″ shims to provide additional adjustability and control.  The Adjustable Air Jet has a variable gap design, and can be adjusted and locked to meet the required airflow and thrust parameters.

When you are needing a simple solution to reduce excessive air consumption and noise levels on compressed air blowoff operations, EXAIR has a large line of Air Nozzles and Jets to solve your problems. You can contact an Application Engineer to discuss which Air Jet or Nozzle to best fit your application.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web
Like us on Facebook
Twitter: @EXAIR_BB