Which Air Nozzle Is Right For Me?

Well, the obvious answer is, of course, an engineered air nozzle…you’re likely aware of this, or you wouldn’t be reading posts on the EXAIR Corporation blog.  We have no issue with narrowing that down a bit, and saying that the answer is an EXAIR air nozzle.  I bet you knew that was coming as well.  So let’s assume that, because of the cost of compressed air, the potential hazards of its unregulated discharge, and the flat-out racket it can make (unless you do something about it,) you’re looking for something efficient, safe, and quiet.

Now that we’re on the same page, let’s unpack that question.  The nature of the application will let us know the airflow pattern & characteristics (mainly flow & force) that we need.

For example, if you need just a pinpoint of airflow, our Atto Super Air Nozzle blows a 1/2″ diameter pattern at a distance of 3″.  Get a little closer than that, and it’s as tight as you want it to be.  Now, it’s only generating a force of 2oz (at 12″ away) but keep in mind that’s all concentrated in a small fraction of an inch diameter.  Which is plenty for most applications that need that precise of an airflow.

Atto Super Air Nozzle

If you DO need a little more flow & force, our Pico and Nano Super Air Nozzles offer incremental increases in performance.  The pattern starts to widen out, but that’s a function of the increased flow expanding in to atmospheric pressure…it has to go somewhere, you know.  But, again, the closer you get, the more focused the flow is to the centerline of the nozzle.

On the other end of the spectrum are EXAIR’s High Force Air Nozzles.  These are particularly useful for stubborn blowoff applications – a foundry blowing slag off hot strip as it cools, for example.  Our largest of these, a 1-1/4 NPT model, generates 23 lbs of force…that’s over 25 times the power of our standard Super Air Nozzle.

 

With 23 lbs of hard hitting force, this 1-1/4 NPT Super Air Nozzle is perfect for the most extreme blow off and cleaning jobs.

Speaking of the standard Super Air Nozzle, it’s the most popular answer to the Big Question.  It’s suitable for a wide range of blowoff, drying, and cooling applications, like the kinds of jobs an awful lot of folks use open end blowoff devices on.  Open ended tubes blow out a great amount of air, but they’re wasteful and noisy, and OSHA says you can’t use them unless you regulate the pressure to 30psig…where they’re not even going to be all that effective.

Choose from (top left to bottom right) 316SS, Zinc Aluminum, or PEEK Thermoplastic…whatever you need to stand up to the rigors of your environment.

If you’ve got a 1/4″ copper tube, for example, it’ll use 33 SCFM when supplied with compressed air at 80psig.  It’ll for sure get the job done (albeit expensively, when you think of all that compressed air consumption,) but it’ll be loud (likely well over 100 dBA) and again, OSHA says you can’t use it at that pressure.  So, you can dial it down to 30psig, where it’ll be marginally effective, but it’s still going to use more air than the Model 1100 1/4 NPT Super Air Nozzle does at 80psig supply pressure.  The hard hitting force of the Model 1100, under those conditions, will make all the difference in the world.  As will its sound level of only 74 dBA.  Not to mention, it’s fully compliant with OSHA 1910.242(b).  Oh…and you can even install it directly on the end of your existing tube with a simple compression fitting.

One of our customers installed Model 1100 Super Air Nozzles on all their lathe blowoff copper tubes, and saved almost $900 a year in compressed air costs.

We’ve also got engineered Air Nozzles smaller than the 1100 (all the way down to the aforementioned Atto Super Air Nozzle) and a good selection of larger ones, including Cluster Air Nozzles that hold tighter airflow patterns than similar performing single Super Air Nozzles.  They’re available in materials ranging from Zinc-Aluminum alloy, bare aluminum, brass, 303SS, 316SS, or PEEK thermoplastic polymer to meet the requirements of most any area of installation, no matter how typical or aggressive.

If you have an loud, wasteful, and likely unsafe blowoff, you owe it to yourself and everyone else who has to put up with it to consider a better solution.  Call me; let’s talk.

Russ Bowman
Application Engineer
EXAIR Corporation
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Free Money! Flat Super Air Nozzles Qualify for Energy Incentive

The patented design of EXAIR’s 1” and 2” Flat Super Air Nozzles makes them a highly efficient option when seeking a powerful, flat airflow. A precise air gap across the width of the nozzle provides a forceful stream of high velocity, laminar airflow without consuming high amounts of compressed air and also resulting in a greatly reduced sound level compared to some of the alternative flat nozzles available in the market.

