Improve Noise Exposure with EXAIR Flat Super Air Nozzles

EXAIR manufactures a variety of nozzles that are OSHA safe, high quality, and very efficient.  They are engineered to entrain the “free” ambient air into the air stream to create a powerful force while reducing compressed air usage.  Thus, saving you money.  With a multitude of blow-off applications like clearing small holes to quickly cleaning gantries on CNC tables, EXAIR has the nozzles for you.  In this blog, I will discuss the features and benefits of the EXAIR Flat Super Air Nozzles.    

The EXAIR Flat Super Air Nozzles are manufactured to blow a wide forceful stream of air.  Their patented design creates a high velocity, laminar air stream with minimal air consumption and low noise.  They come in two widths; 1” (25mm) and 2” (51mm).  EXAIR offers a standard Flat Super Air Nozzle and a High Power Flat Super Air Nozzle in two different materials, zinc-aluminum alloy and 316 stainless steel.  And with a metal construction, breakage is not a concern and performance are not sacrificed even in the harshest of environments. 

The unique patented shims used with the EXAIR Flat Super Air Nozzles will give you three improvements to the design and function.  First, they come in different thickness to create a wide range of forces.  In conjunction with a regulator, you can “dial” in the correct amount of force from a breeze to a blast without overusing your air compressor.  The patented shim also allows an even flow across the entire width of the air nozzle.  Unlike the plastic flat nozzles that use holes which generates a fluctuation of forces across the width.  Lastly, they help to entrain the free ambient air; so that less compressed air is required.  The high efficiency design will save you money.  The EXAIR Flat Super Air Nozzles are effective in uniform blowing with safety and efficiency in mind. 

To expand more on safety, I will direct you to Noise.  With “open” holes in nozzles, the compressed air is turbulent and loud.  The National Institute for Occupational Safety and Health, NIOSH, states that 70% to 80% of all hearing loss within a manufacturing plant is caused by compressed air.  OSHA created a chart to show the maximum allowable noise exposure.  This chart shows the time and noise limits before requiring hearing protection.  The EXAIR Flat Super Air Nozzles are designed to have laminar flow which is very quiet.  As an example, the model 1122 2” Flat Super Air Nozzle has a sound level of only 77 dBA at 80 PSIG (5.5 bar); well under the noise exposure limit for 8 hours.   

With the EXAIR Flat Super Air Nozzles, you can take advantage of the durability, safety, and efficiency for your blow-off devices.  With automated systems, or machine builders, you may want to look at the EXAIR brand for your blow-off, cooling, and coating applications.  The overall cost of your system as compared to the cost of the nozzles should not warrant the use of poor-quality plastic nozzles to save a couple of dollars.  Because in the long run, it will actually cost you more with loss of production, compressed air waste, very loud noises, and unsafe work environments. 

EXAIR stocks these nozzles for quick delivery.  If you are within the U.S. or Canada, they come with a 30-day unconditional guarantee to try them out.  If you need any help with our Flat Super Air Nozzles or how to build an optimum blow-off system, you can speak to an Application Engineer at EXAIR.  We will be happy to assist you. 

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

Save Your Compressed Air Today with These Simple Methods

When discussing ROI, return on investment, for an industrial compressed air system it is necessary to  understand what it costs to produce compressed air.  Generally we calculate that it costs .25 cents to produce 1,000 SCF (Standard Cubic Feet) of compressed air here in the Midwest of the United States. For our example let’s consider a typical 250 HP industrial compressor running 24 hours per day/5 days per week for 52 weeks.  This compressor can generate 374,400,000 SCF per year, using the industry standard utility cost for the Midwest of .25 cents per 1,000 SCF it will cost $93,600 to produce that volume of compressed air.

