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-
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
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-
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.
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.
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.
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.
Late last year I received a call from a customer that was using EXAIR Super Air Knives to create an air curtain that protected the lens on their Robotic Welders from weld spatter. The EXAIR Super Air Knife accomplished this by virtue of its design to deliver a uniform sheet of laminar air flow across its entire length. While this greatly improved the life of the welder lens and reduced maintenance time, further improvements were needed.
The event that triggered this was the challenge they received from their customer (one of the big 3 automobile manufacturers) to increase their output of welded seat frames by 50%. While the EXAIR Super Air Knives greatly reduced lens maintenance the consensus was further improvements would facilitate the goal of increasing output 50% .
This started the discussion on the possibility of using the EXAIR Super Air Wipe, even though it is primarily used for drying/cleaning of long continuous flow products its airflow pattern (see illustration below) was able to direct the weld splatter down and away from the lens. This ultimately proved to be more effective at protecting the lens than the laminar air curtain provided by the EXAIR Super Air Knife.
The installation of the EXAIR Super Air Wipes started on 12/16/2017 and was completed on 12/23/2017. The original production rate was 480 pair of SUV rear seat frames per day running 3 shifts 24/6.
After the Installation of the EXAIRSuper Air Wipes, they had improved the production rate to 750 pair/day running 3 shifts 24/5 days per week. That equates to a productivity increase of 156%, far exceeding the goal of 50%!
Before using the EXAIRSuper Air Wipe their maintenance department would clean the Cover Slide on the Laser Welding Head – 3 times per day at approximately 20 min x 3x daily x 6 days / week 6 hours / week. “With the EXAIRSuper Air Wipe we found that we can weld for 10 days before cleaning the Cover Slide” says the customer.
Each Cover Slide costs $195 and those were being replaced weekly, it was a pleasant surprise to find out that only a small amount of dust collects on the Cover Slide now, which is cleaned off in less than a minute
In 10 weeks of Operation they have not replaced a single Slide since the EXAIRSuper Air Wipe has nearly eliminated pitting from the weld spatter.
Also, Cleaning of the Slides is now performed on Saturday’s at the leisure of the maintenance team and not under the strain of production time. The Labor Rate for Maintenance is $75/hour x 6 hours/week = $450 X 50 weeks/year $22,500 plus the cost of the replacement windows at $195 each x 25 weeks = $4,875 savings per year. Total savings after implementing the EXAIR Super Air Wipe = $27,375 per welding machine!
With the maintenance & replacement cost savings alone it is an easy calculation to make on the purchase of the EXAIRSuper Air Wipe’s. That figure is not counting the productivity increase of 156% which allowed them to meet their customers delivery schedule and reduce overtime!
If you would like to discuss increasing the efficiency of your compressed air usage, quieter compressed air products and/or any EXAIR product, I would enjoy hearing from you…give me a call.