Flat SAN not dumb picture
EXAIR’s Flat Super Air Nozzles have been blowing away the competition since 2003.

Did you know that upgrading to an efficient engineered air nozzle, such as the 1” or 2” Flat Super Air Nozzle, can make you eligible for an incentive from your energy provider? Similar to other energy-saving programs for upgrading to LED light bulbs or high-efficiency HVAC systems, these are made available to you as an incentive to start using more energy efficient products.

The energy costs associated with the generation of compressed air, often referred to in industry as a 4th utility, can make it expensive. These programs are offered to encourage you to use engineered products that are more energy efficient due to the reduction in compressed air consumption. Essentially, they’re offering you free money to implement a solution that will also save you money. It almost sounds too good to be true!! But these products, after implementation and receiving the incentive, will continue to save you money year after year.

The US Department of Energy, in conjunction with the NC Clean Energy Technology Center, provides a website that allows you to search the various programs available to you in your state. The DSIRE® website allows you to select your state, then select your energy provider to determine what programs are offered.

In Southwest Ohio, Duke Energy provides an incentive that offers $40 USD each per engineered air nozzle that is installed. When replacing open pipe or tube, these nozzles generally pay for themselves relatively quickly. But, when combined with a $40 USD rebate, that return on investment happens even quicker!!!

Don’t leave free money on the table. If you’re using open pipe or tube, or inefficient plastic flat nozzles, replace them with an engineered air nozzle from EXAIR. If you need help determining what rebate programs are available to you in your area, we’re also here to help. Contact an EXAIR Application Engineer today!

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

Video Blog: How-To Replace The Super Air Scraper Blade

The EXAIR Soft Grip Super Air Scraper is a great tool for any industrial environment that requires some cleanup. Some examples include removing tapes or sticky metal chips from the floor, scraping material from screening towers or removing stubborn adhesives and labels from workstation tabletops. They are available with extensions up to 72″ so reaching remote areas is also easier.

Today’s video is going to showcase how easy it is to replace the scraper blade within the nozzle and get back to work quickly.

If you would like to discuss how the Super Air Scraper could benefit your facility, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

EXAIR Air Nozzles And Jets: Quiet, Efficient, and Safe Solutions For Blow Off

Compressed air, as a utility, dates back to ancient Egypt, where metal alloy production was enhanced by using bellows devices to force air into furnaces in order to generate the extremely high temperatures needed to meld iron ores.  Major industrial use began in the mid-19th century, as pneumatic drills became popular for tunneling and mining operations.  With the development and large scale production of the modern air compressor in the 20th century, many other uses for compressed air were discovered.

Among the most prevalent of these additional applications is cleaning & blow off.  Mechanical or chemical methods such as washing, scrubbing, brushing, wiping, etc. often take time and considerable effort, when a quick blast of high velocity air from a pressurized source can make quick work of debris and/or moisture removal.  Thing is, unfettered discharge of high pressure air without concern for safety or efficiency has consequences:

  • Open end blow offs without a relief path for the air in case the device is dead ended, can have enough energy to break the skin, causing a dangerous and potentially fatal condition known as an air embolism.  The Occupational Safety and Health Administration (OSHA) specifically addresses this danger in 29 CFR 1910.242(b).
  • They’re also incredibly loud, usually higher than 100 decibels, which exceeds OSHA’s noise exposure limits per 29 CFR 1910.95(a).
  • As if that wasn’t enough, they can waste an awful lot of compressed air too.  The U.S. Department of Energy even goes so far as to classify it as an Inappropriate Use of Compressed Air.

Given these drawbacks, you might wonder why ANYONE would do such a thing!  Well, that’s the nature of our business at EXAIR Corporation: manufacturing quiet, safe, and efficient compressed air products for industry.  Among these are the first engineered products developed by EXAIR:  Air Nozzles and Jets.  No matter what your blow off needs are, we’ve got a solution.  Consider:

  • Performance.  With 73 distinct models to choose from, EXAIR can provide blow off solutions from the pin-pointed precision of our Atto Super Air Nozzle (uses 2.5 SCFM, generates 2 oz of force) to our High Force 1-1/4 NPT Super Air Nozzle (uses 460 SCFM, generates 23 lbs of force.)

    From the Atto Super Air Nozzle’s 2.5 oz pinpoint focus of air flow to the Model 1121’s 23 pounds of force blast, EXAIR has 73 distinct models to choose from.
  • Durability.  Some environments where blow off is required are downright aggressive: high heat, exposure to corrosive chemicals, etc.  With these situations in mind, we offer Air Nozzles & Jets in a variety of materials of construction, as shown to the right:
    • Zinc Aluminum alloy
    • Types 303 and 316 Stainless Steel
    • PEEK (polyether ether ketone) thermoplastic
    • Aluminum
    • Brass
  • Range of operation.  Any blow off device’s performance can be varied by regulating the compressed air supply pressure.  EXAIR offers several products with even greater ability for change:
    • The Model 1009 (Aluminum) and 1009SS (303SS) Adjustable Air Nozzles have a micrometer-like dial that allows you to very precisely set the flow & force to exact requirements.
    • Adjustable Air Jet Models 6019 (brass) and 6019SS (303SS) feature similar operation with a micrometer-like gap adjuster/indicator.
    • Our 1″ and 2″ Flat Super Air Nozzles (available in Zinc Aluminum or 316SS) have a replaceable shim.  The standard models have a 0.015″ thick shim installed, and the High Power models have 0.025″ thick shims.  We also offer individual shims, and sets, ranging from 0.005″ to 0.030″ thicknesses.
    • High Velocity Air Jets come in brass or 303SS, and also have replaceable shims.  The one that comes installed is 0.015″ thick.  The Shim Set gives you a 0.006″ and 0.009″ shim.

      Adjustable Air Nozzles & Jets (left) feature micrometer-type adjustment; Flat Super Air Nozzles and the High Velocity Air Jet (right) have replaceable shims to vary performance.
  • Function. Most of our Air Nozzles generate a high velocity air stream coming straight from its end.  We’ve also engineered some nozzles for specific applications:
    • Model 1144 2″ Super Air Scraper is our popular 2″ Flat Super Air Nozzle with a corrosion resistant scraper blade, making quick work of removing stubborn materials like tape, gaskets, labels, grease, paint, or sealant.  It’s particularly handy when installed on a Soft Grip Safety Air Gun with an appropriate length of pipe extension.
    • Back Blow Air Nozzles are made to clean out inside diameters or blind holes.  Three sizes are available for ID’s of 1/4″ to 16″.

If you’d like to find out more about how EXAIR Intelligent Compressed Air Products can help you get the most out of your compressed air system, 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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Unique Nozzle Application Eliminates Procedure for Tobacco Processing Facility

1006ss_3up_500

I recently worked on a unique application for EXAIR’s Back Blow Nozzle. Generally, these products are used to clean out chips, debris, and coolant from the ID of pipes or tubes. With (3) different sizes available to clean out IDs ranging from ¼”-16” it’s the ideal solution for cleaning out pipes where blowing forward into the pipe won’t work. They’re also available on the end of a Safety Air Gun with extensions up to 72” long, allowing you to get to hard to reach areas.

This particular application, however, was slightly different. The customer has a large machine that rotates a large drum to dry the tobacco, much like a standard clothes dryer. Inside of this drum is a “spray boom” with an angled top designed to prevent the tobacco from settling and sticking in large quantities. At the end of this “spray boom” are Atomizing Nozzles used to apply a cleaning solution after each drying process is completed at the end of the shift.  Unfortunately, the angled design didn’t work quite as well as they’d intended.

The customer needed a solution that could periodically clean off the boom while the drying was in operation. It wasn’t reasonable to do this at the end of the drying process once the majority of material had passed through. The accumulated tobacco on the boom was perfectly usable product and anything stuck after the cleaning operation would have to be thrown out as waste. In order to clean the boom and allow the stuck tobacco to remain as usable product, we needed an automated solution.

The customer installed (4) of the 1006SS Back Blow Nozzles situated around the boom to remove any stuck-on product during the drying process. The results spoke for themselves, at 90 PSIG it removed a 14” wide radius of material from the surface. By implementing the Back Blow Nozzle they were able to reduce waste and eliminate a daily 1-hour long cleaning process to remove stuck on material from the boom.

Just because it’s an outside-the-box application for one of our products, doesn’t mean it won’t work!! With EXAIR’s Unconditional 30-Day Guarantee, you can test any of our stock products out before committing to keep them. Reach out to an Application Engineer today if you have a unique application you’d like to discuss!

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

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