To avoid wasting money on compressed air generation it is extremely important to eliminate unintended or wasteful compressed air use in your plant. The two main offenders are leaks and open tube blow-offs.  While soapy water is a good method for discovering leaks, EXAIR offers the Ultrasonic Leak Detector.  This handy device allows leaks to be detected at distances of up to 20′ away! Also consider how safe and convenient it is to find leaks in overhead pipes while standing on the ground instead of on a ladder. Using a tool like this to do an entire system leak audit can easily result in many small leaks being identified and when fixed result in a large savings.

open tubes
Thirteen Open Tube Blow-Offs

Now let’s look at what an open pipe or tube may consume. A single 1/4″ OD copper tube can use 33 SCFM @ 80 PSIG inlet pressure.  Using the manifold pictured above as our example with 13 open tubes, each tube can consume 33 SCFM @ 80 PSI inlet pressure. With 13 open tubes running 24 hours a day, 5 days a week, 52 weeks per year equates to a total consumption of  160,617,600 SCF annually.  If we installed the EXAIR model 1100 Super Air Nozzle  using a simple compression fitting we would reduce the air consumption dramatically.  The EXAIR 1100 Super Air Nozzle consumes 14 SCFM @ 80 PSIG inlet pressure, running 24 hours a day, 5 days a week, 52 weeks per year equates to a total consumption of 68,140,800 SCF annually.  That change will save you 92,476,800 SCF annually which is equal to $23,119.20 and 24.7% of air compressor capacity!  These calculations are all based on continuous running applications, if intermittent operation is possible consider the EXAIR Electronic Flow Control for even greater savings.  The EXAIR Electronic Flow Control combines a photoelectric sensor with timing control that limits compressed air use by turning it off when no part is present

Open pipe blow offs also violate OSHA standard 29 CFR 1910.242(b) requirement for using compressed air for cleaning when pressurized above 30 PSIG. Not to mention they generally are louder than 90 dBA, which is the maximum allowable noise exposure without hearing protection under OSHA standard 29 CFR – 1910.95 (a). The EXAIR engineered Super Air Nozzle is a great way to avoid a OSHA fine.

A great product that will help you keep your fingers on the pulse of compressed air consumption and demand is by incorporating the EXAIR Digital Flow Meter.  This handy item mounts directly to the pipe.  The digital display shows the amount of compressed air being used in any leg of your distribution system.  The Digital Flow Meter is offered in sizes for 1/2″ – 4″ Schedule 40 Iron Pipe and 3/4″ – 4″ Copper Pipe.  It also is available with the Summing Remote Display that is prewired with a 50′ cable, it is powered by the Digital Flow Meter and with a push of the button will display either the current compressed air consumption, consumption for the previous 24 hours or the total cumulative usage.

The Digital Flowmeters are also available with wireless capability using the ZigBee mesh network protocol, data can be passed from meter to meter to extend the distance over which the wireless system can operate.  Each meter has a range of up to 100′ (30 meters). Or you can opt for the USB Data Logger option.  The USB Data Logger can store approximately 9 hours of readings if set to sample once every second or up to 2 years if sampled every 12 hours.

If you would like to talk about any of the quiet EXAIR Intelligent Compressed Air® products or our line of Optimization Products, feel free to contact me or any EXAIR  Application Engineer.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

What is a Decibel Level?

Decibel level also known as dBA, is how the industry measures sound intensity’s effect on the human ear and is an important value when discussing noise exposure for employees and operators within manufacturing. Manufacturing personnel can be at risk for hearing damage when exposed to high decibel levels if the proper precautions are not taken. For reference, 0 dBA is the softest level that a person can hear. Normal speaking voices are around 65 dBA. A rock concert can be about 120 dBA.

Sounds that are 85 dBA or above can permanently damage your ears. The more sound pressure a sound has, the less time it takes to cause damage. This damage occurs within a sensitive part of our ear called the cochlea, which contain thousands of hair cells used to allow our brains to detect sounds. For example, a sound at 85 dBA may take as long at 8 hours to cause permanent damage, while a sound at 100 dBA can start damaging hair cells after only 30 minutes of listening.

OSHA Max Noise Exposure Chart

The Center for Disease Control (CDC) estimates that 22 million workers are exposed to potentially damaging noise at work each year. Whether you work near machinery, at a sports venue, on a tarmac, or operate a jackhammer—hearing loss is preventable.

