Return On Investment: Does It Matter, And How Much?

I have a friend who participates in a process known as “extreme couponing.” She has multiple subscriptions to the Sunday edition of our major newspaper, and a couple of local papers that also have coupon inserts. When I see her at the grocery store, she’s got two 4″ binders full of baseball card holders, all stuffed with multiples of clipped coupons, organized by store aisle. The insane amount of money saved is a big factor in her being able to be a stay-at-home mother, which is something else she’s pretty good at.

If you get stuck at step one…or even two…extreme couponing may not be for you!

Now, extreme couponing isn’t for everyone. Even beginners to the process can buy a year’s worth of paper towels for next to nothing. However, that may take up so much room in their house that they need to rent a storage facility for other belongings that folks like you and me simply keep in the garage or basement. It also takes a LOT of time and effort to do it right – as well as discipline. Saving half (or more) on a truckload of stuff you don’t need (or will never use) is a waste of money, time, and space. In fact, I know people who have abandoned extreme couponing for those very reasons…the “return on investment” just isn’t there.

That’s the deal in industry too.  Anyone tasked with finding and exploiting efficiencies – or finding and eliminating inefficiencies – is going to be looking at return on investment.  Like extreme couponing, though, it has to make sense in all aspects of the operation.  For example:

*An OEM taking advantage of a quantity discount for components or subassemblies has to not only have the storage space available, but also has to consider the turnover rate…it costs money to keep product on the shelf.

*A machine shop considering a tooling upgrade has to compare the cost difference with the increased performance and/or lifespan of the “new and improved” product.  A tool that costs 10% more but lasts twice as long is probably a good deal.  A tool that costs twice as much but lasts 10% longer might not provide the “bang for the buck.”

*Any facility, before switching a service or utility provider, will “run the numbers” on promotional rates, contract terms, etc. before making a commitment.

Unlike extreme couponing, EXAIR makes it easy – and beneficial – to evaluate the return on investment:

*Our catalog (if you don’t have the latest, get it here) has complete performance & operational data on all of our products.  This is great if you know what you want it to do.

*If you’re not quite sure, our catalog also has a good number of actual application write-ups for most of our Intelligent Compressed Air Products.  You may be able to find something that’s similar to what you want to do, and further inform your selection from there.

*Once you’ve chosen a product, you can use the Calculator Library on our website to determine actual dollar cost savings associated with replacing a current compressed air powered device with an EXAIR product.

*Application Engineers are available to discuss your application and/or product selection via phone, email, or Live Chat.

*No matter how detailed the discussion, and how confident a plan we may make, the age-old saying about how it “looked good on paper” proves itself every now and again.  When this happens, all catalog products are covered by our 30 Day Unconditional Guarantee.  If you’re not satisfied for any reason within 30 days of purchase, we’ll arrange return for full credit.

*Let’s assume that we’re pretty good at this (because we are) and it actually DOES work out (because it usually does) – we can calculate your new (and improved) operating costs and compare them with the cost of your previous devices.  If you don’t have the instrumentation (flow meters, sound level meters, etc.,) this is a free service we provide in our Efficiency Lab.  Send it in, and we’ll do a full performance test & issue a comprehensive report, all at no charge.  And if you qualify for a Case Study, we can even save you some money on your next order.  Contact me for more details if you’re interested.

Free testing. Verifiable data. EXAIR Efficiency Lab.

Russ Bowman
Application Engineer
EXAIR Corporation
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Coupon Pile Stock Photos courtesy of Carol Pyles  Creative Common License

The Case For The Flat Super Air Nozzles

What do you think of when someone says “air nozzle?” Is it a crimp or a “crush” on the end of a piece of tubing? Is it a device that attaches to the end of a pipe or a hose? If so, does it have engineered features that focus the stream, amplify the flow (through entrainment, perhaps,) reduce the noise level, or provide an element of safety?

If so…you’re right. Any of the above descriptions, strictly speaking, qualify as an “air nozzle,” in fact, just a plain open-ended pipe or tube meets the criteria. As long as it serves to discharge a stream of air towards a target, it’s an air nozzle.

Even the devices with those efficient, quiet, and safe engineered features come in a variety of styles, types, and models. Consider EXAIR’s product line of Air Nozzles and Jets…we have seventy-two distinct models, in a range of sizes, materials of construction, and performance.  That’s a LOT to choose from, and it doesn’t even take into account the products that can be fitted with different shims that, technically, make them a wholly different nozzle, performance-wise.  Which brings us, dear reader, to the focus of today’s blog: the Flat Super Air Nozzle.

