Optimize Your Intelligent Compressed Air® Products with EXAIR’s Accessories

EXAIR offers a wide variety of various accessories that can help you to better control and fine-tune any of your compressed air operated products. Most of EXAIR’s line of Intelligent Compressed Air Products have no moving parts and require no maintenance. The caveat to the “no maintenance” aspect is proper filtration at the point of use. Many products have very tight orifices that could get clogged from any contaminants such as particulate, condensate, and lubricant. EXAIR recommends point of use filtration to be installed just upstream of any EXAIR Product for this purpose.

EXAIR has a line of Automatic Drain Filter Separators and Oil Removal Filters, available from stock, to make sure the quality of your air supply is sufficient for proper operation of any EXAIR product. Particulate filters remove any suspended solids from the airstream, ensuring the tight orifices in the products remain free of debris. If your system has residual oil, this should also be removed with a coalescing filter. Check out this short video from my colleague, Brian Farno, that demonstrates these filters in action:

Controlling your compressed air pressure at the point of use is an excellent way of minimizing your compressed air usage. Pressure regulators are available to control the air pressure within the system and throttle the appropriate supply of air to any pneumatic device. As the last of the six steps to optimizing your compressed air system, controlling air at the point of use can often be overlooked. using them to minimize your pressure can result in dramatic savings to your costs of compressed air. As pressure and flow are directly related, lowering the pressure supplied results in less compressed air usage. EXAIR recommends operating your Intelligent Compressed Air Products at the minimum pressure necessary to achieve a successful application. If you notice a desirable result at a pressure of 60 PSIG, or even less, there’s no need to run full line pressure. In-line point of use pressure regulators are the simplest and most reliable way to allow you to dial down to the pressure to any compressed air operated product.

Taking this idea of minimizing air usage one step further, you can achieve even greater savings by simply turning the air off when not needed. The most basic option for turning off the air supply is a simple manual valve. EXAIR offers a range of various sized valves to allow you to do just that.

This process can also be automated as well. If you’d like to automate the control of your blowoff, EXAIR offers solenoid valves that can tie into your existing PLC and eliminate unnecessary air usage. For those that want a solution ready to go right out of the box, EXAIR’s Electronic Flow Controller utilizes a photoelectric sensor and solenoid valve tied to a timer that allows you to shut off the air supply when a part or component is not present. This can lead to dramatic air savings in many applications where parts are traveling along a conveyor.

Once you’ve selected an engineered compressed air nozzle for your blow off application, you’ll likely need a solution to mount and position it as well. Here’s where EXAIR’s Stay Set Hoses and Magnetic Bases come into play. EXAIR’s Stay Set Hoses are available from 6”-36” in length with ¼ NPT male threads on each end, or a ¼ NPT male on one end and 1/8 NPT female on the other. The Stay Set Hoses are rigid and allow you to maintain precise positioning of the blow off nozzle. The hoses have “memory” and will not creep or bend. They’re easily repositionable as well, making them an ideal solution for applications that may require frequent repositioning due to varying parts.

In addition to the Stay Set Hoses, EXAIR also has Magnetic Bases available as well. The powerful magnet permits both horizontal and vertical mounting. A manual valve is also included that will allow you to vary the force and flow. Magnetic bases are available with one or two outlets and can be combined with any of our nozzles and Stay Set Hoses to create your own customized blowoff system.

Regardless of your application, EXAIR has the products available from stock to help optimize your processes. These accessories allow you to help optimize the use of your blowoff products and ensure reliable, repeatable performance. If you’d like to discuss an application, give us a call.

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

Control Air Pressure at the Point of Use with EXAIR’s Pressure Regulators

In any application necessitating the use of compressed air, pressure should be controlled to minimize the air consumption at the point of use. Pressure regulators are available to control the air pressure within the system and throttle the appropriate supply of air to any pneumatic device. As the last of the six steps to optimizing your compressed air system, controlling air at the point of use can often be overlooked. To help you achieve this, EXAIR offers a line of point of use pressure regulators to make sure you’re operating at the optimal pressure for your application.

Pressure regulators utilize a control knob that is turned to either increase/decrease tension on a spring. The spring puts a load on the diaphragm which separates internal air pressure from the ambient pressure. Typically made of a flexible rubber material, these diaphragms react very quickly to changes in the air supply. By either increasing or decreasing the flow of air based on the load on the diaphragm, downstream pressure remains fairly constant.

Regulator Internal

While one advantage of a pressure regulator is certainly maintaining consistent pressure to your compressed air devices, using them to minimize your pressure can result in dramatic savings to your costs of compressed air.

As pressure and flow are directly related, lowering the pressure supplied results in less compressed air usage. EXAIR recommends operating your Intelligent Compressed Air Products at the minimum pressure necessary to achieve a successful application. If you notice a desirable result at a pressure of 60 PSIG, or even less, there’s no need to run full line pressure. In-line point of use pressure regulators are the simplest and most reliable way to allow you to dial down the pressure to any compressed air operated product. For example, a Model 110012 Super Air Knife will consume 42 SCFM when operated at 100 PSIG. When the pressure is reduced to 60 PSIG, this drops to just 27.6 SCFM. That’s a 34% reduction in compressed air usage, just by dialing down the pressure at the point of use!

When selecting a pressure regulator for your application, it’s critical that it is appropriately sized to supply adequate volume to the point of use devices downstream. Doing so, minimizes the risk of experiencing “droop”. Droop is a decrease in outlet pressure from the specified setting due to an increase in flow rate.  Droop occurs when the demand at the point of use exceeds the volume of air that the regulator can supply. By ensuring the pressure regulator is rated to deliver sufficient volume of air, you’ll reduce the chances of experiencing droop. EXAIR offers pressure regulators in kits along with many of our products, we’ve done the hard part for you and made sure they’re properly sized!

If you’re looking for ways to help lessen the demand on your compressor, EXAIR’s team of Application Engineers will be happy to help. Reach out to us via phone, chat, or e-mail and see for yourself just how easy it can be to start saving compressed air!

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

EXAIR Super Air Knives: Controlling the Force

EXAIR has been manufacturing Intelligent Compressed Air® products since 1983.  In the beginning, the Standard Air Knives and Full Flow Air Knives were very effective at that time.  But as leaders in this market, EXAIR did not want to stop there.  We were able to engineer a more efficient and more powerful air knife, the Super Air Knife.

Super Air Knife has 40:1 Amplification Ratio

Bernoulli’s principle explains how a high velocity fluid can generate a low pressure.  The EXAIR Super Air Knife creates a high velocity air stream to produce a low pressure to entrain ambient air.   What does this mean for you?  It will save you much money by using less compressed air.  The mass of the ambient air is added into the air stream to give a strong blowing force.  The Super Air Knife has an amplification ratio of 40:1. For every 1 part of compressed air, 40 parts of ambient air is drawn into the blowing air stream.  Ambient air is free, and compressed air is expensive.  EXAIR was able to engineer a design to use the Bernoulli’s principle to make one of the most efficient air knives in the market place.    In this blog, I will discuss how you can change the air usage and force of the EXAIR Super Air Knives.

We manufacture and stock the widest range in lengths and materials.  To start, EXAIR has Super Air Knives ranging from 3” to 108” (76mm to 2,743mm) in three different materials; aluminum, 303 stainless steel, and 316/316L stainless steel.  There is no-one else in this industry that can manufacture to those lengths.  EXAIR also offers Super Air Knives in PVDF material with Hastelloy hardware for chemical resistant applications from 3” to 54” (76mm to 1,372mm).  Depending on the application requirement, temperature, chemical resistance, and OSHA and FDA regulations, we probably will have one on the shelf for you.  If EXAIR does not have it, we can make special air knives in different lengths and materials to best fit your application.

Pressure Regulators

To adjust the force and air usage a Pressure Regulator is a very helpful tool. The regulator would be considered a fine adjustment for the Super Air Knife.  With the laminar flow, the force is very consistent across the entire length; so, you can “dial” in the exact force.  EXAIR always recommends to use the least amount of pressure to “do the job” because this will save you even more money.  For the coarse adjustment, EXAIR Super Air Knives have replaceable shims.  So, you can increase or decrease the gap to get a variety of force ratings.  The Aluminum version uses colored plastic shims for visual verification.  They come stock with a 0.002” (0.05mm) red shim installed.  We have other thicknesses in our Shim Sets which includes a 0.001” (0.03mm), 0.003” (0.08mm), and a 0.004” (0.10mm) colored as amber, green, and tan respectively.

The Stainless Steel Super Air Knives come with a stainless steel shim for higher temperatures and chemical resistance.  Stock units have the 0.002” (0.05mm) thickness as well.  The Shim Sets come with three additional 0.002” (0.05mm) shims to stack.  EXAIR does have the ability to manufacture other thicknesses in stainless steel.  Similarly, the PVDF Super Air Knives use a PTFE shim for maximum chemical resistance.  It is also 0.002” (0.05mm) thick, and there are three more shims in the Shim Set.

This unique feature of using shims allows for the most flexibility in creating forces for different applications ranging from a blast to remove rocks from a conveyor to a breeze for light duty work.

We can include the pressure regulator, filter, and Shim Sets in our standard kits.  It will make our Super Air Knives a more complete system that is properly sized.  With the today’s cost in making compressed air, it is important to do it as efficiently as possible.  And with the Pressure Regulator and Shim Sets available, you can control the blowing force and air usage.  From now until December 31st, EXAIR is having a promotion.  You will receive a model 1210 Safety Air Gun for free, a $91.00 value, with qualified purchases.  (Check it out HERE).  If you have any questions about the Super Air Knife or if you would like to discuss an application, you can contact an Application Engineer at EXAIR.   We will be glad to help you.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Compressed Air: Only as Intelligent as Your Accessories

How often have you seen a compressed air system functioning at 100% efficiency? Do you have the right accessories to provide a source of clean air at the proper pressure? Even with the right accessories, have they been maintained in good working order? Chances are that some of your components are in fact in need of attention such as a clogged filter, improper regulator or maybe undersized hoses. Your air compressor is only as intelligent as the weakest component in your system.

This is why you need to make sure all of your EXAIR accessories are properly fitted and located in the most efficient locations. Your compressor is capable of producing compressed air but your accessories will allow it to function the way it is meant to function. Using accessories and using them in the right manner is the intelligent choice, it will minimize your maintenance while increasing your energy efficiency for the life of your compressor. Let’s review a few of the most important compressed air accessories you should consider.

Filter Separators: Filters remove and separate water, dirt and scale from your compressed air system to keep your air clean and output pure. Clean air keeps your air products and machines more efficient and reduce the frequency of maintenance. Filter Separators will accumulate particulate matter naturally so they will need cleaned and/or replaced filter elements regularly depending on your operating environment. EXAIR provides Filter Separators and recommend they be installed prior to an Oil Removal Filter, pressure regulator or valve.

Filter Separators

Oil Removal Filters: Many air compressors use oil to lubricate therefore the risk of oil in your air lines is imminent. Although oil may not affect the compressed air system itself it can become a problem with products which do not require oil and have small air gaps. It can also be problematic if oil is blowing on to packaging or the final product. Keep this in mind and remember that oil should be removed from compressed air lines in certain instances. EXAIR’s oil removal filters will remove oil and solid particulate found in many compressed air systems.

Pressure Regulators: Regulators adjust the air pressure being supplied by your air compressor to the level that you require at the point of use. For instance your compressor generates 150 PSI but your compressed air product only requires 80 PSIG, the regulator can adjust the pressure to the desired setting and also relieve undue pressure on fittings, hoses and tools. Reducing pressure at the end-use product will also reduce the air consumption. Almost every compressed air application will use tools with varying pressure ratings making EXAIR Pressure Regulators a must-have accessory.

Hoses & Fittings: Hoses and fittings wear with time. Common issues are kinking, bending, leaks and contaminants, they should be checked often and replaced when required. Another common problem with hoses is that they are either too long and not as efficient or too short which can cause your employees reduced productivity. EXAIR offers STAY SET Hoses, Conveying Hose, Coiled Hoses and Compressed Air Hoses of different sizes and lengths. Our selection of compressed air fittings insures you can get all you need from one location.

Receiver Tanks: The use of receiver tanks can improve your overall system efficiency. Storage receivers can be placed near equipment that consume short duration of high flows of compressed air that might cause localized low pressure. EXAIR’s 60 Gallon Receiver Tank placed near the point of use can smooth out the high flows so as not to cause the start of an extra air compressor or cause localized low pressure.

If you would like more information regarding how proper use of EXAIR’s accessories can make your compressed air consumption more intelligent please contact me or any of our qualified Applications Engineers to discuss your applications.

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