Noise may be a problem in your workplace if you:

  • Hear ringing or humming in your ears when you leave work.
  • Have to shout to be heard by a coworker an arm’s length away.
  • Experience temporary hearing loss when leaving work.

If you need to raise your voice to speak to someone 3 feet away, noise levels might be over 85 decibels. Sound-measuring instruments are available to measure the noise levels in a workspace.

The first step to lowering your sound level is to take a baseline reading of your various processes and devices that are causing the noise. EXAIR’s Sound Level Meter, Model 9104, is an easy to use instrument that provides a digital readout of the sound level. They come with an NIST traceable calibration certificate and will allow you to determine what processes and areas are causing the most trouble.

From there, EXAIR has a wide range of Intelligent Compressed Air Products® that are designed to reduce compressed air consumption as well as sound levels. For noisy blowoffs where you’re currently using an open-ended pipe or a loud commercial air nozzle, EXAIR’s Super Air Nozzles are the ideal solution. Not only can they pay for themselves over a short period of time time due to compressed air savings, but your operators will thank you when they’re able to hear later on in life!

 EXAIR has the tools you need to reduce sound level in your processes. If you’d like to talk to an Application Engineer about any applications that you feel could benefit from a sound reduction, give us a call.

Jordan Shouse
Application Engineer

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

Compressed Air in Farming and Agriculture

I used to help my father-in-law around his farm and this city boy had his eyes opened when he realized it was more than shovels, tractors and livestock. Agriculture is vital for human existence and has become far more advanced over the centuries with a continual thirst for efficiency and technology. Agriculture is just like many other industries looking for continued ways to increase yield, improve quality, maximize labor and improve technology.

EXAIR has many products used in the agriculture and food processing industries. The following details a few example by product line how we can influence efficiencies and quality of products:

Super Air Knife drying fruits and vegetables

Super Air Knives:

EXAIRs Super Air Knives are have ben used to help harvest apples and peaches. In this case they use our Super Air Knives to dry and blow off the fruit after the rinsing process just before the waxing process then again after waxing to blow off any remaining debris or moisture from the fruit before being packed.

A processing company using the Super Air Knife to clean a conveying belt equipped with a weighing system. Before the installation of the the Super Air Knife some of the cut vegetables being weighed would stick to the belt. Their solution was to clean the conveyor belt with EXAIR’s Super Air Knife to ensure continuous operation of the weighing and packaging systems.

Super Air Nozzles:

An onion farmer used EXAIR’s Model 1100 Super Air Nozzle to blow loose onion skins from the onions before packaging to improve the aesthetics to the customers.

Line Vacs:

A food packaging company repackages banana peppers from 55 gallon drums to 1 and 5 gallon containers using our Model 6066 3″ Stainless Steel Line Vac.

Using EXAIRs Model 150200 2″ Heavy Duty Line Vacs a feed stock manufacturer conveys various grains and feed stock simultaneously to a mixer which blends the ingredients. This reduced their blend time by 50%.

A grain processor used Model 142200 aluminum threaded Line Vac to convey small amounts of corn meal into a hopper which feeds into their inspection process.

A company producing worm eggs encapsulated in water soluble wax sold to farmers to enhance soil conditions. They eliminated a hand operation using Model 6081 1″ Aluminum Line Vac  to convey the worm eggs from one classifier to another.

EXAIR has several applications using Atomizing Spray nozzles to add moisture in growing environments . Greenhouses use our Atomizing spray nozzles to control humidity in the air and keep their soils moist to maintain optimal growing environments.

There are many other applications using compressed AIR on farms such as filling tires, cleaning equipment, blowing out water lines and more. Technology drives labor savings and improved quality prototypes are being designed and tested to use compressed air using drones to shoot pods filled with seeds, fertilizer and other nutrients into the soil. EXAIR will remain a strong influence in the growth of compressed air products helping to reduce the carbon footprint, enhance efficiencies and improve cost and quality within the agriculture and food processing industries.

If you have an application and you would like to talk please contact me or any of our qualified Application Engineers at 800.903.9247 and we will gladly help with our best recommendations.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK