E-Vac for Epoxy Recycling

Recently, a manufacturer of custom magnetics called in about a special application. In the manufacturing of certain electronic systems, a very expensive, thick epoxy glue is used. They were exploring ways to be able to collect the excess after application.  They had used a system in the past and were looking to replicate it.  The previous system had an old boxy vacuum generator, and they asked us if we could provide a vacuum source that matched the performance specifications but in a more compact design.  After researching the specifications and a comprehensive comparison, we could offer the EXAIR model 810013 Inline E-Vac, generating up to 27 ” Hg of vacuum.  A basic sketch of the design concept is shown below-

Capture

By using the model 810013 to create a vacuum within the chamber, a strong suction can be generated at the tube inlet, strong enough to draw in the excess epoxy. The glue can be collected in the chamber for recycling and reuse, and because of the design, the glue does not pass through the E-Vac and cause any issues with build up or blockage that would hinder the performance, leading to the need to clean the unit.

In-LineE-VacFamily

The Many Sizes of E-Vac Models Available

EXAIR manufactures E-Vac’s for both porous and non-porous applications, as well as a line of Adjustable E-Vac Generators.  Smallest units use only 1.5 SCFM of 80 PSIG compressed air and the largest Adjustable E-Vac unit can pull 81 SCFM of air at open draw and 15″ Hg vacuum level setting.  With a wide range of sizes and types, there is a model available to meet your vacuum generation needs.

As a side note – the EXAIR Reversible Drum Vac, High Lift Reversible Drum Vac, Chip Trapper, and High Lift Chip Trapper all use this same basic principle of applying a vacuum to a chamber, but on a much larger scale, to turn a 5, 30, 55 or 110 gallon drum into an industrial liquid vacuum system.  The vacuum generating unit is of a different design, made specifically for the Industrial Housekeeping Products.

To discuss your process and how an EXAIR Intelligent Compressed Air Product can solve your toughest application issues, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Twitter: @EXAIR_BB

 

It’s Earth Day! Do Your Part Tomorrow and Throughout the Year.

Saturday, April 22nd marks the 47th annual Earth Day and it will be observed in over 193 countries.  For EXAIR, this year marks our 34th year helping compressed air users save compressed air energy and electrical resources. It is also another year that we continue to focus on manufacturing our products with minimal impact and doing our part to help protect our planet. We are proud to manufacture efficient products, implement processes and programs throughout our facility to help use our resources wisely and recycle everything we possibly can. 

First and foremost, we manufacture and sell Intelligent Compressed Air Products that are specifically designed to reduce the use of compressed air throughout facilities.  On top of that, when you purchase an EXAIR product it will arrive in fully recyclable packaging and, in most cases, is made from a material that will be recyclable should it reach a point it is no longer useful.

EXAIR recycles 100% of the metal scrap from our machining processes, which equates to 6.5 tons. Our cardboard and mixed paper products are also recycled 100%. Of the waste we place into our trash dumpsters – 80% is recycled and 20% is sent to the landfill.  The paper products even get down to all of paper towels that are used and all the scratch paper that the office utilizes.   In total, EXAIR recycled tons 36.6 tons of paper and cardboard in 2016 which equates to 80% of the solid waste we produce is recycled.  We focus on more ways to improve this percentage every year (I am still trying to convince everyone to reuse the coffee and filters in the coffee maker).  Something about it got so thick you needed a spoon to “drink” your coffee.

Another waste reducing factor that has proven to work out well for EXAIR is asking every customer if they accept digital invoices rather than requiring them to be printed and mailed.   Thanks to our wonderful customers we have been able to eliminate 91% of all printed and mailed invoices which helps to reduce our resources used as well as the amount of materials that are possibly turned into solid wastes at their facilities. This also prevents the gas and vehicles necessary to deliver all of these invoices by mail. 

We also generate and recycle our wastewater for reclamation – in 2016 we recycled 1008 gallons. 

To get back to what EXAIR products have done to help reduce waste, we were also able to optimize our own compressed air system by eliminating air leaks and have saved 1 million cubic feet of compressed air.  We have also utilized our very own Chip Trapper Systems in our manufacturing areas and extended the water soluble coolant life from 6 weeks per changeover to 6 months per changeover. Keeping our coolant clean allows us to minimize the total amount of wastewater we recycle each year. 

On top of all the efforts above, we also continue to maintain RoHS compliance on all electronic products, as well as actively track our supply chains to ensure no Conflict Minerals are being sourced from the Democratic Republic of Congo.

If you have any questions on how we can help your facility reduce their use of compressed air or why we continue to reduce our wastes and increase our recycling efforts, contact us.

To see our full Sustainability Plan follow this link.

Enjoy Your Weekend,
EXAIR Corporation

Thank you to Kate Ter Haar for the Happy Earth Day image. Creative Commons License. 

EXAIR & Earth Day

In case you didn’t see our latest E-News, sign up here if you don’t get them, we talked about Earth Day.   April 22nd marks the 46th annual Earth Day and it will be observed in over 193 countries.  This year also marks another year that we continue to focus on manufacturing our products with minimal impact and doing our part to help protect our planet.  So what kind of things does EXAIR do in order to ensure we help?  A few of the ways are listed below with a special addition last.

First and foremost, we manufacture and sell Intelligent Compressed Air Products that are specifically designed to reduce the use of compressed air throughout facilities.  On top of that, when you purchase an EXAIR product it will arrive in fully recyclable packaging and, in most cases, is made from a material that will be recyclable should it reach a point it is no longer useful.

We also recycle 100% of the metal scrap from our machining processes, which equates to 6.5 tons. We also recycle also cardboard and mixed paper products.  The paper products even get down to all of paper towels that are used and all the scratch paper that the office utilizes.   In total, EXAIR recycled tons 36.6 tons of paper and cardboard in 2015  which equates to 80% of the solid waste we produce is recycled.  We focus on more ways to improve this percentage every year, so far some of the team hasn’t liked my idea of reusing the coffee and filters in the coffee maker.  Something about it got so thick you needed a spoon to “drink” your coffee.

Another waste reducing factor that has proven to work out well for EXAIR is asking every customer if they accept digital invoices rather than requiring them to be printed and mailed.   Thanks to our wonderful customers we have been able to eliminate 91% of all printed and mailed invoices which helps to reduce our resources used as well as the amount of materials that are possibly turned into solid wastes at their facilities.

To get back to what EXAIR products have done to help reduce waste, we were also able to optimize our own compressed air system by eliminating air leaks and have saved 1 million cubic feet of compressed air.  We have also utilized our very own Chip Trapper Systems in our manufacturing areas and extended the water soluble coolant life from 6 weeks per changeover to 6 months per changeover.  This has allowed us to reduce the waste-water to a mere 600 gallons for 2015.

On top of all the efforts above, we also continue to maintain RoHS compliance on all electronic products, as well as actively track our supply chains to ensure no Conflict Minerals are being sourced from the Democratic Republic of Congo.

SavingSpecies

The final effort which we have added this year is a recycling program we are performing in our own office.  Through the help of our local Cincinnati Zoo and Botanical Gardens and their Project Saving Species, we are recycling cellphones and other personal electronic devices to benefit both local and worldwide efforts.  The money raised by these recycled devices will go to protecting the Lowland Gorilla habitat in the Congo and to help our own Miami University to provide education to the citizens of the Congo.

If you have any questions on how we can help your facility reduce their use of compressed air or why we continue to reduce our wastes and increase our recycling efforts, contact us.

To see our full Sustainability Plan follow this link.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

 

 

Life Hacking = Better Easier Life. So What Happens When You Hack Compressed Air?

The birth of the internet and personal computer brought to light a new form of hacking.  For many years now hacking has been considered a negative action, even criminal.  However, within the past several years the term lifehacking has come to mean a process of bettering your life through tips and tricks.  There are entire blogs and TED talks about life hacking, so that has gotten me thinking of how can EXAIR hack your compressed air system and turn it into a life hack?

All of our products are designed and engineered to make your life easier and better.  The best product I can think of to demonstrate this is our Super Air Knife With Plumbing Kit Installed.  This is an option for any of our Super Air Knives which are longer than 24″ that makes installation even easier on your end.  The plumbing kit has already connected air to each port on the Super Air Knife so all you have to do is plumb air to a single port at the end of the kit assembly.  See the picture below for a better idea.

Alumina dust 3 PKI

Another item that has helped many customers is our Chip Trapper System.   This is essentially a modified or hacked Reversible Drum Vac System which  adds the benefit of filtering the liquid you are sucking up to a 5 micron level.  (Other filter levels/sizes available.) This means you can make your cutting fluid last longer and cut that rancid coolant smell in your machine shop down because the bacteria in the coolant doesn’t have any solids to live upon.  This also means that you won’t be giving your coolant reclamation company any of your valuable solids so you keep more of your scrap profits.

So if you are looking for a way to make your life easier while you are working with compressed air, let us know, we’ll see how you can hack your compressed air applications.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Sustainability – Fact or Fiction

As the world goes eco-friendly it’s not clear how much environmental good will come from all the green products consumers are buying. Many companies peddle new or improved green products through their marketing campaigns, but it pays to look beyond the product pitches and into how the company behaves.

