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.
In 2012, the National Association of Manufacturers organized an effort to proclaim the first Friday in October (hey, that’s today!) as Manufacturing Day. According to the Advanced Manufacturing National Program Office (a division of NIST, the National Institute of Standards & Testing,) the purpose of MFG Day is “to raise awareness among students, parents, educators and the general public about modern manufacturing and the rewarding careers available.”
Today is kind of a big deal around here. Not only is EXAIR Corporation a manufacturer, but many of the companies that use our products are as well. A lot of us have a rich story, woven into the cloth of the history of American manufacturing (which, in turn, is woven into the larger cloth of American history.) Have you heard the one about the motivated inventor with an idea to make innovative products who started an operation out of his home that, with inspired direction & vision, became a worldwide leader in their industry?
Yeah; that’s us. Today, we’re honoring Roy Sweeney’s legacy (he founded the company in October 1983,) and celebrating MFG Day, by publishing a new Case Study, proving out the benefits of the use of EXAIR Intelligent Compressed Air Products in regard to the monetary savings associated with the reduction in compressed air use, and the noise level reduction from the implementation of our engineered products.
A roll forming operation used to blow off their product with a combination of loud and inefficient devices: copper tubing and modular flexible hose which is designed primarily for machine tool coolant, but often misapplied for use with compressed air.
It worked just fine, but an engineering study noted it as a potential wasteful use of compressed air. That’s when they called us.
Compressed air consumption dropped by more than half, from 190 SCFM to 86.8 SCFM…an annual savings of over $3,200.00. All for an investment of $654.00 (2020 pricing) for those engineered Air Nozzles, Stay Set Hoses, and Magnetic Bases. That means they’ll have paid for themselves in just under two months.
In addition to that, for participation in this Case Study, we’re giving them a generous credit on their order. Happy Manufacturing Day!
Last but certainly not least, this reduction in compressed air usage decreases the load on their air compressors, reducing the electrical power consumed. Product impact, along with our own consumption of resources and waste recycling, is a key component of EXAIR Corporation’s Sustainability Plan. We’re making the world a better place, by making products that make the world a better place, using methods that make the world a better place. I can’t think of a better way to celebrate Manufacturing Day. If you want to get in on it, give me a call.
Visit us on the Web
Follow me on Twitter
Like us on Facebook
Strings of numbers and characters can often appear daunting. For instance, if I wrote in binary code it would be a string of ones and zeros. (01000101 01101110 01100111 01101001 01101110 01100101 01100101 01110010 01101001 01101110 01100111 00100000 01101001 01110011 00100000 01000001 01010111 01000101 01010011 01001111 01001101 01000101.) That can look like gibberish and cause concern if unknown or it can make sense to programmers and people familiar with binary code.
Other alphanumeric strings may cause some concern for industry professionals. Take, for instance, OSHA standards. The OSHA standard 29 CFR 1910.95 (a) may be unfamiliar to some, and thus concerning. Many Environmental Health and Safety Engineers will recognize this code. It is an OSHA standard that revolves around the amount of time an employee is permitted to be exposed to specific sound levels. These sound levels are all based on the weighted sound level of the noise the operators are exposed to. To better understand how the octave and frequency of the sound play into this, there is a chart provided below.
The weighted sound level is the level at which a Digital Sound Level Meter will read the current level of noise within an environment. This scale is then used to move further into the OSHA directive that we focus on helping companies meet to best provide safe environments for their employees to work in.
If you notice, the lowest weighted sound level is 90 dBA, this is also the lowest-rated noise level that OSHA speaks of in 1910.95(b)(2). It has been shown that noise levels over this level for extended periods will result in permanent hearing loss. The standard then goes on to discuss the duration an employee can be exposed to noise levels even with the use of personal protective equipment as well as even impulsive or impact noise. The table of permissible time limits is shown below.
As you can see from the table above provided by OSHA, any noise level that an operator is exposed to for eight hours cannot exceed 90 dBA. Noises within an industrial environment can also be variable throughout the day. For instance, the operator stands outside of a sheet metal press and the concussive strike on the press gives off a 90 dBA strike for every stroke of the press. This would not be a continuous noise level. Maybe the operator is operating a CNC machine that is cutting a nest of parts and uses a handheld blowgun to remove debris and coolant from the parts before taking them from their fixture. This blowgun is not used continuously and therefore would not be rated as such for the exposure time. A time study would be conducted on the average length of time the operator is utilizing this gun along with the level of noise it produces during use. OSHA then gives a calculation to use to appropriately combine the sound level while the gun is being used and when it is not in use. That equation is written out below.
C1 = Duration of time for a specified noise level
T1 = Total time of exposure permitted at that level
Cn = Total time of exposure at a specified noise level
Tn = Total exposure time permitted at that level
Should the summation of the fractions for different exposures be greater than the Total Exposure fraction, the summation value should be used. As mentioned above, a time study on exposure to noise levels will be needed to obtain the information needed for this type of study. Once the study is done the process can proceed to the next level within the OSHA standard which is a hearing conservation program.
I would like to interject a small side-step at this point. Rather than rolling straight into the implementation of PPE which is proven to be the lowest reliable factor of protection by the CDC and NIOSH. If any of these noise levels being generated are due to the use of compressed air points of use, EXAIR can potentially lower the noise of these point of use applications. In the events, open blowoffs or “band-aid” fixes are in place to keep processes running, and Engineered Solutions can easily be implemented that will reduce the noise level produced by this operation. Whether it is on the handheld Safety Air Gun in the hands of a CNC operator, or if it is a part/scrap ejector that is blowing the sheet metal press out after every strike, we have products that have proven time over time using an Engineered Solution will save air, reduce noise levels, and still get the job done.
If you would like to discuss OSHA directives revolving around compressed air, share with us a recent citation you received from an inspector for this standard, or just discuss compressed air usage in general, contact us.
What sound level do you get when you feed an EXAIR Super Air Nozzle at 80psig? What if there are two of them? Or three? Grab your scientific calculators, folks…we’re gonna ‘math’ today!
But first, a little explanation of sound power & sound pressure:
Strictly speaking, power is defined as energy per unit time, and is used to measure energy generation or consumption. In acoustics, though, sound power is applicable to the generation of the sound…how much sound is being MADE by a noisy operation.
Sound pressure is the way acoustics professionals quantify the intensity of the sound power at the target. For the purposes of most noise reduction discussions, the target is “your ears.”
The sound levels that we publish are measured at a distance of 3 feet from the product, to the side. The units we use are decibels, corrected for “A” weighting (which accounts for how the human ear perceives the intensity of the sound, which varies for different frequencies,) or dBA. Also, decibels follow a logarithmic scale, which means two important things:
A few decibels’ worth of change result in a “twice as loud” perception to your ears.
Adding sources of sound doesn’t double the decibel level.
If you want to know how the sound level from a single source is calculated, those calculations are found here. For the purposes of this blog, though, we’re going to assume a user wants to know what the resultant sound level is going to be if they add a sound generating device to their current (known) situation.
Let’s use an EXAIR Model 1100 Super Air Nozzle (rated at 74dBA) as an example, and let’s say we have one in operation, and want to add another. What will be the increase in dBA?
10 x log10[1074/10 + 1074/10] = 77.65 dBA
Now, there are two reasons I picked the Model 1100 as an example:
It’s one of our most versatile products, with a wide range of applications, and a proven track record of efficiency, safety, and sound level reduction.
We proved out the math in a real live experiment:
Why do I care about all of this? My Dad experienced dramatic hearing loss from industrial exposure at a relatively young age…he got his first hearing aids in his early 40’s…so I saw, literally up close and very personal, what a quality of life issue that can be. The fact that I get to use my technical aptitude to help others lower industrial noise exposure is more than just making a living. It’s something I’m passionate about. If you want to talk about sound level reduction in regard to your use of compressed air, talk to me. Please.
Russ Bowman Application Engineer EXAIR Corporation Visit us on the Web Follow me on Twitter Like us on Facebook