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.
EXAIR manufactures a variety of nozzles that are OSHA safe, high quality, and very efficient. In this blog, I would like to discuss the features and benefits of the EXAIR Flat Super Air Nozzles and how to build a system to fit your application.
The EXAIR Flat Super Air Nozzles are manufactured to blow a wide forceful stream of air. Their patented design creates a high velocity, laminar air stream with minimal air consumption and low noise. They come in two sizes; 1” (25mm) and 2” (51mm), and EXAIR stocks them in two different materials, zinc-aluminum alloy and 316 stainless steel. With a metal construction, breakage is not a concern and performance is not sacrificed even in the harshest of environments. I have seen many plastic flat nozzles that were broken in applications. The noise level was loud, and compressed air was wasted. The unique patented shims inside the EXAIR Flat Super Air Nozzles give three improvements to the design and function. First, they come in different thicknesses to create a wide range of forces. In conjunction with a regulator, you can “dial” in the correct amount of force from a breeze to a hurricane without overusing your air compressor. The patented design also allows an even force across the entire width of the air nozzle. Lastly, they help to entrain the free ambient air; so that less compressed air is required. The high efficiency design will save you money. The EXAIR Flat Super Air Nozzles are effective in uniform blowing; efficient; and superior in quality and durability. You can watch a video blog on the importance of using our patented shim.
To show the different types and styles of Flat Super Air Nozzles that EXAIR stocks, you can correspond to the model number make-up sheet below.
To give force adjustments to the individual Flat Super Air Nozzles, EXAIR offers a way to change the thickness of the shim to better suit your application. You can increase or decrease the force of the nozzle by just removing two screws and changing the shim inside. This is a unique feature as most competitive flat nozzles do not allow you to do this. EXAIR offers different thicknesses of the patented shims in our Shim Sets. The chart below corresponds the appropriate Shim Set to the Flat Super Air Nozzle.
What can make the Flat Super Air Nozzles even better? More flexibility. The Stay Set Hoses can add that flexibility to the Flat Super Air Nozzles. They are designed to manually position the Flat Super Air Nozzle to accurately target the air stream. They allow maneuverability to locate the nozzle at different heights or angles; and once positioned, the Stay Set Hose will hold the nozzle in place. They come in different lengths from 6” (152mm) to 36” (914mm). We carry two different styles of connections to adapt to any of the Flat Super Air Nozzles. You can select the different lengths of Stay Set Hoses (SSH) to the Flat Super Air Nozzle by the model number make-up sheet below.
To build your system even further, EXAIR also can offer a Magnetic Base to your Stay Set Hoses and Flat Super Air Nozzles. The Magnetic Base has a powerful magnet on the bottom to securely attach the blow-off nozzles vertically or horizontally. This feature is great if you need to move the nozzles to different areas in your application. EXAIR manufactures a one-outlet and a two-outlet design. Each outlet has a ¼ turn valve to manually turn on or off the nozzle and only require one air supply inlet. To add this product to the Flat Super Air Nozzle with the Stay Set Hose, you can use the model number make-up sheet below.
With the EXAIR Flat Super Air Nozzles, you can take advantage of the durability, safety, and efficiency for your blow-off device. In addition, you can build a system that will best suit your requirements. You can add different lengths of Stay Set Hoses and/or different Magnetic Bases. With these combinations grouped into one model number and in stock for quick shipments, it makes it simple to purchase from EXAIR. Just to let you know, they also come with a 30-day unconditional guarantee to try them out. If you need any help in building your optimum blow-off system, you can speak to an Application Engineer at EXAIR. They will be happy to assist you.
To begin with all EXAIR ASN’s are made from SS for durability and liquid compatibility. As its name implies it creates a flat fan pattern that exit’s the nozzle perpendicular to the air & liquid inlets as shown above. This unique design lends itself nicely to applications with space constraints. The AD1010SS is the ideal choice for coating the inside of enclosures or ductwork. It is compatible with liquids up to 300 centipoise and the air and liquid are mixed in the air cap. The AD1010SS is designed for pressure fed applications not requiring independent air and liquid control. What is meant by that statement is that if you vary either the air or liquid pressures you change the spray pattern and volume. See the chart below for clarification on pressures, volumes and spray patterns.
Next we will look at EXAIR model AT1010SS internal mix 360° hollow circular pattern ASN.
The AT1010SS internal mix 360° nozzle is designed for applications where the spray pattern must be oriented away from the nozzle in all directions. 360° nozzles are ideal where a smooth, even coating is needed on the ID of a pipe or similar ductwork. It is compatible with liquids up to 300 centipoise and the air and liquid are mixed in the air cap. The AT1010SS is designed for pressure fed applications not requiring independent air and liquid control. As above if you vary either the air or liquid pressures you change the spray pattern and volume. See the chart below for clarification on pressures, volumes and spray patterns. They also work great for operations where a mist over a broad area is needed, such as dust suppression, humidification and cooling. See the chart below for clarification on pressures, volumes and spray patterns.
The generation of compressed air accounts for approximately 1/3 of all energy costs in an industrial facility. According to the Compressed Air Challenge, about 30% of that compressed air is lost through leaks. This means nearly 10% of your facility’s energy costs are simply wasted through poor connections, faulty air valves, improper installation, etc. In addition to simply wasting money, compressed air leaks can also contribute to a variety of other operating losses. A leak can cause a drop in system pressure. When this occurs, end users may not operate as efficiently, having an adverse effect on production. This same drop in system pressure will also cause the equipment to cycle on/off more often, shortening the life of your compressor and other equipment. If the leaks cause an issue in supply volume, it may lead to the belief that more compressor capacity is necessary, further increasing your operating costs.
To put leaks in perspective (assuming energy costs of .10/ kWh), the Compressed Air Challenge states this:
A $200/year leak cannot be felt or heard
A $800/year leak can be felt, but not heard
A $1,400/year leak can be felt and heard.
If you walk through your facility, how many leaks can you hear?
We know that a large portion of the compressed air is being wasted, but what do we do about it? A proper leak prevention plan is the key to success. Since these leaks are impossible to see and some cannot even be heard, you need a tool to help assist you. EXAIR’s model 9061 Ultrasonic Leak Detector is the right tool for the job. When compressed air leaks through a pipe, it creates an ultrasonic signature due to turbulence. While this sound is not always detectable by the human ear, this meter will allow you to locate leaks up to 20’ away.
The first step will be locating the leaks using an Ultrasonic Leak Detector and tagging them throughout the facility. Don’t let this overwhelm you!! If you have a larger facility, break it up into sections that can be completed in 1 day. This will allow you to decide which areas of the plant should be looked at first. Once you’ve located and tagged all of the leaks, rate them under two separate criteria so that you can prioritize what to fix first. Rate them based on the difficulty that it will take to fix them and also by the severity of the leak. Those that are severe yet easy to fix would make sense to begin fixing first. Those that may require a period of shutdown can be planned to fix at a more appropriate time.
When you’ve had the opportunity to fix them, don’t just forget about it. When new piping is installed, new lines are added, or anything involving compressed air is installed there is the potential for new leaks to develop. Set this as one of your regular PM activities and complete your own compressed air audit once a year. Implementing the process and maintaining it are the keys to your success.
If you have questions about developing a leak program or how to use the Ultrasonic Leak Detector, give us a call. An Application Engineer will be happy to help with the process and recommend additional methods to save on your compressed air supply.
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 personal 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
Gain from investment could include many factors, such as energy savings, reduced scrap savings, cost per part due to increased throughput savings, and many more. It is important to analyze the full impact and to truly understand all of the savings that can be realized.
Cost of investment also could have many factors, including the capital cost, installation costs, downtime cost for installation, and others. The same care should be taken to fully capture the cost of the investment.
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 $37, assuming a $5 compression fitting and $50 in labor to install, the result is a Cost of Investment of $92.00. The ROI calculation for Year 1 is-
ROI = 1,759% – a very large and positive value. Payback time is only 13 working days.
Armed with the knowledge of a high ROI, it should be easier to get projects approved and funded. Not proceeding with the project costs more than implementing it.
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.