EXAIR Provides you with the Necessary Tools for Training

I recently participated in a spicy wing eating competition here in Cincinnati. A last-man-standing format where contestants were tasked with finishing a single wing in 30 seconds per round. As the rounds increased, so too did the heat level of the sauce the wing was tossed in. The GRAND PRIZE for the daring winner was quite a haul, a $50 gift card to a local wing joint. Why put yourself through this for the chance at winning a $50 gift card I was repeatedly asked. Who knows, maybe I’m crazy. But, anyone who knows me knows I love a good competition and I wasn’t going to go into this one unprepared. Training for the competition was going to be necessary if I wanted to stand a chance.

peach reaper queen of the wing
Peach Reaper Peppers – The Breakfast of Champions

Several weeks of putting myself through a hellacious bout of pain, misery, and indigestion by way of Ghost Peppers, Trinidad Scorpion Peppers, and Peach Reaper peppers from my garden, I felt like I was ready to go. I started off the morning of the competition with some Peach Reapers in my breakfast burrito (the hottest I had on hand). Through the sweat, tears, and pain (along with a few eye rolls from my wife) I felt as prepared as I could possibly be. Unfortunately, all of my training didn’t quite get me the win. But, a respectable 2nd place finish wasn’t a bad showing. I suppose I’ll have to step my game up for next year…

queen of the wing
Do note the usage of proper PPE during the competition…

At EXAIR, we’re committed to providing our customers with the tools necessary to train themselves, their customers, and their employees on the proper ways to use compressed air. From right here on the EXAIR Blog, our YouTube Channel, and the Knowledge Base on our website there’s a ton of valuable information out there for your use. Best of all? It’s Free!

Within our Knowledge Base, you’ll find case studies that highlight examples of applications where we’ve helped customers improve their processes, save money by reducing compressed air consumption, and help improve on worker safety. There’s a list of FAQs categorized by product line, a library of calculators to help estimate the savings you’ll experience, and a list of application examples.

In addition, we also have a library of previously recorded webinars that are free to view at your convenience. With topics such as “Intelligent Compressed Air Solutions for OSHA Compliance”, “Intelligent Solutions for Electrical Enclosure Cooling”, “Optimize Your Compressed Air System in 6 Simple Steps”, “Simple Steps for Big Savings”, and “Understanding Static Electricity” all of the tools are readily accessible to make sure you’re fully prepared and equipped to handle your compressed air system.

Don’t let these free resources go to waste and take the time to train yourself on the available solutions to Intelligent Compressed Air usage. I promise it’ll be a lot less painful than a steady diet of super hot chili peppers!

Don’t feel like we’re leaving you to figure everything out on your own. In addition to all of the resources available to you within the Knowledge Base, EXAIR has a team of highly-trained Application Engineers with experience in a wide variety of industries and processes. There’s a good chance one of us has dealt with the very same application and we’ll be happy to help point you in the right direction. Don’t wait, give us a call!

Tyler Daniel
Application Engineer
E_mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

 

What’s So Great About Air Entrainment?

Air entrainment is the phenomenon that occurs when air (or any gas) under pressure is released from a device in such a way that a low pressure is generated in the immediate area of the air (or gas) discharge.  Air (or gas) from the surrounding environment is then pulled (or entrained) into the discharged air stream, increasing its volumetric flow rate.  EXAIR Corporation has been engineering & manufacturing compressed air products to take maximum advantage of this phenomena since 1983…and we’ve gotten better & better at it over the past 36 years.

Obviously, the first thing that’s so great about air entrainment is…free air flow.  Every cubic foot that’s entrained means that’s a cubic foot that your compressor didn’t have to spend energy compressing.  Considering the EXAIR Super Air Knife’s entrainment ratio of 40:1, that makes for a VERY efficient use of your compressed air.

Another thing that’s so great about air entrainment is…it’s quiet.  As you can see from the graphic at the top of this blog, the Super Air Knife entrains air (the lighter, curved blue arrows) into the primary compressed air stream (the darker, straight blue arrows) from above and below.  The outer layers of the total developed flow are lower in velocity, and serve as a sound-attenuating boundary layer.  The sound level of a Super Air Knife (any length…here’s why) is only 69dBA.  That means if you’re talking with someone and a Super Air Knife is running right next to you, you can still use your “inside voice” and continue your conversation, unaffected by the sound of the air flow.

I always thought it would be helpful to have more than just a graphic with blue arrows to show the effect & magnitude of air entrainment.  A while back, I accidentally stumbled across a stunning visual depiction of just that, using a Super Air Knife.  I had the pleasure of talking with a caller about how effective a Super Air Knife might be in blowing light gauge paperboard pieces.  So I set one up in the EXAIR Demo Room, blowing straight upwards, and tossed paper plates into the air flow.  It worked just as expected, until one of the paper plates got a little closer to the Super Air Knife than I had planned:

As you can see, the tremendous amount of air flow being entrained…from both sides…was sufficient to pull in lightweight objects and ‘stick’ them to the surface that the entrained air was being drawn past.  While it doesn’t empirically prove the 40:1 ratio, it indisputably demonstrates that an awful lot of air is moving there.

If you’re looking for a quiet, efficient, and OSHA compliant solution for cleaning, blow off, drying, cooling…anything you need an even, consistent curtain of air flow for – look no further than the EXAIR Super Air Knife.  If you’d like to discuss a particular application and/or product selection, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Chip Shields, OSHA, And You

Safety is a key part of our culture at EXAIR Corporation.  We have regularly scheduled, all-hands required, safety training on a number of topics.  Our Order Entry team can likely tell you as much about our lockout/tagout procedures as our Machinists can.  Nobody even thinks about entering The Shop without safety glasses, and it’s not just because of the signs.

We pay attention to these…
…so we don’t ever have to use this.

OSHA 1910.242(b) states that “Compressed air shall not be used for cleaning purposes except where reduced to less than 30 p.s.i. and then only with effective chip guarding and personal protective equipment. (emphasis mine)  All EXAIR Intelligent Compressed Air Products are engineered to meet the requirements of the first part (30psi outlet pressure to prevent dead ending…we’ve written about that numerous times, including here, here, and here) and we can also provide pre-installed devices to satisfy the second part:  the EXAIR Chip Shield.

Any EXAIR VariBlast or Heavy Duty Safety Air Gun can come fitted with a Chip Shield, and any Soft Grip Safety Air Gun, except for those with Stay Set Hoses, can as well.  Safety Air Guns with Back Blow Nozzles automatically come with a Chip Shield. The principle is simple: a clear polycarbonate (so you can still see what you’re doing) round disc slips over a short (or long if you want) pipe extension between the gun & the nozzle.  It’s fitted with a rubber grommet so you can position it to where it’s most effective – sometimes that might be closer to the part being blown off; sometimes it may be back a little closer to the operator.

EXAIR Safety Air Guns are available, from stock, with Chip Shields.

If you already have an air gun that’s doing the job, you can easily add an EXAIR Chip Shield to it.  They’re made to fit a wide range of extension diameters, and can even come with the extension if you need it.  We also stock a number of adapter fittings; if you know what threads your air gun has (or if you can send us some photos) we can quickly & easily spec those out for you.

Convenient and inexpensive “thumb guns” with cross drilled nozzles (left) are compliant with the first part of OSHA 1910.242(b). Fitting one with an EXAIR Chip Shield (center) makes it compliant with the second part. A Model 1102 Mini Super Air Nozzle (right) makes it quiet & efficient.
We can provide a Chip Shield for most any device with a threaded fitting. I couldn’t find a way to re-use the non-OSHA-compliant nozzle that came with this gun (thank goodness.)
Another example of a larger air gun fitted with a more powerful cross drill nozzle (left) that can be made totally OSHA compliant with an EXAIR Chip Shield (center.) An EXAIR High Force Super Air Nozzle (right) keeps the power, while reducing noise level and compressed air consumption (right.)

Since 1983, EXAIR Corporation has been manufacturing quiet, safe, and efficient compressed air products for industry (emphasis mine.)  If you have concerns or questions about safety in regard to your compressed air use, call me.

Russ Bowman
Application Engineer
EXAIR Corporation
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OSHA Safety Standards for Compressed Air

Safety should always be a serious concern within industrial environments.  Walk through any production facility and you should see all kinds of steps taken to give a safe workplace to the operators, contractors, and other team members.  Whether this is through a sign showing PPE required to enter an area, an emergency exit sign, a safe walkway, or machine guards.  Safety has become a standard that should never be lowered and there is good reason for that.

EXAIR designs all of our products to be safe and they meet or exceed OSHA standards that are directed toward compressed air safety.  The first is to ensure that an operator or maintenance worker will not be injured through air impinging their skin should they come into contact with an EXAIR product.   This OSHA standard is 29 CFR1910.242(b) claiming that all point of use compressed air products must be regulated to have less than 30 psig of dead end pressure.   This directive is critical for worker safety and the way many blowoffs skirt by is to cross drill holes in the end of the blowoff.

Cross drilled holes may satisfy the dead end pressure standard but it does not address OSHA’s next important compressed air standard about noise exposure, OSHA standard 29CFR1910.95(a).  The allowable noise level standard combined with 30 psig dead end pressure will render many home made or retail nozzles near useless because few, if any, meet both standards.  Again, EXAIR has engineered and designed our Super Air Nozzles to permit 80 psig inlet pressure and still meet or exceed both of these OSHA standards so that the work can still be done by the operators while remaining safe and retaining their hearing.

For a better explanation and demonstration of how our nozzles meet these standards please see the video below.

While I use nozzles and cross drilled pipes as examples within this blog these safety features are designed into every product that EXAIR offers.  This is due to the fact that OSHA, NIOSH, and the CDC do not delineate between a blow gun, blow off within a machine, or even a Cabinet Cooler System.  If the device is powered by compressed air then the two key OSHA standard are in effect due to the inherit dangers of compressed air.

I encourage you now to walk through your facility and try to listen or spot compressed air points of use within your facility.  Then, I ask you to call, chat, e-mail, or tweet an Application Engineer here at EXAIR and let us help you determine the most efficient and safest product to get the work done.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

VariBlast®Compact Safety Air Gun

EXAR’s VariBlast® Compact Safety Air Guns are small and lightweight air guns capable of handling the toughest of jobs. With its variable flow trigger being its greatest design feature, it can take on small jobs and even big ones! This means you can get different flow and force out of the same nozzle by just adjusting the amount you pull the trigger.

The VariBlast Safety Air Gun, when outfitted with an EXAIR nozzle is OSHA safe and CE compliant. 

VariBlast Safety Air Gun With Extension and Chip Shield

The VariBlast can also be customized by adding one of our many 1/8 NPT engineered air nozzles, a chip shield and even an extension pipe up to 72″ long.

 

Flat Air Nozzle, with Chip shield and extension
Back Blow Nozzle, with 6″ extension and Chip Shield

 

 

The VariBlast is easy to rebuild, every wear item is available in the 902001 rebuild kit. These parts can be used to rebuild any VariBlast Compact Safety Air Gun that, through use, has become worn. See this video to see how easy it is to rebuild this gun, and make it feel brand new!

If you have questions about the VariBlast or to discuss any of the 15 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and one of our Application Engineers can help you.

Jordan Shouse
Application Engineer
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Business Benefits From Compressed Air Efficiency

Use of compressed air, or “the fourth utility” as it’s called, is widespread in many industries.  How you use it in your business is important, for a couple of key considerations:

Monetary cost

Compressed air isn’t free.  Heck, it isn’t even cheap.  According to a Tip Sheet on the U.S. Department of Energy’s website, some companies estimate the cost of generation at $0.18 – $0.30 per 1,000 cubic feet of air.  A typical industrial air compressor will make 4-5 Standard Cubic Feet per Minute per horsepower.  Let’s be generous and assume that our 100HP compressor puts out 500 SCFM and is fully loaded 85% of the time over two shifts per day, five days a week:

500 SCFM X $0.18/1,000 SCF X 60 min/hr X 16 hr/day X 5 days/week X 52 weeks/year =

$22,464.00 estimated annual compressed air cost

If you want to go jot down some numbers from your compressor’s nameplate and your last electric bill, you can accurately calculate your actual cost.  Here’s the formula:

Taking our same 100HP compressor (105 bhp required,) fully loaded 85% of the time, and assuming the motor’s good (95% efficient):

(105 bhp X 0.746 X 4,160 hours X $0.08/kWh X 0.85 X 1.0)÷ 0.95 =

$23,324.20 actual annual compressed air cost

So, our estimate was within 4% of our actual…but the point is, $22,000 to $23,000 is a significant amount of money, which deserves to be spent as wisely as possible, and that means using your compressed air efficiently.  Engineered solutions like EXAIR Intelligent Compressed Air Products can be a major part of this – look through our Case Studies; implementing our products have saved companies as much as 60% on their compressed air costs.

Health & Safety

Injuries and illnesses can be big expenses for business as well. Inefficient use of compressed air can be downright unsafe.  Open ended blow offs present serious hazards, if dead-ended…the pressurized (energized) flow can break the skin and cause a deadly air embolism.  Even some air nozzles that can’t be dead ended (see examples of cross-drilled nozzles on right) cause a different safety hazard, hearing loss due to noise exposure.  This is another case where EXAIR can help.  Not only are our Intelligent Compressed Air Products fully OSHA compliant in regard to dead end pressure, their efficient design also makes them much quieter than other devices.

Efficient use of compressed air can make a big difference in the workplace – not only to your financial bottom line, but to everyone’s safety, health, and livelihood.  If you’d like to find out more about how EXAIR can help, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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EXAIR Standard Air Knife Keeps Bottles Free From Contaminants

Recently I worked with a customer on an application to remove contaminants from the inside of glass bottles. During production, dust from the ambient environment was collecting inside of the bottles. They needed a way to remove it prior to filling. The solution was to briefly pause the conveyor, pulsing air into the bottles to free any dust that had accumulated. Their problem was that while the dust was blowing out of the bottle without an issue, some of it was settling back down into the bottles.

P_20190502_123926_vHDR_On

The customer needed a way to mitigate the risk of dust particles resettling into the bottles after it was removed. The solution was to install a Model 2012 12” Standard Air Knife to provide a curtain of air across the top of the bottles, catching any freed dust particles and blowing them away from the conveyor.

After noticing positive results, we wanted to take things one step further and help to reduce overall air consumption in the process. The blowoff was achieved with (8) ¼” open tubes operating at a pressure of 80 PSIG. Although they were only operating for a fraction of a second, they still consume a whopping 33 SCFM! Replacing them with Model 1101 ¼” NPT Super Air Nozzles (14 SCFM at 80 PSIG) resulted in compressed air savings of 58%!!

In addition to saving compressed air, the noise level was also dramatically reduced. At just 74 dBA, we’re below the threshold for an 8-hour exposure time for operators according to OSHA. Where earplugs were necessary before, they’re now able to operate safely without the need for PPE to protect their hearing. The second most effective fundamental method of protecting workers, according to NIOSH, is to substitute or replace the hazard with an engineered solution. It’s not possible to eliminate the hazard as a compressed air blowoff was necessary, but the next best step is to replace it with something safer.

HierarchyControls

In addition to complying with OSHA 1910.95(a), the Super Air Nozzle also cannot be dead-ended. In applications for compressed air blowoff with unsafe nozzles, pipes, or tubes, the pressure must be regulated down to below 30 PSIG according to OSHA 1910.242(b). The installation of an engineered compressed air nozzle by EXAIR allows you to operate safely at much higher pressures.

If you have inefficient blowoff processes in your facility, give one of our Application Engineers a call. We’ll be happy to take a closer look at your application and recommend a safe, reliable, engineered solution!

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