You Don’t Need to Spend Thousands to Optimize Your Compressed Air System

There is no denying it, saving compressed air is a process.  This process often involves some type of energy audit or at the very least an evaluation of something going wrong with production and a way to improve it.  Many programs, consultants, and sales reps will devise a solution for the problem.

Often times the solution is to create a more efficient supply side of the compressed air system. The supply side is essentially everything within the compressor room or located in close proximity to the actual air compressor. While optimizing the supply side can amount to savings, many of these solutions and services can involve great expense, or capital expenditure processes.  These processes can often lead to delays and continued waste until the solution is in place.  What if there was a way to lower compressed air usage, save energy, solve some demand issues on the compressed air system and save some money while the capital expenditure process goes through for the larger scale project.

These solutions are a simple call, chat, email or even fax away. Our Application Engineers are fully equipped to help determine what points of your compressed air demand side can be optimized. The process generally starts with our Six Steps To Compressed Air Optimization.

6 Steps from Catalog

Once the points of use are evaluated the Application Engineer can give an engineered solution to provide some relief to the strain on your compressed air supply side.  For instance, an open copper pipe blow off that is commonly seen within production environments can easily be replaced with a Super Air Nozzle on the end of a Stay Set Hose that will still bend and hold position like the copper pipe does while also saving compressed air, reducing noise level, and putting some capacity back into the supply side of the compressed air system.

engineered nozzle blow offs
Engineered solutions (like EXAIR Intelligent Compressed Air Products) are the efficient, quiet, and safe choice.

One of the key parts to the solutions that we offer here at EXAIR is they all ship same day on orders received by 3 PM ET that are shipping within the USA. To top that off the cost is generally hundreds, rather than thousands (or tens of thousands) of dollars. Well under any level of a capital expenditure and can generally come in as a maintenance purchase or purchased quickly through the supply cribs.  Then, to take this one step further, when the EXAIR solution shows up within days and gets installed EXAIR offers for you to send in the blow off that was replaced and receive a free report on what level of compressed air savings and performance increases you will be seeing and provide a simple ROI for that blow off (though we would also encourage a comparison before a purchase just so you have additional peace of mind).

This amounts to saving compressed air and understanding how much air is being saved, adding capacity back into your supply side which will reduce strain on the air compressor, give the ability to increase production while the capital expenditure for the end solution of controls and higher efficiency on the supply side is approved to then save even more compressed air and energy.

The point is this, savings and efficiency doesn’t have to involve a capital expenditure, if that is the end game for your project that is great! Let EXAIR provide you a solution that you can have in house by the next business day to save money NOW and then put that savings towards another project. No matter the method, it all starts with a call, chat, email or fax.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Air Knife Shim Adjustment can be Key to Successful Applications

On January 2, 1960 Little Anthony & The Imperials appeared on The Dick Clark Saturday Night Beech-Nut Show to sing Shimmy Shimmy Ko Ko Bop. While I wasn’t around at that time, I have heard the song quite a few times and get it stuck in my head more than I have heard it. What does that song and EXAIR have to do with each other? Well, we shimmy shimmy Super Air Knives to dramatically increase or decrease their flow and force.

The stock shim that is assembled in every Super Air Knife is a .002″ (0.05mm) thick. This sets a continuous opening the full length of the knife that drives the performance of the knife. The shim sets the gap height between the cap and the body of the Super Air Knife. If we evaluate a 24″ Super Air Knife with the stock shim installed we could calculate the airflow opening of the knife as the surface area of a rectangle.  To obtain the surface area we take the length of the air knife times the thickness of the shim.  See the example below.

As you can see with the stock .002″ thick shim installed we are actually operating at a surface area opening of 0.048 square inches.  If we were to install the .004″ thick shim into the knife then we would double the height which in turn doubles the surface area, shown below.

This doubling effect will increase the force out of the Super Air Knife when applications require more power.  Thinning out the shim will have the exact opposite effect, if the shim thickness is reduced to .001″ thick then the air consumption and force will be reduced.

Changing the shims out of the Super Air Knives is a fairly simple task as shown in the video below.  Installing a different thickness of shim is a coarse adjustment to the volumetric flow needed for your application.  Then a pressure regulator can be used to fine tune the needed force and flow for the ideal setting to meet your needs, and operate at maximum efficiency for the application.

