Want to Know How Much Money you can Save? Use EXAIR’s Efficiency Lab

Growing up as a kid of the 80’s I remember wanting a Nintendo 64. This was very much a want due to the excellent advertising and having friends that got them when they first came out. So, like many kids of the times, I set forth to present my case to my parents and sell them on the benefits to me receiving this 64 bit wonder of the world. These benefits all revolved around me doing chores and “helping” to earn money to go towards the end goal. Thinking back now, I really should have started to learn more about negotiating earlier in life because my parents and older brother really made out on the deal. The point is, I had to make sure that they saw a return on their investment. Mainly, I would be entertained and they would get some stuff done around the house without complaints.

1 – NUTS For Nintendo special on ABC news 20/20 from 1988

Well, flash forward to today and I still feel as though it is always an easy justification if I have supporting evidence of the benefits and even better, if there is some form of cost savings that will be had by spending money on a project or a tool. Often times the justification is the amount of time spent on a task. Well, here at EXAIR we completely embrace that justification culture and, in many cases, can provide you the information necessary to present to management or budget committee – the simple ROI your company will see when investing in EXAIR products. The best part is, this study is always free.

The way it works is pretty simple, we want to compare your current solution to our engineered products. EXAIR has a simple form that gets filled out (or you can call, e-mail or chat) explaining your application to us. We ask for a few key pieces of detailed information, and for you to send one of your current solutions (the nozzle, homemade device, or open tube for example). Then we run side by side tests in house to determine air consumption, noise, and force at the same pressure you are using at your facility. That’s right, this testing is all done here at EXAIR through our EXAIR Efficiency Lab. We document these performance characteristics and send a report showing a simple return on investment for you if you replace your device with an EXAIR engineered solution.

EXAIR’s Free Efficiency Lab

This information is then easily backed up by our 30 day guarantee on stock products. Get the EXAIR solution in, test it in your facility and see how the savings stack up. If there is anything that doesn’t stack up, you simply let us know and send the units back.

The entire Efficiency Lab and 30 day guarantee are offered to all of our customers that are within the US and Canada. If you would like to discuss what is possible for you and your team, please reach out to an Application Engineer.

Brian Farno
Application Engineer

1 – Hertz, Steve – NUTS FOR NINTENDO special on ABC news 20/20 from 1988, 6/24/2010 – Retrieved from https://www.youtube.com/watch?v=yt4KG9ib8S4

Engineered Compressed Air Products = Less Noise & Money Saved

Everyone dislikes loud noises for the most part. Here in Ohio we just got done surviving the constant buzz and swarming of cicadas. We all deal with noise on a daily basis, some of it enjoyable and some of it not so much. Noise is an inescapable fact of life and all we can do is try to reduce noise level to save our sanity. But, did you know that cutting down on the noise produced by compressed air blow offs can actually save you money? Your loud homemade blow off system is not only way too loud, but it is most likely also costing you more money than you need to spend.

EXAIR’s engineered compressed air products are designed to operate quietly and efficiently. The reduction in noise they produce is only one of the benefits – another is the reduction in money by reducing compressed air use.

EXAIR Super Air Knife Promotion

But how does one calculate out the ROI? 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 typical ROI preformed and replaced with a corresponding EXAIR Super Air Nozzle:

  • ¼” drilled pipe with (3) 3/32” Holes which uses 9.4 SCFM per hole at 80 psig (denoted as DP)
  • A Model 110003 3” Super Air Knife can be used to replace and only uses 8.7 SCFM at 80 psig (denoted below as SAK)


(DP air consumption) * (60 min/hr) * (8 hr/day) * (5 days/week) * (52 weeks/year) = SCF used per year for Copper Pipe 

(28.2) * (60) * (8) * (5) * (52) = 3,519,360 SCF

(SAK air consumption) * (60 min/hr) * (8 hr/day) * (5 days/week) * (52 weeks/year) = SCF used per year for EXAIR Product 

 (8.7) * (60) * (8) * (5) * (52) = 1,085,760 SCF

Air Savings:

SCF used per year for DP – SCF used per year for SAK = SCF Savings

               3,519,360 SCF – 1,085,760 SCF = 2,433,600 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.

Yearly Savings:

                (SCF Saved) * (Cost / 1000 SCF) = Yearly Savings

                                (2,433,600 SCF) * ($0.25 */ 1000 SCF) = $608.40 annual Savings

With the simple investment of $216 (as of date published) you can calculate out the time it will take to pay off the unit.

