Tag: safe

The Hierarchy of Controls and How It Applies to EXAIR Compressed Air Solutions

Published on by Jordan T ShouseLeave a comment

In industrial environments, safety teams rely on the Hierarchy of Controls to reduce workplace hazards. Rather than relying on personal protective equipment (PPE), this process prioritizes eliminating risks at their source or engineering them out of the process. For manufacturers, maintenance teams, and engineers, applying the hierarchy of controls can significantly improve safety, reduce downtime, and increase efficiency.

Many compressed air applications—blow off, cooling, conveying, and static elimination—present opportunities to implement safer and more effective solutions using products from EXAIR.

What Is the Hierarchy of Controls?

The Hierarchy of Controls is a widely accepted framework in occupational safety used to minimize or eliminate exposure to hazards. It is commonly promoted by organizations like the Occupational Safety and Health Administration and the National Institute for Occupational Safety and Health.

The hierarchy ranks safety controls from most effective to least effective:

  1. Elimination – Remove the hazard entirely
  2. Substitution – Replace the hazard with a safer alternative
  3. Engineering Controls – Isolate people from the hazard
  4. Administrative Controls – Change the way people work
  5. Personal Protective Equipment (PPE) – Protect the worker with gear

While elimination and substitution are ideal, they are not always feasible in manufacturing environments.

Applying the Hierarchy of Controls to Compressed Air Systems

1. Elimination

The most effective control is removing the hazard entirely. In compressed air systems, this can mean eliminating unsafe blow-off methods like open pipes or drilled tubing that create excessive noise, dangerous dead-end pressure, and flying debris. Replacing these setups with engineered solutions from EXAIR Corporation removes many of these hazards while maintaining performance.

2. Substitution

Substitution replaces hazardous equipment or processes with safer alternatives. In many facilities, this involves switching from improvised blow-off devices to engineered products like air nozzles or air knives. These solutions reduce noise, improve airflow efficiency, and significantly lower compressed air consumption.

3. Engineering Controls

Engineering controls isolate workers from hazards through equipment design. Many EXAIR products function as engineering controls by improving safety and reliability in compressed air systems. Devices like safety air nozzles, cabinet coolers, and air knives help control airflow, reduce noise levels, and prevent unsafe pressure conditions.

EXAIR Electronic Flow Control

4. Administrative Controls

Administrative controls focus on improving procedures and training. This includes compressed air safety training, pressure guidelines, and routine system audits. While helpful, these controls rely on human behavior, so they are most effective when combined with engineered solutions.

5. Personal Protective Equipment (PPE)

PPE—such as safety glasses or hearing protection—is the last line of defense. It protects workers from hazards but does not remove the risk itself. Implementing engineered compressed air solutions can reduce many hazards before PPE becomes necessary.

Compressed air is one of the most widely used utilities in manufacturing—but it’s also one of the most misused. Improper blow off setups, excessive noise, and inefficient airflow can introduce safety hazards and energy waste.

With the right approach and the right equipment, companies can create safer, quieter, and more efficient processes—while maximizing the performance of their compressed air systems.

Solutions from EXAIR, help organizations move up the hierarchy by replacing unsafe methods with engineered products designed specifically for industrial environments.

Jordan Shouse, CCASS

Application Engineer / Sales Operations Engineer

Send me an email

Hierarchy of Controls Image courdsey of CDC.Gov

How One Customer Improved Safety and Reduced Noise with a Simple Retrofit

Published on by Brian FarnoLeave a comment

I recently had the opportunity to help a customer facing some serious concerns about their compressed air usage. They had just completed a safety audit conducted by a third-party firm, and one of the main issues identified was the use of handheld blow guns throughout their production floor.

“Thumb guns” are especially popular for blowoff because of their compact size, ergonomic design. and low price.

Even though the tools in question were commercially available and marketed as having “safety tips,” the auditors recorded noise levels exceeding 90 dBA—well above the acceptable threshold. The audit team explained that to maintain a safe work environment, noise levels needed to stay below 84 dBA, and the simplest way to get there was to address the blow guns being used.

That’s when the customer turned to us for help.

We discussed the application in detail, and it quickly became clear that EXAIR’s Model 1100 Super Air Nozzle would be a great fit. Not only does it significantly reduce noise levels—down to 74 dBA—but it also meets OSHA’s 30 PSI dead-end pressure requirement, ensuring operator safety in the event of a blocked nozzle.

This customer wasn’t focused on maximizing air output or performance—they simply wanted to make their environment safer for their team. What made this installation even better was the unexpected benefit: while addressing the safety concerns, it also reduced compressed air consumption. A win-win.

It’s always rewarding when we can help customers meet compliance goals and improve safety, but it’s even better when we can go beyond their expectations and help them uncover savings they weren’t even looking for.

Free testing. Verifiable data. EXAIR Efficiency Lab.

If you’re dealing with high noise levels or safety compliance issues around your compressed air applications, don’t hesitate to reach out. Our team is ready to help you find a solution that protects our people, meets regulations, and improves overall efficiency through the EXAIR Efficiency Lab.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Compressed Air In The Wild

Published on by Brian FarnoLeave a comment

Over the past weekend, I had the honor of visiting a local MakerSpace. These types of places are what my dreams are made of. The one we toured had a full metal and woodworking shop as well as a separate area for 3D printing, sewing, standard printing, electronics, and even laser engraving/cutting. Every workstation has an electrical drop and a compressed air drop coming from the ceiling as the area can be used for any number of projects.

Handheld air guns are something that you can find in nearly any and all manufacturing facilities that have compressed air within them. Suppose they are not at every operator station because the machines don’t require compressed air. In that case, they are generally found at the very least within the maintenance department, where they continually keep the facility functioning and may be the only ones in the facility with compressed air.

