EXAIR Super Air Nozzles: 38 Day ROI Saves Money

Blow off station

I received an email from an engineer that was looking at our Super Air Nozzles.  They currently were using four blow-off lines that were made from 6mm ID copper tubes.  (Reference picture)  The system was designed to blow out holes after machining.  The engineer was in charge of the task of optimizing 25 machining stations similar to this one.  He was familiar with EXAIR products from his previous employment, and he recognized the waste of compressed air by using open pipe.  He purchased four Nano Super Air Nozzle, model 1110SS, for a trial.  He was impressed with the performance, the low sound level, and the engineered design in safety.  But, for upper management in his company, he had to show a cost savings in order to change all the stations in the facility.  He asked me to help him in calculating the compressed air savings.

He gave me some additional details about their application.  He was using the compressed air about 30% of the time throughout an 8 hour day at a pressure of 80 PISG.  He wanted to present the savings per day, week, and year as well as the payback period in his evaluation.  I have performed many of these calculations for other customers and was happy to help.  It is sometimes easier to speak in terms of savings, as everyone can relate to money, especially management.  (The numbers below can be adjusted to match your application and blow-off devices).

Knowns:

Cost of compressed air: $0.25/1000 cubic feet of air (this is based on $0.08/Kwh of electrical cost)

Flow: 1110SS Nano Super Air Nozzle – 8.3 SCFM at 80 PSIG

Flow:  6mm ID copper tube – 42 SCFM at 80 PSIG

 

The difference in compressed air flows from a 6mm tube to the Nano Super Air Nozzle is (42 SCFM – 8.3 SCFM) = 33.7 SCFM.  At a 30% duty cycle, we get 33.7 SCFM * 0.3 = 10.2 SCFM (cubic feet/minute) of additional compressed air being used.

Per day, the additional amount of compressed air wasted is:

10.2 cubic feet/minute * 60 min/hr * 8 hr/day (one shift) = 4,896 cubic feet per day.

Per week, the additional amount of compressed air wasted is:

4,896 cubic feet/day * 5 days/week = 24,480 cubic feet per week.

Per year, the additional amount of compressed air wasted is:

4,896 cubic feet/day * 250 days/year = 1,224,000 cubic feet per year.

 

With the cost to make compressed air at $0.25/1000 cubic feet, we have the following:

4,896 cubic feet/day * $0.25/1000 cubic feet = $1.22 per day

24,480 cubic feet/week * $0.25/1000 cubic feet = $6.12 per week

1,224,000 cubic feet/year * $0.25/1000 cubic feet = $306.00 per year.

From these values, the payback for a model 1110SS Super Air Nozzle is just under 38 days.  Because the EXAIR Super Air Nozzles are so efficient, some utility companies will offer a rebate program to use them.  This will improve your ROI even more.  (We can check to see if your local electric company participates in these programs).  Just think, the remaining life of the Super Air Nozzle will be using less compressed air and saving much money for the company.

The calculations above are only for one nozzle.  As discussed above with the engineer, they had 4 tubes/station and 25 stations in their plant.  So, if you multiply each figure by 100, you can see the large amount of money that can be saved.   The engineer presented these figures to upper management, and it was an easy decision to replace all the copper tubes with EXAIR nozzles.

Nano Super Air Nozzle

Don’t be fooled by the initial cost of a tube, pipe, drilled holes, or a substandard nozzle.  You can see by the facts above, if you use any additional compressed air in your blow-off application, it will cost you a lot of money in the long run.  If you need any help in calculating how much money EXAIR products can save you, you can use our Air Savings Calculator from our website, or you contact an Application Engineer at EXAIR.  We will be happy to help you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

ROI – Return on Investment

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-

ROI

  • 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-

ROI2

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.

Brian Bergmann
Application Engineer

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Find us on the Web 
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Twitter: @EXAIR_BB

I Love It When They Show The Math

In every math or science class I ever took – from high school Algebra I, to CHEM101 in college, or a variety of classified material courses in Naval Nuclear Power School – it was always good form to show your work. And by “good form” I mean “necessary to avoid an F.” I’ve found, through helping my teenage sons with their homework (whether they want me to or not, but that’s another story,) the same rules apply today. And rightly so.