If you would like to discuss this further or even see what kind of custom thicknesses we can offer on the shims to truly make a tailor fit Super Air Knife for your application, please contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Little Anthony & The Imperials “Shimmy Shimmy Ko Ko Bop” – [Merlin] XelonEntertainment, WMG (on behalf of Turntable Recordings LTD); ARESA, LatinAutor, União Brasileira de Compositores, Spirit Music Publishing, UNIAO BRASILEIRA DE EDITORAS DE MUSICA – UBEM, Abramus Digital, BMI – Broadcast Music Inc., and 4 Music Rights Societies – https://www.youtube.com/watch?v=5mLjZRAXRRA

Watch EXAIR Webinars On-Demand

That’s right, just like your local cable or satellite TV provider, EXAIR offers On-Demand content that can be streamed and used for training, education, help with cost justification, or improve awareness around compressed air costs and safety.

The best part about this content is that you don’t have to pay for it, simply register on our website (where your information is not shared) and go to the Webinars section of our Knowledge Base.  Then gain access to the library of five webinars that have all been broadcast around compressed air safety, efficiency, and optimization.

EXAIR.com – Webinars On-Deman

The current On-Demand offering is listed below:

Intelligent Compressed Air Solutions for OSHA Compliance
Intelligent Solutions for Electrical Enclosure Cooling
Optimize Your Compressed Air System in 6 Simple Steps
Simple Steps for Big Savings
Understanding Static Electricity

The most recent webinar we created is currently only On-Demand for registered attendees and will soon be added to the Knowledge Base library.  If you did not get to see it live, the content was extremely helpful for anyone that works within a facility that uses compressed air.  Use This Not That – 4 Common Ways To Save Compressed Air In Your Plant, keep an eye out for the release date in our On-Demand section.

If you would like to discuss any of the webinar topics further, please feel free to reach out to an Application Engineer.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Don’t Forget About Operating Cost: How To Calculate Return On Investment

If you have a stock portfolio, or even a retirement account, you’ve likely heard the term “return on investment.” It basically tells you how hard your money is working for you, and, the higher, the better.

The term is also used to determine the financial benefits associated with the use of more efficient products than you’re using right now:

  • The cost of operating industrial pumps, air compressors, and a variety of industrial rotating equipment, can be greatly reduced by using variable frequency drive systems that sense the demand and change the motor’s speed (and hence power consumption) accordingly.  These systems are not cheap, but the reduction in operating costs is often quite noticeable.
  • At home, installing energy efficient windows (spoiler alert: your builder probably used the cheapest ones he could find…mine sure did) or upgrading appliances & HVAC can cost a pretty penny, but you’ll also see your electric bill go down.

EXAIR Corporation has a worldwide reputation for providing highly efficient compressed air products for industry.  Our Engineering Department has a company-wide reputation for being data fanatics…which is key to allowing us to provide our customers with ample information to make the best choices to optimize your use of your compressed air.

It’s not hard at all to calculate your potential savings from the use of an engineered compressed air product, assuming you know how much air your current device is using.  If not, we can tell you if you can send it in for Efficiency Lab testing (free and fast; call me to find out more.)  Here’s an example for a VERY typical situation: replacing an open copper tube blow off with an EXAIR Super Air Nozzle:

  • A 1/4″ copper tube uses 33 SCFM @80psig
  • A Model 1100 Super Air Nozzle uses 14 SCFM @80psig

33 SCFM X 60 min/hour X 8 hours/day X 5 days/week X 52 weeks/year = 4,118,400 SCF

14 SCFM X 60 min/hour X 8 hours/day X 5 days/week X 52 weeks/year = 1,747,200 SCF

4,118,400 – 1,747,200 = 2,371,200 Standard Cubic Feet of compressed air savings

If you know your facility’s cost of compressed air generation, you can calculate the monetary savings.  If not, we can get a good estimate via a thumbrule used by the U.S. Department of Energy that says it typically costs $0.25 to generate 1,000 SCF of compressed air:

2,371,200 SCF X $0.25 ÷ 1,000 SCF = $592.80 annual monetary savings

In 2019, the cost of a Model 1100 Zinc Aluminum Super Air Nozzle is $41.00.  Daily savings (not counting weekends) is:

$592.80 ÷ 260 days (5 days/week X 52 weeks/year) = $2.28 daily savings

Meaning the payoff time for the $41.00 investment in the Model 1100 is:

$41.00 ÷ $2.28 = 17.9 days

Or…just over three weeks.  Now that I’ve shown you the math, I’d like to introduce you to the EXAIR Cost Savings Calculator.  Just enter the data, and it’ll check your math (because I know you’re going to do the math anyway, just like I would.)  It even does the ROI for you too.