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Don’t let this happen to your air gun…use an EXAIR Precision Safety Air Gun with a quiet, efficient Super Air Nozzle instead.

Handheld blowguns like the one shown above are easily overlooked when it comes to operator safety and energy savings. Often, the cheapest gun possible is also the most costly regarding ownership and operation. These are just a few of the reasons EXAIR designed the VariBlast Precision Safety Air Gun.

The ergonomic design fits well in any sized hand and the long trigger makes for easy pull and variation in the amount of air being used. The integrated loop allows the tool to easily hang on a tether or hook near an operator station, while the optional Chip Shield adds additional protection for the operator and can be adjusted to any location along the extension. Effective chip guarding is a portion of the OSHA standard for dead-end pressure. Lastly, the extension pipe is offered in three different lengths: 6″, 12″, or 20″ overall length. Each one of these components is also field replaceable in the event one becomes damaged. That means it’s not disposable like the other guns on the market.

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Three different Super Air Nozzle models are available at the end of the extension in two separate materials. You can purchase the Atto, Pico, or Nano Super Air Nozzle in either stainless steel or PEEK thermoplastic for more sensitive applications. These nozzles coupled with our engineered valve design permit the user to vary the amount of air coming out of the gun by pulling the trigger to a higher flow or pulling it slightly and letting less volume of air through.

If you want to discuss whether your current air gun meets or exceeds OSHA standards and how much air it may use versus what an EXAIR VariBlast Precision can do for you, please contact an Application Engineer today.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Creating a Safer Environment for Industries

Published on by John BallLeave a comment

EXAIR has been at the forefront of safety and efficiency when it comes to blow-off devices since 1983.  We understand the importance of keeping personnel and the workplace safe.  Controlling an employee’s exposure to hazards is a fundamental method of protecting them. The CDC published a useful guide called “Hierarchy of Controls” detailing five types of control methods as a means to implement effective solutions.

  • Elimination
  • Substitution
  • Engineering controls
  • Administrative controls
  • Personal protective equipment (PPE)

Elimination:

Elimination removes the hazard from the source.  Elimination is at the top of the chart because it is the best way to protect workers.  In my previous line of work, we had to use MEK to dilute a solvent-based epoxy.  By switching over to a water-based epoxy, we were able to eliminate the chemical hazard from our process.  In some situations, this can be a difficult task, but the elimination criteria should be the first thing to review.

Substitution:

Substitution is looking for a different but safer modification to the source of the hazard.  An example would be static elimination.  If we take into consideration an ionization bar to remove static, there are manufacturers that make “hot” bars that will shock the operator if they get too close to the ionizing point.  EXAIR Gen4 Ionizing Bars are shockless.  By substituting the “hot” bars with EXAIR Gen4 Ionizing Bars, you just removed the shock hazard for your operators.  When considering substitution, it is important to compare the new risk of the replacement to the original risk.  Remember, we are trying to reduce the potential effects of injuries. 

The CDC explains these first two methods with this statement, “Elimination and substitution can be the most difficult actions to adopt into an existing process. These methods are best used at the design or development stage of a work process, place, or tool.  At the development stage, elimination and substitution may be the simplest and cheapest options.  Another good opportunity to use elimination and substitution is when selecting new equipment or procedures.  Prevention through Design is an approach to proactively including prevention when designing work equipment, tools, operations, and spaces.”1

Engineering Controls:

Engineering controls are very common.  Companies can evaluate an area for hazards and address them with proven controls.  This can be as simple as adding light curtains to a stamping machine.  Another area would be using compressed air for blow-off applications.  EXAIR has been providing engineered products to reduce these hazards.  We offer Safety Air Nozzles, Safety Air Guns, Super Air Knives, and Air Amplifiers to reduce the noise level and dead-end pressure as found in the OSHA directives 29CFR 1910.65(a) for maximum allowable noise exposure and 29CFR 1910.242(b) for dead-end pressure/chip shielding.  By adding an engineered nozzle like our Super Air Nozzle over an open pipe, it will protect your workers, stop OSHA fines, and reduce energy costs. 

Administrative Controls:

These controls will move personnel or change the process to limit the length of exposure time to the hazard.  As you notice, this is toward the bottom of the hierarchy chart as one of the least effective ways for dealing with a hazard.  As an example, an operator is exposed to a blow-off application that has a noise level of 95 dBA.  The maximum exposure time allowed by OSHA is 4 hours.  So, another operator would have to be placed in that area to work another 4 hours.  But, if the company added a Super Air Nozzle to the blow-off device, then the noise level would be reduced to 74 dBA.  Now, you can have one operator run the machine for the full 8 hours.  

PPE:

Personal Protection Equipment, or PPE, is equipment that is purchased to help protect the operators from hazards.  What may the problem be?  First, you have to train the operators on how to properly use them, as well as trust that they will follow the instructions explicitly.  It also adds cost to purchase and maintain them.  This is why this method is the least effective. 

At EXAIR, we have a statement: “Safety is everyone’s responsibility.”  The idea behind the NOSH hierarchy is to help review hazardous areas and implement safer products.  EXAIR can help your company follow the Hierarchy of Controls, to eliminate or reduce the hazards of compressed air usage.  Many EXAIR products, including Super Air Knives, Super Air Nozzles, Safety Air Guns, and Air Amplifiers are engineered to meet OSHA standards. If you have questions or want to talk to an EXAIR Application Engineer, please contact us to discuss how our products will be beneficial to your work environment’s safety. 

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

Note 1: https://www.cdc.gov/niosh/topics/hierarchy/default.html

Picture:  Safety First by Succo.  Pixabay License