My oldest is slightly (at least) more interested in athletics than academics. Sunday night, as I was going to bed, I saw him in the living room. His face was not obstructed by his cell phone and he didn’t have his headphones on, so I saw a rare opportunity for a real-time conversation. He was watching game 7 of the NBA Championship, and it was near enough to the end of the game that I figured I could watch it with him and not sacrifice too much desperately needed sleep.

If you watched the series, you saw some phenomenal play by both the Cleveland Cavaliers and the Golden State Warriors. If you saw the end of game 7, you saw “the block” – Cleveland’s LeBron James came out of NOWHERE to rob Andre Iguodala of a quick two points on a breakaway lay-up. During the obligatory replays, I kept thinking that what James had done might border on the physically impossible. Then, ESPN’s “Sport Science” reel put into perspective just how close to that border he came:

Now, we don’t have anyone who can chase down a professional athlete and jump 12 feet in the air to take a basketball away from him, but we DO have a staff of engineers who can test air blow off products and “do the math” on how much better a fit to your application an EXAIR Intelligent Compressed Air Product would be. Our Efficiency Lab service is free and tests your current product to provide you a report comparing air savings, noise reduction, force values and a simple return on investment.

In our defense, I believe we are MUCH better at this than LeBron James or Steph Curry would be.

In our defense, I believe we are MUCH better at this than LeBron James or Steph Curry would be.

Do you want to find out how much quieter and efficient an EXAIR Intelligent Compressed Air Product might be than what you’re using now?  Give me a call…you can try one of our products in your facility, or we’ll test one of yours in ours.

Russ Bowman
Application Engineer
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How Much Money Will You Save with Engineered Air Nozzles

The simplicity of installing an air nozzle and the importance of saving compressed air (which in turn saves money) go hand-in-hand with our engineered air nozzle product line. For an 8 hour shift running 250 days per year, replacing one 1/4″ open air tube can save $650 dollars per year. Replacing any run-of-the-mill, commercial air nozzle can typically save $330 dollars per year!

How many open tubes or commercial air nozzles do you have?
10 tube replacements = $6500 saved per year
25 tube replacements = $16,250 saved per year
50 tube replacements = $32,500 saved per year                          

10 commercial nozzle replacements = $3300 saved per year
25 commercial nozzle replacements = $8250 saved per year
50 commercial nozzle replacements = $$16,500 saved per year

If you want to know EXACTLY how much replacing your current compressed air blow off devices with EXAIR engineered air nozzles will save you, take advantage of our free Efficiency Lab. We will test your current device for flow, force and noise levels with our calibrated equipment. You will receive a report with all the details, including and ROI – which is generally within weeks!Capture2

 

To see our complete line of nozzles, get our Blowoff Guide sent to your desk. EXAIR offers Air Nozzles ranging in thread size from our smallest Atto Super Air Nozzle with an M4 thread providing 2.0 ounces of force to our largest 1-1/4″ NPT Super Air Nozzle providing 23 lbs. of force. In addition to the various thread size and force levels, select nozzles are also offered in brass, stainless steel, zinc aluminum alloy and even PEEK plastic for superior chemical resistance or applications needing a non-marring nozzle (a maintenance crew for a large telescope used the PEEK nozzles to blow off their large mirrors). Offering such a wide variety to choose from, selection can seem like a daunting task. Luckily we have you covered with our FREE Blowoff Guide to help make the best product selection for your needs. The Blowoff Guide features performance specs as well as dimensional information and airflow patterns. Some things to consider when making a choice would be matching existing pipe size, material compatibility, noise level in the area, compressed air requirement and/or force required for successful blowoff.

Blowoff guide

To order your FREE Blowoff Guide, please click here.

We also offer a few handy accessories for our Air Nozzles as well. For example our Flexible Stay Set Hose are available with 1/4 MNPT X 1/4 MNPT fittings or 1/4 MNPT x 1/8 FNPT connections and lengths from 6″ up to 36″. The Stay Set Hose can be bent to deliver the air to the critical area while holding position until it is manually repositioned.

stay sets

Flexible and durable, EXAIR Stay Set Hoses come in lengths from 6″ to 36″.