Engineered solutions (like EXAIR Intelligent Compressed Air Products) are the efficient, quiet, and safe choice. Does the one on the right look familiar?  It’s literally the example I used for the above calculations.

If you’d like to find out more about how – and how fast – EXAIR Intelligent Compressed Air Products can pay off for you, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Engineered Compressed Air Nozzles and Utility Rebates

When EXAIR started to manufacture compressed air products, we created a culture in making high quality products that are safe, effective, and efficient.  Being leaders in this industry, we created a program, the Efficiency Lab, to compare blow-off devices with EXAIR products in noise levels, flow requirements, and force measurements.  With calibrated test equipment, we compare the data in a qualified report to share with our customers.  This information can be helpful to determine the total amount of air savings and safety improvements that EXAIR products can offer.

Flat SANs 1in
Zinc Aluminum models are suitable for general purpose blow off (left) and 316SS models are specified for food/pharma and high heat applications.

In conjunction with the Efficiency Lab, we created a Cost Savings Calculator.  It is a quick way to view payback periods and annual savings when using EXAIR products.  As an example, I used a 1” Flat Super Air Nozzle, model 1126, and compared it to a 1/8” open pipe.  (The reason behind the comparison is that the model 1126 can screw onto the end of the 1/8” NPT pipe.)  With an operation of 24 hours/day for 250 days a year, the amount of air used by an 1/8” open pipe is near 70 SCFM (1,981 SLPM) at 80 PSIG (5.5 Bar).  The model 1126 has an air consumption of 10.5 SCFM (297 SLPM) at 80 PSIG (5.5 Bar).  By putting the information in the Cost Savings Calculator, it determined that the ROI was in 2.1 days.  The annual savings was $5,355 USD per year.  Imagine if you replaced ten blow-off spots in your facility, the amount of money that could be saved.  Here is the worksheet below:

flat 1

The people that started to notice the savings were the utility companies that make electricity.  Depending on your location, electrical suppliers initiated a rebate program to use engineered nozzles in your facility.  Similar to other energy saving rebates, like LED light bulbs and high efficiency furnaces, the electrical providers notice a big savings when using EXAIR products.  If you qualify, the total cost to purchase and implement the EXAIR Super Air Nozzles are reduced.(Even if a rebate program has not been implemented in your area, the idea of saving energy and compressed air makes it very profitable and environmentally sound in changing over to EXAIR products).

To see if your utility offers rebates on compressed air optimizations, go to the DSIRE database. This database is easy to search and informative.

For Example, here in Ohio Duke Energy has a Prescriptive Incentive Program for its customers. The Prescriptive Incentive Program makes it easy for Duke Energy customers to receive an incentive for their natural gas and electric energy efficiency projects. Prescriptive Incentives are energy efficient measures paid per-unit, reimbursing the customer up to the total cost (including materials and labor) after the measures have been installed. See the image below for their incentives for using Engineered Nozzles;

capture.jpg
Ohio Duke Energy Prescriptive Incentive Program

https://www.duke-energy.com/business/products/smartsaver/industrial-equipment

To discuss your application and how an EXAIR Intelligent Compressed Air Product can help your process and save you money, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer

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Six Steps to Optimization, Step 4 – Turn Off Your Compressed Air When Not in Use

Step 4 of the Six Steps To Optimizing Your Compressed Air System is ‘Turn off the compressed air when it isn’t in use.’  Click on the link above for a good summary of the all the steps.

6 Steps from Catalog

Two basic methods to set up a compressed air operation for turning off is the ball valve and the solenoid valve. Of the two, the simplest is the ball valve. It is a quarter turn, manually operated valve that stops the flow of the compressed air when the handle is rotated 90°. It is best for operations where the compressed air is needed for a long duration, and shut off is infrequent, such as at the end of the shift.

manual_valves (2)
Manual Ball Valves, from 1/4 NPT to 1-1/4 NPT

The solenoid valve offers more flexibility. A solenoid valve is an electro-mechanical valve that uses electric current to produce a magnetic field which moves a mechanism to control the flow of air. A solenoid can be wired to simple push button station, for turning the air flow on and off – similar to the manual valve in that relies on a person to remember to turn the air off when not needed.

wa_solvalv
A Wide Array of Solenoid Valve Offerings for Various Flows and Voltage Requirements

Another way to use a solenoid valve is to wire it in conjunction with a PLC or machine control system. Through simple programming, the solenoid can be set to turn on/off whenever certain parameters are met. An example would be to energize the solenoid to supply an air knife when a conveyor is running to blow off parts when they pass under. When the conveyor is stopped, the solenoid would close and the air would stop blowing.

The EXAIR EFC (Electronic Flow Control) is a stand alone solenoid control system. The EFC combines a photoelectric sensor with a timer control that turns the air on and off based on the presence (or lack of presence) of an object in front of the sensor. There are 8 programmable on/off modes for different process requirements. The use of the EFC provides the highest level of compressed air usage control. The air is turned on only when an object is present and turned off when the object has passed by.

efcapp
EFC Used To Control Bin Blow Off Operation

By turning off the air when not needed, whether by a manual ball valve, a solenoid valve integrated into the PLC machine control or the EXAIR EFC, compressed air usage will be minimized and operation costs reduced.

If you have questions about the EFC, solenoid valves, ball valves or any of the 15 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer
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Candy Producer Saves $4600 in Compressed Air with EXAIR’s EFC

A few months ago, I took a phone call from a manufacturing engineer who worked at a large candy production facility here in the United States. Extra chocolate was dripping out of the candy molds onto the conveyor belt below.  Within a few hours the belt was dirty enough they would have to stop the line and clean the residual chocolate off the belt. 

The best solution I found was a 72” 316 Stainless Steel Super Air Knife. It worked great when powered at 60 psig inlet pressure. The laminar flow of the Super Air Knife was perfectly suited for this application.  The knife was mounted between the mold and the belt to help solidify and blowoff the excess drips of chocolate. There was one drawback, the Super Air Knife was not needed to blow the belt continuously and the continuous demand was not desirable during peak production.

The simple solution for this was the EXAIR Electronic Flow Control, the EFC minimizes compressed air use by turning off the air when a sensor is triggered. Since there was a 4.5-minute time gap between each mold set this was a great solution. When the photoelectric eye saw a mold, it then told the solenoid valve to open and supply the knife with compressed air for 30 seconds while the mold was open and the excess chocolate would be dripping. See the Savings calculations below;

efcapp

Without using the EFC

(* Using $ 0.25 per 1000 SCFM used)

  • 72” Super Ion Air Knife = 165.6 SCFM @ 60 PSIG
  • 165.6 SCFM x 60 minutes x $ 0.25 / 1000 SCFM = $ 2.48 per hour
  • $ 2.48 per hour x 8 hours = $ 19.84 per 8-hour day
  • $ 19.84 x 5 days = $ 99.20 per work week
  • $ 99.20 per week x 52 weeks =$5,158.40 per work year without the EFC control

 

With the EFC installed (turning the compressed air off for 4 minutes 30 seconds with a 30 second on time = 6 minutes/hour compressed air usage)

  • 165.6 SCFM x 6 minute x $ 0.25 / 1000 SCFM = $ 0.25 per hour
  • $ 0.25 per hour x 8 hours = $ 2.00 per 8-hour day
  • $ 2.00 x 5 days = $ 10.00 per work week
  • $ 10.00 per week x 52 weeks = $520.00 per work year with the EFC control 

$ 5,158.40 per year (w/o EFC) – $ 520.00 per year (w/ EFC) = $4,638.40 projected savings per year by incorporating the EFC.

EFC287x250

This example illustrates, clearly, why choosing the EFC is a good idea. It has the ability to keep compressed air costs to a minimum and saves compressed air for use within other processes around the plant. With this type of compressed air savings, the unit would pay for itself in less than 3 months.

If you would like to see how we might be able to improve your process or provide a solution for valuable savings, please contact one of our Application Engineers.

Jordan Shouse
Application Engineer
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