Many manufacturing plants have a strong focus on safety for their workers. One major safety concern that is overlooked is noise. OSHA, Occupational Safety and Health Administration, has a directive that defines the noise exposure over time; 29CFR 1910.95(a). For an eight-hour day, the maximum noise level is 90 dBA. Hearing loss is irreversible, but it can be preventable. The CDC, Center for Disease Control, and NIOSH, National Institute for Occupational Safety and Health, report that “approximately 18% of all manufacturing workers have hearing difficulty”1.
EXAIR manufactures engineered products to reduce noise levels in the work environment. We offer Super Air Nozzles and Safety Air Guns for blow-off applications and pneumatic mufflers for discharge exhaust. In this blog, I will cover the different types of EXAIR Mufflers that we offer.
Reclassifying Mufflers are designed to have two functions. They can cut noise levels by 35 dB and remove oil mist from the exhaust air. Cylinders and valves that exhaust pressurized air may have oil in the line to keep the seals from sticking. When exhausted, it can create a fine mist which is dangerous for operators. The Reclassifying Mufflers can reduce the loud noise as well as collect any contamination from the exhaust air.
Sintered Bronze Mufflers are simple in design, cost effective, and easy to install. They have a minimal back pressure to not restrict operations of the pneumatic device. They come in sizes from #10-32 thread to 1-1/2” NPT. For a quick and simple way to reduce noise, the Sintered Bronze Mufflers are in stock for fast delivery.
Straight-Through Mufflers offer a way to reduce noise levels without worrying about clogging. They have an aluminum shell lined with sound absorbing foam, and they can reduce the noise level by 20 dB. EXAIR offers them with ports of ¼” NPT, 3/8” NPT, and ¾” NPT. One side has a female thread while the opposite side will have a male thread. This can allow you to connect other items like hose kits to reduce noise.
Heavy Duty Mufflers are used within aggressive environments. They have an outer aluminum shell with an internal stainless-steel screen. They protect components like valves and cylinders from contamination entering into the part. And, the Heavy Duty Muffler can keep contaminant like rust from being ejected at high speed into the work area. They have a typical noise reduction of 14 dB.
Here is a test for you. If you go and stand in your plant, you can probably hear loud noises coming from your compressed air system. EXAIR has an engineered product to solve most of them. On the Hierarchy of Controls for NIOSH, Personal Protection Equipment, PPE, is the least effective. A better control would be to isolate your operators from the hazard with an engineered product. EXAIR can offer that solution for many of your blow-offs and pneumatic discharges to reduce noise levels. This would include; and not limited to; Super Air Nozzles, Safety Air Guns, Super Air Knives, and Mufflers. If you wish to discuss further the safety improvements that EXAIR can provide, you can contact an Application Engineer. We will be happy to help.
A while back, I had the pleasure of assisting a customer with selection and implementation of our Super Air Nozzles, to replace open-ended blow offs on their machine tools. They installed the Super Air Nozzles after shutdown one afternoon. When he came in to work the next day (he arrived after production started), he thought there was a major problem in the shop, because (as they say in the movies right before something bad happens) “it was quiet…too quiet.” Turns out that, even though the goal was to reduce air consumption, they also reduced the sound level of the blow offs to an unexpected degree.
Another time, a metal stamping plant tried out our Model 1122 2″ Flat Super Air Nozzle on a stamping machine, using a Stay Set Hose to replace the copper tubing that was used to eject parts from the platen. They did the switch in the middle of the day…the operator at the adjacent machine noticed the dramatic noise level drop and came over to see what was wrong. Then he asked when they were getting one for HIS machine.
Both of these solutions originated with calls to discuss ways to reduce compressed air consumption costs. The fact that noise levels went down so dramatically just added to the benefits of using engineered compressed air products from EXAIR. If you’d like to find out how to make your electric bill – and your shop noise level – go down, give me a call.
Russ Bowman, CCASS
Application Engineer EXAIR Corporation Visit us on the Web Follow me on Twitter Like us on Facebook
I live near an amusement park called Kings Island. In the later part of Spring I can hear and see the people and rides. As the Summer enters and the tree leaves have all grown they act like a muffler reducing the roller coaster noises and screaming people on the roller coasters. These trees are not high enough to block the nightly fireworks but this is a good thing for me as I enjoy the sights and sounds of the fireworks.
An important focus in every manufacturing environment is a “Noise Reduction” campaign making a safer and healthier area for people working in the environment. EXAIR has Silencing Mufflers that can support your efforts for noise reduction. We have a variety of mufflers which will help to reduce work area noise produced by air exhausting from cylinders, valves and other air powered equipment. EXAIR Silencing Mufflers help plants meet OSHA Standard 1910.95(a) by reducing the sound to safer levels. Not only do our Silencing Mufflers reduce sound but they also eliminate harmful dead end pressures by covering up an open port or opening. These openings do not have a pathway for harmful pressurized air to escape if they become blocked.
Sintered Bronze Mufflers: A low cost solution and easy to install in new and existing air powered products. Sintered bronze muffler come in a variety of sizes (10-32 thread size up through 1/2-20 UNF female) and are capable of passing a certain volume of air with minimal back pressure restriction.
Reclassifying Mufflers: These mufflers are an upgrade from Sintered Bronze Mufflers. They offer the best noise reduction, up to 35 decibels. Available from 1/8 NPT up to 1 NPT. Reclassifying Muffles also eliminate oil mist. The patented wrap design of the removable element separates oil from the exhausted air so virtually no oil is released into the environment.
Straight-Through Mufflers: These mufflers offer a corrosion resistant aluminum outer shell lined with sound absorbing foam for better noise reduction. The typical noise reduction is up to 20dB.
Heavy Duty Mufflers: feature a corrosion-resistant aluminum outer shell with an internal stainless steel screen that protects valves and cylinders from contamination that could enter through the exhaust ports. The typical noise reduction is up to 14 dB.
EXAIR can help in your noise reduction projects with many options to consider. If you have any questions or need help selecting the right muffler for your needs please contact any of our qualified Application Engineers.
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.
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.
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.
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.
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 Visit us on the Web Follow me on Twitter Like us on Facebook