Additionally we offer our Swivel Fittings allowing for 25 degrees of movement to provide the best angle for air delivery to the part. These useful tools are available in 316ss or 303ss from M4 thread up to our largest 1″ NPT size.

Swivel Fittings

Swivel Fittings make it easy to adjust the aim of your Air Nozzle.

For help selecting the right engineered Air Nozzle and accessory to fit your specific application, please contact EXAIR for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

EXAIR’s Efficiency Lab can Help With your Energy Audit, Quantify Savings and Provide an ROI

I recently received an inquiry from a customer to test their current air guns through our Efficiency Lab service. According to the operators, the handheld blow gun they were purchasing from a commercial retailer was too loud and complaints were rolling in.  They were also hoping to save some compressed air in the process as they were performing an energy audit at the same time.

Commercial Air Gun w/ Cross Cut Hole

Commercial Air Gun w/ Cross Cut Hole

Cross Cut Hole Nozzle

Cross Cut Hole Nozzle

The gun they sent in looked fairly similar to our Precision Safety Air Gun but it did not have an engineered nozzle on the tip of it.   Instead, it was simply a cross cut hole in a piece of material.   The air inlet to the gun was a 1/4″ NPT just like our Precision Safety Air Gun, the extension on the gun was slightly longer, the only significant variance I saw was the tip.

EXAIR Model 1410SS-CS

EXAIR Model 1410SS-CS

The Model 1110SS Nao Super Air Nozzle and Chip Shield

The Model 1110SS Nao Super Air Nozzle and Chip Shield

To try and get as much information as possible I measured the O.D. and I.D. of the extension, the hole size was approximately .140″.  I measured the extension on our Precision Safety Air Gun just to see what is different, it came in at the same size.  So, I flow tested the competitive blow gun with their tip on it and came up with air consumption of 12.69 SCFM, noise level of 92 dBA at 3′ away, and a blowing force of 11.5 oz at 80 psig.   I then measured the same attributes of EXAIR’s model 1410SS-CS Precision Safety Air Gun at 80 psig inlet pressure.  The model 1410SS-CS measured 8.3 SCFM, gave 8.1 ozs of working force, and only produced a 75 dBA sound level from 3′ away.

The sound level reduction was a total of 17 dBA which is below the OSHA standard for allowable noise level exposure, as well as reduced their air consumption by 4.39 SCFM.  That is almost a 35% reduction in their compressed air usage per gun replaced.  After seeing these levels of reduction the customer had more than enough information to provide management with in order to replace the blow guns not just for noise level reduction but also because it will reduce air use and save money. A clear supportive role in their energy audit.

If you would like to discuss how EXAIR can provide some free force, flow, and noise level testing for your facility, please contact an Application Engineer or check out the Efficiency Lab page on our site.

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

Hard Work Leads To Good Results

A few months ago I wrote a blog titled Great Team Make-up about being an assistant coach for my oldest son’s youth football team. I take pride in the opportunity to work with young kids in teaching them the value of teamwork and showing them when you work hard, the results will speak for themselves. It’s not just about winning or losing, but rather learning to listen, be respectful (win or lose) and growing as a player.

18836062401_fb883d8eea_z

6 rushing touchdowns in a single game? I’ll take it.

The first 3 practices were no pads, no contact so these days were spent conditioning and learning offensive and defensive positions. (or as the kids called it – “The most boring thing EVER!”). We have been in full contact practice for the last 5 weeks and it’s pretty cool to see how much the kids have learned in such a short time. We’ve had a couple scrimmages but this past weekend we had our first real game.

As both teams took the field you could see the nervousness of the players and the anticipation of the coaches on both sides. When you start playing at 9:00 AM, with dew on the ground, it’s kind of difficult for 5-7 year olds to hold on to a wet football. The game started pretty slow and by halftime it was only a 6 point difference. The second half was much different, our team really started to “click” on offense. We had some great blocking up front coupled with some determined running backs and scored consecutive 65, 52 and 49 yard rushing touchdowns. On the opposite side, our defense tightened up and held their opponent to only 1 score in the second half leading to a 38-16 victory! It was awesome to see our group of young men (who were very recently mere 5-7 year-olds trying to hang on to the wet ball) so excited about winning and to see their effort pay off. As coaches we were equally satisfied that not only were we able to get the win, but to see these incredible kids execute what they’ve learned in practice and transition that to the game.

Here at EXAIR, our commitment to be the best in the industry is best reflected in the solutions we provide for our customer’s needs. Two of our most informative tools are the Application Database and Case Study Library. The Application Database is over 1000 applications in a problem/solution format, detailing various industrial processes and the EXAIR product solution. Whether you’re dealing with a static electricity issue, needing to provide cooling to critical instruments, drying product, looking to convey media or just needing to provide blowoff, chances are you will find the information you are looking for.

The Case Study Library is a database where you can see quantifiable benefits or ROI of installing EXAIR products. We typically show improvements in dollar savings, compressed air savings, production increases, noise exposure decreases and safety improvements focused on reaching important OSHA standards. We are always seeking new case studies and can offer an incentive or SWAG in return for providing us the details on your application. A great place to start is with our Efficiency Lab, where we can actually gather the details for you.

Some examples of the information we are looking to obtain:

  • A decrease in air consumption
  • Improved safety
  • Lowering noise level
  • Reducing the amount of rejects – increasing production

Give us a call at 800-903-9247 to team up with one of our application engineers to see how we can coach you to a win in your facility.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Harvard Stadium 57240 image courtesy of Ted Eytan, Creative Commons License

 

Where Does 25 Cents For 1,000 Standard Cubic Feet Of Air Come From?

Wasting compressed air 2

Being an Application Engineer at EXAIR you tend to do a good amount of return on investment (ROI) calculations.   This is mainly to tell customers just how fast installing an EXAIR product on their system is going to pay its purchase price back and start saving them money.

In order to do these calculations there are several variables we must know.   The list is below.

  • Cost of EXAIR Product (This is an easy one for us to know.)
  • EXAIR Product Consumption (Another easy one!)
  • Current Product Consumption (If this is an unknown, we will test it for free!)
  • Cost of Compressed Air / 1,000 SCF (This is the most common unknown.)

With these four variables we can calculate the amount of air and the amount of money the EXAIR product will save over an existing non-engineered blowoff.   Let me address the two variables which have to come from you, the customer.

Current Product Consumption – If this value is not known please don’t guess at it.  We offer a free service which we refer to as our Efficiency Lab where you send us in your existing blowoff device and we will test it for force flow and noise level.   If you don’t know what pressure you are operating the piece at we will help you find out how to get that and then we will test our products at the same pressures.   This way you get a true apple to apples comparison.   Then, once we are done testing, you will get a recommendation from us in a formal report as to what EXAIR product will best replace your existing product.  Then we will pay for return shipping of your blowoff device back to you. So, if you don’t know how much air you are currently using then give us a call.  We will figure it out for you.

Efficiency Lab

The EXAIR Efficiency Lab is FREE!

Cost of Compressed Air/ 1,000 SCF – This is more often than not, the unknown variable in the equation.  The good news is there is a general standard assumption of twenty-five cents per 1,000 Standard Cubic Feet of compressed air.   This works out to be around 8 cents per kW/hr.  So even if you don’t know what you pay to compress the air, if you know what you are paying per kilowatt hour for your energy then we can calculate within reason what it costs for you to generate your compressed air. For reference, 8 cents per kilowatt-hour falls between the average US cost per kilowatt hour for commercial end-users (10.7/kWh) and industrial end-users (6.9/kWh).*

The best part of all is…EXAIR has a calculator available right on our website which provides air and dollar savings per minute, hour day and year as well as a payback in days for the EXAIR product purchase. On top of that, any step along the way that you aren’t sure of, we will help you out for free, even testing your product!

In case you would like to see the math, the formula used is below.

Basic Equation To Go From Cost Per kiloWatt Hour to Cost Per 1,000 Standard Cubic Feet of Compressed Air

Basic equation to go from Cost Per kiloWatt Hour to Cost Per 1,000 Standard Cubic Feet of Compressed Air

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

*latest U.S. EIA report here

 

 

 

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