Flat nozzles are not unique to EXAIR…there are dozens of others on the market in a variety of sizes and materials.  What IS unique about EXAIR’s Flat Super Air Nozzles is their performance…

Efficiency: When a competitor’s flat nozzle was replaced with a Model 1122 2″ Flat Super Air Nozzle, consumption was reduced from 31 SCFM to 21.8 SCFM.  Since the nozzle was operated 24/7, this resulted in a savings in compressed air cost of $3.31 per day…meaning the nozzle paid for itself in under three weeks.

EXAIR’s Flat Super Air Nozzles have been blowing away the competition since 2003.

Durability: Both our 1″ and 2″ Flat Super Air Nozzles are available in rugged Zinc Aluminum alloy, or heat & corrosion resistant Type 316 Stainless Steel.

Zinc aluminum models are perfect for general purpose blow offs (left,) while 316SS models are specified for food/pharma and high heat or corrosive environments (right.)

Versatility: A 0.015″ thick shim is installed in the Flat Super Air Nozzles.  These provide optimal performance in a wide variety of typical industrial and commercial blow off applications.  We also offer High Power versions, with a 0.025″ thick shim, for additional flow and force.  You can also experiment with other shims, from 0.005″ to 0.030″ in thickness, for customized applications.  These shims are all 316SS, and are available in sets, or individually.  The patented design of these shims, in fact, is key to their high efficiency, as explained in this video:

Ingenuity: While this EXAIR characteristic is not specific to the Flat Super Air Nozzles, our most recent ingenious development features them: the Super Air Scraper.  By combining a scraping blade with the 2″ Flat Super Air Nozzle, we’ve turned our very popular Soft Grip Safety Air Gun into the perfect tool for easy removal of sticky or stubborn debris from most any flat surface.

Scrape off, and blow away, stubborn debris with the Model 1244-48 Soft Grip Super Air Scraper.

EXAIR Flat Super Air Nozzles are Intelligent Compressed Air Products with a 15 year history of successfully solving all kinds of air blowing applications.  To find out more about how they can work for you, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Where Has The VariBlast Compact Safety Air Gun Been All My Life?!?

Have you ever happened across something that would have been a real “game changer” at some time in the past? I’ll never forget the time that I went camping with my sons’ Boy Scout Troop, and I was introduced to the peanut butter and bacon sandwich. I still enjoy one from time to time, but my doctor does not enjoy hearing about it…

I’ve also written before (and before) about when I found out EXAIR Vortex Tubes were being used in some shipyards for freeze sealing pipes…a task that (when I worked in a shipyard) we used tanks of liquid nitrogen for.  I was amazed that such a cumbersome ordeal was replaced by something so simple and easy.

When we were developing the VariBlast Compact Safety Air Gun, a key feature…the variable flow trigger…also would have been real handy at a time in my not-so-distant past.  See, I used to run a small industrial equipment service department, and one time I found myself in a pinch to get a structural steel tube frame made for a support for a particular piece of equipment.  This wasn’t something we did all the time, and this particular job was a bit larger scale than most of what we’d done before.   It wasn’t really a big deal; I just had to cut some rectangular tubing to length with our band saw, drill some small holes (for bolts) and bore some larger holes (for cables & hose) along the length.

We had a small air compressor and a cheap commercial grade air gun, which served the purpose of our infrequent usage. Blowing the shavings away from those holes, and the inside of the tubing was a challenge…that air gun would just barely move them all the way from the holes near the middle, and when I blew out the holes near the ends, the spray of coolant-soaked shavings was making a heck of a mess in our relatively small shop.  After a while, I found that I could kind of “mash” the trigger a little to one side and get a rough measure of control…I was only going to have to mop about half the floor, instead of the whole thing, and I wasn’t going to have to wash the service truck parked in the closest garage bay to the shop area.

Needless to say, this wasn’t exactly ergonomic, and it was  real pain (literally) to use my left hand for a few days following.  Which, being left-handed, was kind of a drag.

Fast forward to just last year, when we rolled out the latest and greatest (in a distinguished line of latest and greatest) EXAIR product: the VariBlast Compact Safety Air Gun.  Now, individually, the key features might not be all that mind-blowing to the casual observer, but taken together, they’re a pretty big deal. Consider:

*Aluminum construction – lightweight, durable, corrosion resistant.

*Two compressed air inlets – one on the bottom (below your pinkie finger) and one on the rear (above your thumb;) your choice…whichever makes your task easier.

*Cast-in hanger – to keep it out of the way, but still handy, when you’re not using it.

*Chip Shield – you still have to wear safety glasses, but this will keep them cleaner.

*Wide selection of engineered nozzles – from our Atto Super Air Nozzle (2.5 SCFM; 2.0 oz force) to the 1″ High Power Flat Super Air Nozzle (17.5 SCFM; 16 oz force,) there are 20 distinct models in stock.  We can customize the performance of the VariBlast Compact Safety Air Gun to the specific needs of your intended use for it.

*Extensions – for applications that require a little (or a little more) reach, we offer the VariBlast Compact Safety Air Gun with rigid aluminum extensions up to 72″ in length.  These are particularly handy when used with the Atto Back Blow Nozzle.

*Variable pull trigger – as the name implies, you can “vary the blast” by how hard (or not) you pull the trigger.  Like I said before, you can do this – kind of – with a run of the mill commercial grade air gun, but it’s not very precise, and far from ergonomic.  Here’s a short video showing just how sensitive that trigger pull is:

If you’d like to give one a try, EXAIR offers these – and any catalog product for that matter  – with a 30 Day Unconditional Guarantee.  We invite you to put it through its paces for up to a month.  If it’s not going to work out for you, for any reason, we’ll arrange return for full credit.  Give me a call – we can talk about how you intend to use it, and which one’s right for you.

Russ Bowman
Application Engineer
EXAIR Corporation
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EXAIR Optimization Products: Ultra Sonic Leak Detector Overview

Ultrasonic Leak Detector

The Ultrasonic Leak Detector is a hand-held, high quality instrument that can locate costly leaks in a compressed air system.  When using the Ultra Sonic Leak Detector, you only need to aim it in the direction of the suspected leak and if a leak is present an audible tone can be heard through the supplied headphones and the LED will light.  This can be accomplished from up to 20′ away!

If you are not maintaining your compressed air system you can easily waste up to 30% of your compressor’s output through leaks.  We all know compressed air is expensive, so mitigating wasteful leaks should be high on your to do list!

 

ultrasonic_2
EXAIR Ultrasonic Leak Detector

What is Ultrasound

Since most compressed air leaks emit only Ultra Sonic sound it would be next to impossible to find a leak by listening for them since the sound is above the human thresh hold.   That is where the EXAIR Ultrasonic Leak Detector comes in.  Its sensitivity is is adjustable with 3 settings X1, X10 and X100 along with an on/off thumb wheel for fine sensitivity adjustments.  The Ultra Sonic Leak Detector also comes with both a parabola or tubular extension to aim the unit and block out extraneous background noise.

If you have an application where you need to find an ultrasonic noise, you can speak with an Application Engineer to see if the model 9061 Ultrasonic Leak Detector could help.

If you would like to discuss the Ultra Sonic Leak Detector or any EXAIR product, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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Turn The Pressure Down & Save Money

In the past your typical industrial air compressor was rated to run at 100 psi and it was not often that this pressure was exceeded.  Lately with modern advances pressures have slowly crept up and have surpassed this threshold.  Unfortunately this has proven costly to the industrial user of compressed air.

To clarify this point, if a compressed air system is set to maintain 102 psi it will cost the plant 1% more in electric costs than if the system ran at 100 psi.  Also noteworthy is that unregulated air demands consume about 1% more flow for every psi of additional pressure.

So why is the air pressure getting so high and what can you do about it?  Here are some possible causes and solutions:

Devices that do require more than 100 psi:  It may not be the pneumatic device at all. If these devices are connected with restrictive fittings or there are excessive leaks in the system this can cause up to a 30 psi increase in line pressure just to make up for the poor piping. If this can be corrected it is possible that the pressure can be reduced.

EXAIR offers the Ultrasonic Leak Detector to facilitate tracking down hard to find system leaks and a wide variety of Air KnivesAir Amplifiers, Super Air Wipes, Air Nozzles, Line Vacs, Vacuum Generators and all of them are engineered to provide peak performance at 80 psi and make efficient use of compressed air. Though it is not uncommon for these products to provide a solution at much less pressure.

9061
EXAIR 9061, Ultrasonic Leak Detector

Applications that are believed to be high pressure:  Plant workers sometimes think that a higher air pressure is required than actually necessary.  This can be caused by a lack of training or perhaps the trainers are simply repeating what they have been taught in error.  It is good practice to review all locations that are using a higher pressure to determine if it is really necessary.

Loss due to undersize pipes:  If your plants compressed air supply lines are undersized for the volume demand, this can cause a significant restriction and raise the line pressure.  The EXAIR Digital Flow Meter can assist in recording how much demand is for a given point in time which will clarify usage.

9093
EXAIR Digital Flow Meter

 

Filter/Dryer restrictions:  If the Dryer or Filter/Separators are dirty and/or undersized the compressor operating pressure is typically raised to overcome these restrictions.  EXAIR has six sizes of Filter/Separators to ensure they are properly sized for the SCFM required by the devices that are connected to them.  Five of the models feature an automatic drain system and of course we carry the replacement filter elements and rebuild kits to keep them in top operating condition.

Temporary demands: There may be occasional peak compressed air demands in the plant that may be caused by a different or special compressed air process or machine. If the demand is greater than the supply, the pressure may be pulled down to unacceptably low levels.  In an attempt to make up for the increased demand a plant may raise the operating pressures.  The best way to cope with temporary demands is to install a receiver tank that stores compressed air that can be released when the demand calls for it.

receiver_tank
EXAIR 9500-60, 60 Gallon Receiver Tank

Factory default settings:  It is common for compressor manufacturers to set the air pressure at or very near the maximum pressure rating for that compressor.  There is no reason for this other than to verify that the air compressor will perform at its rated maximum pressure.  To save on air and maintenance costs the compressor should be set only as high as the maximum pressure for approved uses in the facility.

In the compressed air industry, EXAIR provides tools and products with quick payback times.

If you would like to discuss increasing the efficiency of your compressed air usage, quieter compressed air products and/or any EXAIR product,  I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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EXAIR’s Electronic Temperature Control for Cabinet Coolers

48xx-ETC120
EXAIR NEMA 4X 316SS Cabinet Cooler System with Electronic Temperature Control installed on control panel in a pharmaceutical plant.

Are you concerned about high temperatures this summer causing problems on your control panels? EXAIR’s Electronic Temperature Control (ETC) can be used with an EXAIR Cabinet Cooler to maintain precise control of the temperature inside of the cabinet. The ETC is available in both 110 and 240 VAC and is compatible with all Cabinet Cooler Systems.

After taking a few quick measurements, fill out the Cabinet Cooler Sizing Guide and an Application Engineer will be in touch with you to provide the most suitable system for your conditions. Don’t wait until the heat becomes a major problem, get yourself a Cabinet Cooler installed today and stop worrying about those high ambient temperatures!!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

 

Advantages of Thermal Mass or Thermal Dispersion Flow Measurement

EXAIR’s Digital Flow Meter offers an easy way to measure, monitor and record compressed air consumption. The Digital display shows the current amount of compressed air flow, allowing for tracking to identify costly leaks and/or inefficient air users.

dfm

How exactly does the Digital Flow Meter work?  The unit falls under the category of Thermal Mass or Thermal Dispersion type flow meters.  Below shows the backside of a unit.

IMG_7387

Thermal mass flow meters have the advantage of using a simple method of measuring flow without causing a significant pressure drop. The EXAIR units have (2) probes that are inserted through the pipe wall and into the air flow.  Each of the probes has a resistance temperature detector (RTD.) One of the probes measures the temperature of the air flow.  The other probe is heated to maintain a preset temperature difference from the temperature measured by the first probe.  The faster the air flow, the more heat that is required to keep the second probe at the prescribed temperature.  From Heat Transfer principles, the heat energy input required to maintain the preset temperature is based on the mass velocity of the air.  Using basic physical properties for compressed air, the volumetric rate can be determined (SCFM), and displayed.

It is important to note that the compressed air should be filtered to remove oils, and dried to remove water, as these liquids have different physical properties from air, and will cause erroneous readings.

Advantages

  • Easy to install – No cutting or welding required
  • Summing Remote Display and Data Logger available
  • Sensitive at low flows
  • Rugged, reliable and no moving parts
  • No calibration or set-up required
  • Models from 1/2″ to 4″ schedule 40 iron pipe in stock
  • Short lead time for sizes up to 6″ Schedule 40 iron pipe
  • Available for size 3/4″ to 4″ copper pipe
  • New Wireless Capability

If you have any questions about the Digital Flow Meter or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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