At EXAIR we want to do everything we can to ensure you’re getting the most out of our products. In many applications, we’re offering a replacement for an inefficient or unsafe “homemade” compressed air device. In these cases, replacing the inefficient device with an engineered product by EXAIR often leads to a quick payback time.
To help you understand your compressed air products, EXAIR offers a free Efficiency Lab Service. Simply send in the device your currently using for testing, and one of our qualified Application Engineers will provide you with a comprehensive report. Included in this report is an ROI calculation, so you’ll know down to the day of when your EXAIR Product will begin paying YOU!
For some more information on this service, and a view of the EXAIR Efficiency Lab, check out my video below:
If you believe there’s places in your facility that could benefit from this service give us a call. We’re ready to help you start saving!
Tyler Daniel Application Engineer E-mail: TylerDaniel@EXAIR.com Twitter: @EXAIR_TD
You may have asked…why should I switch over to an engineered air nozzle if my system already works? Or…How can air nozzles be much different?
Manufacturing has always been an advocate for cost savings, where they even have job positions solely focused on cost savings. Return on Investment (ROI) is a metric they look toward to help make good decisions for cost savings. The term is used to determine the financial benefits associated with the use of more efficient products or processes compared to what you are currently using. This is like looking at your homes heating costs and then changing out to energy efficient windows and better insulation. The upfront cost might be high but the amount of money you will save over time is worth it.
But how is ROI calculated? It is very simple to calculate out your potential savings of using one of EXAIR’s Intelligent Engineered Compressed Air Products. If you would rather not do the calculations out yourself then we can do it for you by sending the item in question to our Efficiency Lab Testing. The Efficiency Lab Testing is a free service that we offer to show you the possible savings by switching to one of our products.
The following is a simple ROI calculation for replacing open blowoffs with an EXAIR Super Air Nozzle:
¼” Copper Pipe consumes 33 SCFM at 80 psig (denoted below as CP)
A Model 1100 ¼” Super Air Nozzle can be used to replace and only uses 14 SCFM at 80 psig (denoted below as EP)
(CP air consumption) * (60 min/hr) * (8 hr/day) * (5 days/week) * (52 weeks/year) = SCF used per year for Copper Pipe
(33) * (60) * (8) * (5) * (52) = 4,118,400 SCF
(EP air consumption) * (60 min/hr) * (8 hr/day) * (5 days/week) * (52 weeks/year) = SCF used per year for EXAIR Product
(14) * (60) * (8) * (5) * (52) = 1,747,200 SCF
SCF used per year for Copper Pipe – SCF used per year for EXAIR Product = SCF Savings
4,118,400 SCF – 1,747,200 SCF = 2,371,200 SCF in savings
If you know the facilities cost to generate 1,000 SCF of compressed air you can calculate out how much this will cost you would save. If not, you can us $0.25 to generate 1,000 SCF which is the value used by the U.S. Department of Energy to estimate costs.
($592.80/year) / (5 days/week * 52 weeks/year) = $2.28 per day
(Cost of EXAIR Unit) / (Daily Savings) = Days until product has been paid off
($42) / ($2.28/day) = 17.9 days
As you can see it doesn’t have to take long for the nozzle to pay for itself, and then continue to contribute toward your bottom line.
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 Visit us on the Web Follow me on Twitter Like us on Facebook
Process improvement projects can be detailed, complex, expensive, and take a long time to prove their worth. Today, I want to tell you about one that WAS NOT ANYTHING like that.
A metal stamping company used compressed air to blow their products from their dies. They did what many do – they ran some copper tubing, and aimed it at the platen so it would properly eject the parts as they were stamped. They KNEW it was loud, and they suspected it was inefficient as well.
After discussing the setup and seeing a picture of it (the one on the left, below,) I recommended installing a few engineered Super Air Nozzles to lower the noise levels considerably. Boy, was I wrong. About “a few” nozzles, that is…turns out, they only needed one Model 1122-9212 2″ Flat Super Air Nozzle with 12″ Stay Set Hose. The copper tubes come from a manifold that already had 1/4 NPT ports – installation took a matter of minutes. Nothing detailed, complex, or expensive about it:
It didn’t take much longer than that to prove its worth either: as soon as they noticed how much the noise level went down on THIS press, they ordered them for the other eighteen presses in their facility as well.
The 1/4″ copper tubes blew continuously from a pressure regulator set @60psig…the three of them theoretically consumed a total of ~80 SCFM. The Model 1122, at 60psig supply, consumes only 17.2 SCFM. Simple return on investment was as follows:
80 SCFM was costing them $48.00 a week
80 SCFM X 60 min/hr X 8 hr/day X 5 days/week X $0.25/1,000 CFM = $48.00
17.2 SCFM, using the same formula, only costs $10.32 a week (I’ll let you do the math; it’s good practice.)
They saved $37.68 a week. The Model 1122-9212 costs $116.00 (2020 pricing) – that means that each of them paid for themselves in just a hair over three weeks.
$37.68 x 50 work weeks per year = $1884.00 saved annually per nozzle
$1884 x 18 (the number of presses) = $33,912 saved annually
Considering they also didn’t have to listen to those very loud open ended copper tube blowoffs, I think you’ll have to agree it made for a very good investment. They did. The new nozzle runs at 77 decibels, a comfortable level and well below the OSHA standard [29 CFR – 1910.95(a)] for allowable noise exposure.
If you’d like to find out how EXAIR Intelligent Compressed Air Products can save you money on compressed air – and save everyone’s hearing – give me a call.
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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.