EXAIR NEW Product Offering – Pressure Sensing Digital Flowmeters

Six Steps to Optimizing Your Compressed Air System

The first step to optimizing compressed air systems within an industrial facility is to get a known baseline. To do so, utilizing a digital flowmeter is an ideal solution that will easily install onto a hard pipe that will give live readouts of the compressed air usage for the line it is installed on.  There is also an additional feature that we offer on the Digital Flowmeters that can help further the understanding of the compressed air demands within a facility.

The Pressure Sensing Digital Flowmeters are available from 2″ Sched. 40 Iron Pipe up to 8″ Sched. 40 Iron Pipe.  As well as 2″ to 4″ Copper pipe.  These will read out and with the additional Data Logger or Wireless Capability options record the information. When coupled with the wireless capability an alarm can be set for pressure drops that give live updates on the system as well as permits data review to see trends throughout the day of the system.

EXAIR Digital Flowmeters w/ Wireless Capabilities

Generating a pressure and consumption profile of a system can help to pinpoint energy wasters such as timer-based drains that are dumping every hour versus level based drains that only open when needed. A scenario similar to this was the cause of an entire production line shut down nearly every day of the week for a local facility until they installed flowmeters and were able to narrow the demand location down to a filter baghouse with a faulty control for the cleaning cycle.

If you would like to discuss the best digital flowmeter for your system and to better understand the benefits of pressure sensing, please contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Process Improvement, ROI and Safety from One Air Nozzle

Process improvement projects can be detailed, complex, expensive, and take a long time to prove their worth.  Today, I want to tell you about one that WAS NOT ANYTHING like that.

A metal stamping company used compressed air to blow their products from their dies.  They did what many do – they ran some copper tubing, and aimed it at the platen so it would properly eject the parts as they were stamped.  They KNEW it was loud, and they suspected it was inefficient as well.

After discussing the setup and seeing a picture of it (the one on the left, below,) I recommended installing a few engineered Super Air Nozzles to lower the noise levels considerably.  Boy, was I wrong.  About “a few” nozzles, that is…turns out, they only needed one Model 1122-9212 2″ Flat Super Air Nozzle with 12″ Stay Set Hose.  The copper tubes come from a manifold that already had 1/4 NPT ports – installation took a matter of minutes.  Nothing detailed, complex, or expensive about it:

This loud & inefficient copper tubing blowoff was just a compression fitting (and a Model 1122 2″ Flat Super Air Nozzle) away from being quiet and efficient.

It didn’t take much longer than that to prove its worth either: as soon as they noticed how much the noise level went down on THIS press, they ordered them for the other eighteen presses in their facility as well.

The 1/4″ copper tubes blew continuously from a pressure regulator set @60psig…the three of them theoretically consumed a total of ~80 SCFM.  The Model 1122, at 60psig supply, consumes only 17.2 SCFM.  Simple return on investment was as follows:

  • 80 SCFM was costing them $48.00 a week
    • 80 SCFM X 60 min/hr X 8 hr/day X 5 days/week X $0.25/1,000 CFM = $48.00
  • 17.2 SCFM, using the same formula, only costs $10.32 a week (I’ll let you do the math; it’s good practice.)
  • They saved $37.68 a week.  The Model 1122-9212 costs $116.00 (2020 pricing) – that means that each of them paid for themselves in just a hair over three weeks.
  • $37.68 x 50 work weeks per year = $1884.00 saved annually per nozzle
  • $1884 x 18 (the number of presses) = $33,912 saved annually 

Considering they also didn’t have to listen to those very loud open ended copper tube blowoffs, I think you’ll have to agree it made for a very good investment.  They did. The new nozzle runs at 77 decibels, a comfortable level and well below the OSHA standard [29 CFR – 1910.95(a)] for allowable noise exposure.

If you’d like to find out how EXAIR Intelligent Compressed Air Products can save you money on compressed air – and save everyone’s hearing – give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Video Blog: Filter/Separator and Pressure Regulator Mounting and Coupling Kit Installation

Using EXAIR mounting and coupling kits you can assemble EXAIR Filters and Regulators into one plug and play assembly. Follow along with the video posted below to complete this task!

If you need a deeper understanding about how EXAIR’s products can be applied and help your process or product, feel free to contact us and we will do our best to give you a clear understanding of the benefits when using our engineered compressed air products. We can also explain proper implementation of accessory items such as compressed air filters and regulators.

Jordan Shouse
Application Engineer

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Save Compressed Air Energy with Pressure Regulators

Why should you consider a Pressure Regulator when designing your compressed air system? As many know, our products and those of other  product manufacturers have a certain set of specifications regarding performance at stated input pressures. But what if your application doesn’t require that “full, rated performance”? Maybe instead of needing two pounds of force, you only need one pound? Sometimes more force does not produce the desired result for an application. By that, I mean you cause damage to the target or other surrounding items in the application. Or, perhaps blowing too hard (or vacuuming too hard in the case of a Line Vac or E-vac) might cause the vessel or the material you are picking up to collapse or deform (due to too much power).

Regulators catalog
EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

There is also the concern about using more energy than one really needs to in order to achieve the desired effect in an application. In other words, if you can achieve your goals with only 40 PSIG, then why would you ever use 80 PSIG to accomplish the goal? By reducing your compressed air from 80 down to 40 PSIG, you can easily reduce the air consumption of the “engineered” solution by another 40% or more.  Once you have installed engineered air nozzles to reduce compressed air on blow off applications, a pressure regulator can fine tune the pressure to save even more energy.

Regulator Internal
Regulator Internals

Then there is the issue of taking advantage of the pressure differential (from 80 down to 40 PSIG) that creates a little bit more air volume capacity. At 80 PSIG, your compressed air to free air volume ratio is 6.4:1. At 40 PSIG, it is only 3.7:1. The net effect is you effectively have an overall larger volume of air you can use for other applications in your facility. By reducing compressed air pressure of your demand applications, you may be able to reduce over all compressor discharge pressure. Reducing compressor discharge pressure by 2 PSIG also reduces required input power by 1 percent – so keep your pressure as low as possible!

Regulating pressure is definitely warranted given the benefits that compliment the operation of the core EXAIR products.

If you need a deeper understanding about how EXAIR’s products can help your application, feel free to contact us and we will do our best to give you a clear understanding of all the benefits that can be had by our products’ use as well as proper implementation of accessory items such as compressed air filters and regulators.

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS