Know How Much Money You Can Save with EXAIR’s Efficiency Lab

 
Free testing. Verifiable data. EXAIR Efficiency Lab.

When it comes to buying new gear for any kind of outdoor hobby the research almost becomes a full-time job to decided what to get. When I’m hanging 200 ft. in the air off of a single rope, I want to make sure that my harness, rope, and all my other gear is top notch and not going to fail me as my literal life is hanging on the line. Sometimes it would be nice to have a professional climber standing there telling you all of the pros and cons, what they like and dislike about it, and weather it’s worth the buy. Outdoor gear is expensive and climbing equipment is no exception, in an ever-changing world of innovation new things are coming out every week and is just to hard for one person to keep up with.

Similarly, EXAIR has multiple product lines, many new products, and countless applications for our products. That is where our Application Engineers come in; as experts on our products and their applications we can provide in-depth knowledge on the various uses and expected outcomes. 

EXAIR’s Products in action

EXAIR has been making compressed air products since 1983, and have since created a culture of making high quality, safe, and efficient compressed air products. With this in mind we started the Efficiency Lab program for people to take advantage to test your current pneumatic blow-off device and compare it to an EXAIR Intelligent Compressed Air product. We will generate a detailed report on our findings and send it to you for your review. This free service provided to U.S. and Canadian companies allows people to test and look into possible upgrades and cost savings.

During my time as a project and process engineer at Valeo and Tyson I wish I had known about this service.  The Efficiency Lab allows you to look at what your current process is, whether it is an open-ended pipe or some other nozzle and have EXAIR compare it to an EXAIR product for free. Its like getting a free inspection of all your gear and having an expert help you find the best replacement if needed.

You may be wondering why we offer this service; it’s simple, compressed air can be expensive and we want to save you money. Not only are open ended pipes unsafe and can violate OSHA Standards on both dead-end pressure and noise level, but they also use a lot of compressed air. To operate an 1/8” open pipe you are looking at over $2000 a year for just one pipe; there isn’t a single plant that is just going to use one pipe. That is a lot of money that can add up over time, which could easily be saved by changing out what you are using.

The Efficiency Lab is quite simple to use. The simplest way is to contact us (my info below) and we can exchange the information needed to get your product into EXAIR. Once received, we will proceed. We will then calibrate the equipment and standardized procedures to test for noise level, air consumption, and force generated. Based off of this information we will recommend a similar product. Don’t be afraid, let us take care of the hard part of choosing which product is best for your application. If you cannot send any product in, use our  Product Efficiency Survey to provide as many details as possible. 

If you have any questions about compressed air systems or want more information on any of EXAIR’s products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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EXAIR’s Return on Investment For One Engineered Air Nozzle is Amazing!

Return on Investment (ROI) is a measure of the gain (preferably) or loss generated relative to the amount of money that was invested.  ROI is typically expressed as a percentage and is generally used for financial decisions, examining the profitability of a company, or comparing different investments.  It can also be used to evaluate a project or process improvement to decide whether spending money on a project makes sense.  The formula is shown below-

ROI
ROI Calculation
  • A negative ROI says the project would result in an overall loss of money
  • An ROI at zero is neither a loss or gain scenario
  • A positive ROI is a beneficial result, and the larger the value the greater the gain
1100group
Our catalog publishes most products’ performance and specification data for a compressed air supply pressure of 80psig.

Example – installing a Super Air Nozzles (14 SCFM compressed air consumption) in place of 1/4″ open pipe (33 SCFM of air consumption consumption) .  Using the Cost Savings Calculator on the EXAIR website, model 1100 nozzle will save $1,710 in energy costs. The model 1100 nozzle costs $42, assuming a $5 compression fitting and $45 in labor to install, the result is a Cost of Investment of $92.00. The ROI calculation for Year one is-

ROI2

ROI = 1,759% – a very large and positive value.  Payback time is only 13 working days!

If you have questions regarding ROI and need help in determining the gain and cost from invest values for a project that includes an EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer

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Video Blog: EXAIR’s Efficiency Lab

If you’d like to know how efficient (or not,) quiet (or not,) and effective (or not) your current compressed air devices are, the EXAIR Efficiency Lab can help.  For more details, we hope you’ll enjoy this short video.

If you’d like to talk about getting the most out of your compressed air system, we’d love to hear from you.

Russ Bowman
Application Engineer
EXAIR Corporation
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Gen4 Super Ion Air Knives Remove Pesky Dust from Crepe Paper Manufacturing Process

Paper Measuring Equipment

A paper manufacturer was having issues with their measuring equipment (reference photo above).  They were producing 6” (152mm) wide crepe paper which is very thin and dusty.  As it would pass through the machine, a real-time measurement of basis weight and moisture content was being performed.  The basis weight of the sheet was around 14g/m2 which is like facial tissue.  The machine was giving false errors in the basis weight measurement.  As they opened the device, they noticed dust particles on the optical lens.  Because the basis weight was so small, any dust would cause a false reading.  They contacted EXAIR to see if we could help with their problem.

With a dry fibrous material like crepe paper, static can be a big issue.  Static has a strong force that can cause small fragments to “stick” to surfaces.  As you can see in the photo, the paper material is sticking to the sides and lens of the measuring device.  For this application,  I recommended two pieces of the model 112206 Gen4 Super Ion Air Knife Kits.  The Gen4 Super Ion Air Knife is uniquely designed to have two functions; remove static and blow off dust.  The Gen4 Ionizing Bar creates both positive and negative ions to remove any type of static charge.  The Super Air Knife creates a laminar air stream to carry the ions and also generate an even blowing force to remove the dust particles from the surface.  With this combination, it becomes a very effective non-contact way to remove the contamination.  This was an important requirement as the crepe paper is very thin and could break very easily.  They were able to mount one Super Ion Air Knife above and below the paper in order to blow the dust particles in a counter-flow direction.  This would keep the particles from entering the measurement device.

Super Ion Air Knife Kit

The Super Ion Air Knife Kit includes the Super Air Knife with a Gen4 Ionizing Bar attached.  The kit also includes a power supply, filter, regulator, and a shim set.  The power supply is specifically designed for the Gen4 Static Eliminators.  The Gen4 Super Ion Air Knives use the high voltage from the power supply to generate enough ions to remove static from the paper at a running speed of 49.5 ft/sec (15m/sec).  The filter will remove any contamination and liquid water from the compressed air system before it enters the Super Ion Air Knife.  This is important to keep the product clean.  The shim set is a set of three different shims with a thickness of 0.001” (0.025mm), 0.003” (0.076mm), and 0.004” (0.1mm).  They are used to dramatically change the blowing force from the stock shim at 0.002” (0.05mm) thick.  Being that the paper was extremely thin, they opted to put the 0.001 (0.025m) thick shim inside the Super Ion Air Knife.  With the regulator in the kit, the customer could “dial” in the correct amount of force to keep the machine running optimally without breaking the delicate paper.

When the customer installed the Gen4 Super Ion Air Knives just before the entrance into the measuring device, the air stream was able to carry the ions to neutralize the static and to remove the dust from the paper surface.  The system was now able to make accurate measurements without disruptions.

For this customer above, the Gen4 Super Ion Air Knives made their system run accurately and consistently by removing any pesky dust particles.  If you have an optical device that needs to stay clean, you can contact an Application Engineer to review your application.

John Ball

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