One and Done – Not EXAIR

Cincinnati professional sports teams are getting a reputation of one and done. If you are a die-hard Bengals fan you are probably enrolled in some sort of grief support group by now. With all the hype about how this was finally going to be the year they would win a playoff game but they failed to come through – again. If you are a Reds fan, you are still recovering from a disappointing season finale.

Not all is doom and gloom in Cincinnati though, as we have one clear and consistent winner…the EXAIR Corporation. For the past 30 years we have consistently met customer expectations with 99% on time deliveries, consistent product development, and customer support second to none.

awards

EXAIR’s has been recognized for its innovation by the readers of major publications who have voted us product of the year awards. The walls of our hallways are lined with award plaques, 29 in all and 2013 is pending.

Our customers recognize our accurate and on time deliveries. Grainger has awarded us their prestigious Partners in Performance award.

graingerSo for me, its great to live in Cincinnati because I work for the best company in the city. A true winner.

I would welcome your challenge to assist you with your compressed air application and in doing so, demonstrate why we are receiving so many performance awards.

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363
Web: http://www.exair.com
Twitter: http://www.twitter.com/exair_jp
Facebook: http://www.facebook.com/exair

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When The Obvious Choice Isn’t

Do you have a copy of EXAIR’s Product Catalog? My opinion may be biased, but I think it’s one of the best ones out there. It’s arranged by product category, and gives you easy access to not only the model numbers of all of our stock products, but succinct and pointed details on principles of operation, examples of applications, dimensions, technical specifications, features & benefits, etc. They’re free for the asking – and if you don’t have the latest (as of this writing, #26), go ahead and ask too – you might be pleasantly surprised by what we’ve added recently!

Now, your application may be straightforward and simple, in which case, you can quickly and easily order any catalog product…almost all of them ship the same day. Our Design Engineers aim to make them simple to install and operate, so you could very well be “off to the races” in very short order. That’s our intent, anyway. But if your situation isn’t so clear cut, here’s a part of the catalog you should pay particular attention to:

tech800at120You’ll find this on the front cover, and the phone number is on darn near every page, too.

See, sometimes, “the usual suspect” isn’t the product that’s going to solve your application. Here’s a prime example:

willy wonka meme

A very popular candy maker (not this guy, but I do so love those Facebook memes) wanted to automate a part of their operation where they cut a large slab of chocolate into small squares, and then move them to a machine that individually wraps them. They were transferring them by hand, but figured they could improve efficiency by using a “pick and place” process, and were particularly interested in an air-operated vacuum system. On the surface, it looked like a “textbook” application for an E-Vac Vacuum Generator. Due to the delicate nature of the product, though, the higher vacuum levels produced would cause the lifting mechanism to mar the surface. And, as delicious as these candies are, it would be a shame if they didn’t look perfect too.

That’s where Application Engineering comes in. Like Joe Panfalone wrote about on Monday, we’ve got the education, and experience, that allow us to “marry the practical with the hypothetical to find the best answer.” We knew we couldn’t use high vacuum, but the pieces are so small and lightweight that a low vacuum level could be quite effective, if we had a decent vacuum flow. After discussion of the application and their expectations, we recommended a Model 120024 4” Super Air Amplifier which they fitted a stainless steel mesh screen to the inlet of, and were able to pick up the freshly cut chocolate squares delicately enough to prevent any marring of the surface at all. The automated process made it quicker and easier for the operators to get the candies to the wrapping machine, defect-free, every time.

So, no matter what the obvious choice (of product) may (or may not) be, the obvious choice for guidance with your compressed air application is EXAIR.  Call us and find out.

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Web: www.exair.com
Blog: https://blog.exair.com/
Twitter: twitter.com/exair_rb
Facebook: http://www.facebook.com/exair

Sustainability – Fact or Fiction

As the world goes eco-friendly it’s not clear how much environmental good will come from all the green products consumers are buying. Many companies peddle new or improved green products through their marketing campaigns, but it pays to look beyond the product pitches and into how the company behaves.

It’s refreshing to work for a company that is really walking the talk. EXAIR’s sustainability plan has real and quantifiable achievements.

  • Our variable speed drive air compressor reduced our electrical consumption by over 4,000 kWh in the past year compared to a conventional air compressor
  • Through a leak detection and mitigation program, one million cubic foot of compressed air per yer was saved
  • Migrating our customers to electronic delivery of invoices reduced traditional postal service mailed copies by over 50% and a 67% reduction in  printed paper pages
  • Most shipments use recycled Kraft paper with a perfect “green score ” of 360
  • Fresh water consumption was reduced through a coolant management program that extends usable life of water-soluble coolant from six weeks to six months.
  • Natural gas consumption was reduced by installing programmable thermostats wherever possible to match heating and cooling cycle with facility usage patterns
  • Solid waste/trash was reduced by 88% through and expanded recycling program
  • All metals, wood, waste water, cans, and plastics are 100% recycled

Do you want to improve your sustainability scorecard by reducing compressed air consumption?  Give our application engineers a call and they will be happy to assist you. They can be reached at 1-800-903-9247

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363
Web: http://www.exair.com
Twitter: http://www.twitter.com/exair_jp
Facebook: http://www.facebook.com/exair

“Advice Is Temporary; Knowledge Is Forever”

I stumbled across this recently, and it’s become one of my new favorite adages. In the context of the writing I found this in, it was meant to call out the difference between telling someone WHAT to do (e.g., giving advice) and telling them HOW or WHY to do it (e.g., imparting knowledge, or possibly, wisdom.) It made me think about how I can do my job as an Application Engineer better.

For example, this time of year, we get a lot of inquiries from folks who need to protect their sensitive electric/electronic devices from heat – both from inside and outside the enclosure. With just a few key pieces of data, we can accurately specify the proper Cabinet Cooler System for their needs. Sometimes, the caller doesn’t understand why we need to know the temperatures inside & outside the enclosure, but a simple explanation – the difference in those two temperatures is directly proportional to the heat being generated inside the enclosure – serves to gain their understanding, and their trust.

It’s also been said that a picture is worth a thousand words. We’re no strangers to this concept either. It’s not uncommon for us to ask for a photo of an application, or to email a photo (or series of photos) to, for instance, show how a Cold Muffler is installed on a Medium Vortex Tube:

Med VT-muffler1 Med VT-muffler2 Med VT-muffler3

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If a picture is worth a thousand words, how many pictures is a video worth?  Regular readers of our blogs are treated, once a month or so, to a Video Blog that highlights a particular product, product line, “how-to,” etc.  You can search for a specific one at blogs.exair.com, or here is a list of links for your convenience:

Proper Supply Plumbing for Compressed Air Products
EXAIR Vac-u-Gun
Digital Flow Meter Software Installation
How To Change a Shim in a Super Air Knife
Silencing Mufflers
How To Rebuild an EXAIR Safety Air Gun
How To Replace an EXAIR Filter Element
Flow Meter Data Logger Installation
EXAIR Vortex Tubes, Some History, Some Products
Digital Flowmeter Installation
How To Reset the Thermostat in a Cabinet Cooler System
Introducing the EXAIR Mobile Website
Line Vac Abrasion Resistance
How to Convert a Super Air Knife to Add Static Elimination
Ultrasonic Leak Detector Explained
Taking Care of Your Ion Air Gun
How to Assemble Mounting Brackets to EXAIR Filters & Regulators
Ionizing Bar Maintenance
Air Knife Plumbing Kits
Electronic Flow Control Time Delay Operation
Receiver Tanks: When to Use One, and How to Set One Up
Care and Feeding Of Your Vortex Tube
How To Use an EXAIR Static Meter
How To Rebuild Your Reversible Drum Vac
Universal Air Knife Mounting System
Vortex Tube Demonstration

Like I said, we’re making a new video every month, and we’re always on the lookout for ideas. If you have any questions about an application or a product, whether it’s “what” “how” or “why,” we’ll be happy to help in any way that we can. Who knows…your question could lead to next month’s video!

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Web: www.exair.com
Blog: https://blog.exair.com/
Twitter: twitter.com/exair_rb
Facebook: http://www.facebook.com/exair

Vacuum Chips from Blind Holes

An engine manufacturing plant had an issue with removing shavings from a blind hole to be threaded. The machining of the engine block is done on a transfer machine and is unmanned from station to station. Shavings in the drilled holes would interfere with the bottoming forming taps, causing them to break. When a tap breaks, sensors shut the entire line down.

Capture

The initial concept was to use an EXAIR Deep Hole Vac U Gun where compressed air is blown down into the hole with a small compressed air tube. The savings are captured by a soft vinyl tube under vacuum generated by the gun. This worked quite well but would require an operator positioned at that station. The customer wanted to keep the operation unmanned.

GM Romulus BO-Vacuum System HP Chip-VacThey added another station in the transfer line and installed an EXAIR 5 gallon Chip Vac with the end of its hose modified to replicate the Deep Hole Vac U Gun. They moved the modified hose end with a robot from hole to hole. This eliminated tap breakage, line shutdown, and increased uptime by 10%. 

There are a lot of innovative  ways that EXAIR products can be used.

Give our application engineers a call. 1-800-903-9247.  They would be happy to assist you.

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363
Web: http://www.exair.com
Twitter: http://www.twitter.com/exair_jp
Facebook: http://www.facebook.com/exair

http://www.exair.com/28/dhvg.htm

We Love Our Pets

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My 110 Pound Buddy

We all love our pets and I for one, am guilty. It is amazing the money we pet owners will spend on our pets. According to the Denver Post, Americans are projected to spend $50.84 billion on pets this year. That is more than Americans spent on  child care ($47 billion).  A neighbor of mine just spent $6,000 for double knee surgery on his 8-year-old German Shepard. Which presents an interesting question; would I do that for my best friend? What would you do? It is the emotional ties to our pets that drives this market.

The pet market is not the only market driven by emotion. Harley Davidson, Apple computer, automakers, farm implements, and others have die-hard followers.  The rational for brand loyalty more than not is just emotional. My dad worked for GM and his brother Chrysler. A couple of beers and they would come to fisticuffs over which had the better car.

EXAIR takes a pragmatic approach to producing and implementing compressed air products. We do not put on a gold-colored finish that only serves as eye candy.  We strive to engineer our products to perform. Performance specifications are actual measured values. We do not play the shell game of presenting consumption values at reduced pressures to get the number we want. All our data is at a consistent 80 PSIG benchmark. It is that commitment that has earned us 26 product awards.

I am an application engineer and would be happy to assist you with your application. Feel free to contact me. I genuinely appreciate the opportunity!

Joe Panfalone
Application Engineer

Phone (513) 671-3322
Fax (513) 671-3363
Web: http://www.exair.com
Blog: http://blog.exair.com
Twitter: http://www.twitter.com/exair
Facebook: http://www.facebook.com/exair

The Importance Of Accurate Instrumentation

A sailor from a destroyer said to a submariner, “It must be scary, going to sea on a ship that’s designed to sink!”

The submariner replied, “It must be REALLY scary, going to sea on a ship that operates at test depth ALL THE TIME!”

The implication, of course, is that a destroyer could not survive a dive to any depth. Oh, and submariners don’t call it “sinking;” we call it “diving,” because submarines are also designed to perform an all-important maneuver known as “surfacing.” There are no guarantees, of course, but the odds are absolutely in our favor, due to the highest caliber of engineering, fabrication, inspection, and training that make the Silent Service so successful.

I thought of this today because of an event that happened on this day in 1973: USS Greenling (SSN-614), a US Navy fast attack submarine, accidentally went below her test depth, and actually approached crush depth, due to a sticky needle on the main depth gauge in the Control Room. According to unofficial reports, a junior enlisted man noticed that the seawater pressure reading on another gauge indicated they were far deeper than the depth gauge was showing. Official reports said they surfaced rapidly (I bet), immediately returned to port, and underwent an extensive inspection in drydock before returning to duty.

USS Greenling (SSN-614) Depth Gauge Reading zero (assumed)
USS Greenling – Depth Gauge reading zero (assumed)

Now, your plant’s compressed air system instrumentation may not be as life-or-death critical as a submarine’s depth gauge, but there’s still no reason to skimp on, or settle for, second-rate gear that might cause you undue hassle. For instance, I recently had the pleasure of testing a customer’s Model 6061 1” Stainless Steel Line Vac in our Efficiency Lab – they weren’t able to draw our published vacuum rating (-42” water) or flow rate (14.7 SCFM), when supplying compressed air at 80psig. Curiously, they were getting values that corresponded with operation at 70psig. Using their pressure gauge and commercial-grade inline flow meter, I verified it was indeed under-performing, with 80psig compressed air supplied…this was measured UPSTREAM of their flow meter, however. I installed a pressure gauge at the Line Vac’s inlet port (downstream of the flow meter) and found that the flow meter was (quite unexpectedly) responsible for a 10psi pressure drop! Once the supply was regulated to provide 80psig at the inlet to the Line Vac, we found that it performed as specified.

EXAIR’s Digital Flow Meters, on the other hand, won’t restrict your compressed air flow at all. They’re easy to install…you simply drill two small holes in the pipe, using the included Drill Guide Fixture. They’re just as easy to remove, if you need to, and their holes can be covered with blocking plates (sold separately.)

Our Summing Remote Display can be easily wired to any Digital Flow Meter, and mounted up to 50 feet away. With the push of a button, you can also cycle the display to show not only current compressed air flow, but the previous 24 hours’ usage, and total cumulative usage.

For the ultimate in data management, our USB Data Logger connects just as easily to a Digital Flow Meter, and can be removed and inserted into any available USB port on your computer. It comes with software that will automatically graph your compressed air usage, or you can import the data directly into Microsoft Excel®. Since its introduction early last year, it’s won Environmental Protection Magazine’s New Product of the Year Award, Plant Engineering’s Product of the Year Gold Award, and Design News deemed it a “Better Mousetrap” Award Finalist.

In closing, here’s our Senior Application Engineer, Joe Panfalone, holding the Plant Engineering Gold Award. In case you were wondering, the other three are for our Model 1114SS Large Super Air Nozzles, our Dual High-Temperature Cabinet Cooler Systems, and Siphon-Fed Atomizing Nozzles, all of which were introduced in 2012, with great success – hence the literal armload of awards!

Joe and Awards 2013

If you use compressed air, odds are very good that EXAIR products can improve your results. Let’s talk!

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Web: http://www.exair.com
Blog: https://blog.exair.com/
Twitter: twitter.com/exair_rb
Facebook: http://www.facebook.com/exair