It’s refreshing to work for a company that is really walking the talk. EXAIR’s sustainability plan has real and quantifiable achievements.

  • Our variable speed drive air compressor reduced our electrical consumption by over 4,000 kWh in the past year compared to a conventional air compressor
  • Through a leak detection and mitigation program, one million cubic foot of compressed air per yer was saved
  • Migrating our customers to electronic delivery of invoices reduced traditional postal service mailed copies by over 50% and a 67% reduction in  printed paper pages
  • Most shipments use recycled Kraft paper with a perfect “green score ” of 360
  • Fresh water consumption was reduced through a coolant management program that extends usable life of water-soluble coolant from six weeks to six months.
  • Natural gas consumption was reduced by installing programmable thermostats wherever possible to match heating and cooling cycle with facility usage patterns
  • Solid waste/trash was reduced by 88% through and expanded recycling program
  • All metals, wood, waste water, cans, and plastics are 100% recycled

Do you want to improve your sustainability scorecard by reducing compressed air consumption?  Give our application engineers a call and they will be happy to assist you. They can be reached at 1-800-903-9247

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363
Web: http://www.exair.com
Twitter: http://www.twitter.com/exair_jp
Facebook: http://www.facebook.com/exair

EXAIR Receives Honorable Mention in Green Manufacturer Product Innovation Award

EXAIR’s model 1126, 1″ Flat Super Air Nozzle received an honorable mention from Green Manufacturer magazine for the 2013 Product Innovation Awards. This competition was open to technology developers and manufacturers who have introduced new products designed to ensure environmental sustainability between January 1, 2012 and April 1, 2013. Green Manufacturer magazine includes a diverse range of products from biological building materials to welding tools, each with a unique set of qualifications and applications.

The competition focuses on the greenness of the product and how sustainably it is manufactured, as well as the ecopractices of the company. The claims were verified through judging which relied on third party testing and certification, reports to published databases, provision of specific metrics/quantitative information, and customer testimonials with quantitative data.

IMG_3206

The award with the 1″ Flat Super Air Nozzles and shims

Our engineered air nozzles, when compared to open blow off or traditional commercial nozzle designs, reduce compressed air consumption and the associated costs of producing compressed air. The lower compressed air volume required from EXAIR’s engineered air nozzles results in less electricity to generate the compressed air. Engineered air nozzles also reduce noise pollution better than traditional solutions and reduce noise exposure levels for personnel.

The model #1126, 1″ Flat Super Air Nozzle is available in a zinc/aluminum alloy suitable for most environments or 316 stainless steel when a higher level of corrosion resistance is necessary. The zinc/aluminum alloy used for this nozzle generally requires less energy
than similar materials to transform into finished products, release no pollutants and no toxic residues during the work cycle, and are fully recyclable at the end of their useful lives.

EXAIR’s whole line of Flat Super Air Nozzles also utilize an internal shim which restricts large amounts of compressed use. The design entrains additional surrounding air in order to provide added volume and force for each application.

EXAIR also takes responsibility for our own processes and manufacturing facility by adhering to our own sustainability plan. This plan helps us reduce waste, recycle more material, reduce energy consumption, reduce water consumption, and keep our employees informed and responsible.

Thanks to Green Manufacturer magazine for recognizing our efforts to keep energy consumption low and sustainability high.

Kirk Edwards
Application Engineer
kirkedwards@exair.com

 

Are you a DIY / Hacker / Too cheap to pay for stuff like me?

I have noticed over the past decade that the definition (or at least what I considered the definition) of a hacker has altered.  When the term “Hacker” is tossed around, most will think of computers and electronic devices.  Now, there are people who consider it to be a hack when simply finding a way to alter a device to be used for something other than it’s original intent.  Wikipedia® lists the definition of a hacker as having three different types.  (Wikipedia link)

Today I would consider myself a Hacker (that would be of the hobbyist type).  In the past month, I have helped to re-purpose several items that may have been thrown away, refused to pay someone to fix a faulty gas range, and built a cheaper more robust pedestal for our washer and dryer.  I’ve been told I do this simply because I am frugal or cheap.  The truth of the matter is I simply won’t give up on trying to do something myself until I feel I have exhausted every idea I can conjure up.

That is the same effort that we put into our applications and projects here at EXAIR. If we can’t figure it out with the first try, we don’t stop there.  This is what gives us the knowledge needed to answer the questions when you call.  If we haven’t worked with the exact application before, chances are we’ve come close and we’ll have a very good idea about what can be done to meet or exceed your needs.

Brian Farno
Application Engineer / Hacker
BrianFarno@EXAIR.com
@EXAIR_BF

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