If you need a deeper understanding about how EXAIR’s products can be applied and help your process or product, feel free to contact us and we will do our best to give you a clear understanding of the benefits when using our engineered compressed air products. We can also explain proper implementation of accessory items such as compressed air filters and regulators.
Why should you consider a Pressure Regulator when designing your compressed air system? As many know, our products and those of other product manufacturers have a certain set of specifications regarding performance at stated input pressures. But what if your application doesn’t require that “full, rated performance”? Maybe instead of needing two pounds of force, you only need one pound? Sometimes more force does not produce the desired result for an application. By that, I mean you cause damage to the target or other surrounding items in the application. Or, perhaps blowing too hard (or vacuuming too hard in the case of a Line Vac or E-vac) might cause the vessel or the material you are picking up to collapse or deform (due to too much power).
There is also the concern about using more energy than one really needs to in order to achieve the desired effect in an application. In other words, if you can achieve your goals with only 40 PSIG, then why would you ever use 80 PSIG to accomplish the goal? By reducing your compressed air from 80 down to 40 PSIG, you can easily reduce the air consumption of the “engineered” solution by another 40% or more. Once you have installed engineered air nozzles to reduce compressed air on blow off applications, a pressure regulator can fine tune the pressure to save even more energy.
Then there is the issue of taking advantage of the pressure differential (from 80 down to 40 PSIG) that creates a little bit more air volume capacity. At 80 PSIG, your compressed air to free air volume ratio is 6.4:1. At 40 PSIG, it is only 3.7:1. The net effect is you effectively have an overall larger volume of air you can use for other applications in your facility. By reducing compressed air pressure of your demand applications, you may be able to reduce over all compressor discharge pressure. Reducing compressor discharge pressure by 2 PSIG also reduces required input power by 1 percent – so keep your pressure as low as possible!
Regulating pressure is definitely warranted given the benefits that compliment the operation of the core EXAIR products.
If you need a deeper understanding about how EXAIR’s products can help your application, feel free to contact us and we will do our best to give you a clear understanding of all the benefits that can be had by our products’ use as well as proper implementation of accessory items such as compressed air filters and regulators.
The EXAIRSuper Air Knife is the most efficient compressed air knife on the market. We know this because we’ve tested them, and our competitors’ offerings, for performance, using the same instruments, controls, and procedures. We’re not going to publish data that we can’t back up, and that’s a fact.
They’re also ideally suited to a wide variety of applications – they come in lengths from 3 inches to 9 feet long (and can actually be coupled together for uninterrupted air flows of even longer lengths,) a variety of materials for just about any environment. But the best thing about our Super Air Knives is how you can adjust the air pressure and flow to complete a wide variety of tasks. You can adjust them in two different ways, Replacing or adding Shims, or regulating the incoming air pressure.
Changing out your shim!
A larger shim gap will give you higher flow and force from your Air Knife. Honestly, the 0.002″ shim that comes pre-installed in all of our Air Knives is perfectly suitable for most blow off applications, and appropriate air supply conditions are the first thing you should check for before going with thicker shims, but if you do indeed need a boost, a thicker shim will indeed give you one…here’s a blog with the video to show you how it’s done:
Another advantage to having a Pressure Regulator at every point of use is the flexibility of making pressure adjustments to quickly change to varying production requirements. Not every application will require a strong blast sometimes a gentle breeze will accomplish the task. As an example one user of the EXAIR Super Air Knife employs it as an air curtain to prevent product contamination (strong blast) and another to dry different size parts (gentle breeze) coming down their conveyor. For Performance at different supply pressures see the chart below.
EXAIR products are highly engineered and are so efficient that they can be operated at lower pressures and still provide exceptional performance! This save’s you money considering compressed air on the average cost’s .25 cents per 1000 SCFM.
If you’d like to discuss altering the performance of your Super Air Knife, give us a call.
If you’re a regular reader of the EXAIR blog, you’re likely familiar with our:
This guideline is as comprehensive as you want it to be. It’s been applied, in small & large facilities, as the framework for a formal set of procedures, followed in order, with the goal of large scale reductions in the costs associated with the operation of compressed air systems…and it works like a charm. Others have “stepped” in and out, knowing already where some of their larger problems were – if you can actually hear or see evidence of leaks, your first step doesn’t necessarily have to be the installation of a Digital Flowmeter.
Here are some ways you may be able to “step” in and out to realize opportunities for savings on your use of compressed air:
Power: I’m not saying you need to run out & buy a new compressor, but if yours is
aging, requires more frequent maintenance, doesn’t have any particular energy efficiency ratings, etc…you might need to run out & buy a new compressor. Or at least consult with a reputable air compressor dealer about power consumption. You might not need to replace the whole compressor system if it can be retrofitted with more efficient controls.
Pressure: Not every use of your compressed air requires full header pressure. In fact, sometimes it’s downright detrimental for the pressure to be too high. Depending on the layout of your compressed air supply lines, your header pressure may be set a little higher than the load with the highest required pressure, and that’s OK. If it’s significantly higher, intermediate storage (like EXAIR’s Model 9500-60 Receiver Tank, shown on the right) may be worth looking into. Keep in mind, every 2psi increase in your header pressure means a 1% increase (approximately) in electric cost for your compressor operation. Higher than needed pressures also increase wear and tear on pneumatic tools, and increase the chances of leaks developing.
Consumption: Much like newer technologies in compressor design contribute to higher efficiency & lower electric power consumption, engineered compressed air products will use much less air than other methods. A 1/4″ copper tube is more than capable of blowing chips & debris away from a machine tool chuck, but it’s going to use as much as 33 SCFM. A Model 1100 Super Air Nozzle (shown on the right) can do the same job and use only 14 SCFM. This one was installed directly on to the end of the copper tube, quickly and easily, with a compression fitting.
Leaks: These are part of your consumption, whether you like it or not. And you shouldn’t like it, because they’re not doing anything for you, AND they’re costing you money. Fix all the leaks you can…and you can fix them all. Our Model 9061 Ultrasonic Leak Detector (right) can be critical to your efforts in finding these leaks, wherever they may be.
Pressure, part 2: Not every use of your compressed air requires full header pressure (seems I’ve heard that before?) Controlling the pressure required for individual applications, at the point of use, keeps your header pressure where it needs to be. All EXAIR Intelligent Compressed Air Product Kits come with a Pressure Regulator (like the one shown on the right) for this exact purpose.