Time Until payoff:

                (Yearly Savings) / (5 days/week * 52 weeks/year) = Daily Savings

                                ($608.40/year) / (5 days/week * 52 weeks/year) = $2.34 per day

                (Cost of EXAIR Unit) / (Daily Savings) = Days until unit has been paid off

                                ($216) / ($2.34/day) = 92.3 days 

As you can see it doesn’t take long for the air knife to pay for itself. You also get better overall performance as the Super Air Knife will provide a solid curtain of air. In the end you get to breathe a sigh of relief as no more jump scares and a loud hiss when you turn your air on. Who doesn’t like to save a little money and sanity, especially in these crazy times?

If you have any questions or want more information on EXAIR’s Air Knifes or like 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
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Flat Super Air Nozzle vs. Open Pipe ROI

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 widths; 1” (25mm) and 2” (51mm).  EXAIR offers a standard Flat Super Air Nozzle and a High Force Flat Super Air Nozzle in two different materials, zinc-aluminum alloy and 316 stainless steel.  And with a metal construction, breakage is not a concern and performance are not sacrificed even in the harshest of environments. 

The unique patented shims inside the EXAIR Flat Super Air Nozzles will give you three improvements to the design and function.  First, they come in different thickness 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 blast without overusing your air compressor.  The patented design also allows an even flow 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 with safety and efficiency in mind.

2″ Flat Super Air Nozzle

To expand more on force adjustments with the Flat Super Air Nozzles, EXAIR has an easy way to change 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 thickness of the shim inside.  EXAIR offers a variety pack called a Shim Set to give you a wide range of forces with the nozzles.  For the standard Flat Super Air Nozzle, they come stock with a 0.015” (0.38mm) shim for both the 1” and 2” sizes.  The corresponding Shim Sets will include a 0.005” (0.13mm), 0.010” (0.25mm), and 0.020” (0.51mm) shim.  The High Force Flat Super Air Nozzles will come standard with a 0.025” (0.64mm) shim; and the Shim Set will include a 0.020” (0.51mm) and 0.030” (0.76mm) thick shim.  This is a unique feature as most competitive flat nozzles do not allow you to do this.  The chart below corresponds the appropriate Shim Set to the Flat Super Air Nozzle.

Not only are they safe, and easily adjustable they can help save compressed air vs using a open ended pipe!

For example, let’s look at the average operating costs for a single 1/4″ open copper tube. (If you don’t know you current energy costs, a reasonable average to use is $ 0.25 per every 1,000 SCF used, based on $ 0.08/kWh.

1/4″ Copper tube

A single 1/4″ open copper tube consumes 33 SCFM @ 80 PSIG and costs roughly $ 0.50 per hour to operate. (33 SCF x 60 minutes x $ 0.25 / 1,000 = $ 0.50). For an 8 hour shift, the total cost would be $ 4.00 ($ 0.50 x 8 hours = $ 4.00).

If we were to replace the 1/4″ open copper tube with our Model # 1122 2″ Flat Super Air Nozzle with 1/4″ FNPT inlet, the air consumption would be reduced to 21.8 SCFM @ 80 PSIG. This may not seem like much of an air usage reduction, but when you look at the monetary, total cost of ownership for purchasing and operating the nozzle, the savings can quickly add up.

The operating cost for a 2″ Flat Super Air Nozzle with 1/4″ FNPT inlet is $ 0.33 per hour (21.8 SCF x 60 minutes x $ 0.25 / 1,000 = $ .033) or $ 2.64 per 8 hour shift ($ 0.33 x 8 hours = $ 2.64).

We can now compare the operational cost between the 2 devices:

1/4″ open copper tube operating costs:
$ 0.50 per hour
$ 4.00 per day (8 hours)

2″ Flat Super Air Nozzle operating costs:
$ 0.33 per hour
$ 2.64 per day (8 hours)

Cost Savings:
$ 4.00 / day (open copper tube) –  $ 2.64 / day (2″ Flat Super Air Nozzle) = $ 1.36 savings per day

The Model # 1122 2″ Flat Super Air Nozzle has a list price $ 67.00 USD.

ROI or Return On Investment calculation:
$ 67.00 (Cost) / $ 1.36 (savings per day) = 49.26 days.

The 2″ Flat Super Air Nozzle would pay for itself in just over 49 days in operation. This is the savings for replacing just ONE 1/4″ open copper tube with an engineered solution! In most industrial plants, there could be several of these which presents even more opportunities to reduce the overall operational costs.

Our focus here at EXAIR is to improve the overall efficiency of industrial compressed air operating processes and point of use compressed air operated products. If you are looking to reduce compressed air usage in your facility, contact an application engineer and let us help you optimize your current system.

Jordan Shouse
Application Engineer

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Video Blog: What is EXAIR’s Free Efficiency Lab Service Offered to All US & Canadian Customers!

EXAIR’s Free Efficiency Lab

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