FREE TESTING!!!! EXAIR’s Award Winning Efficiency Lab Saves Air and Money

EXAIR’s Efficiency Lab is now the “award-winning Efficiency Lab”. Thank you to Environmental Protection Magazine for recognizing the value and importance of this EXAIR service.

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I have blogged about this many times and we continue to help customers by using our free Efficiency Lab service that EXAIR provides to customers throughout the USA.  The EXAIR Efficiency Lab allows customers to send in their existing blow off device and we will test it for compressed air consumption, sound level, and force.  Ideally we try to take these measurements at the same operating pressure that is being supplied in the field so that we can compare it to an EXAIR product and offer the customer the best solution, the safest solution, and an engineered solution capable of saving them money through air savings and effectiveness.

Here is a recent example of  a product sent in by a customer concerned with compressed air consumption and safety of their people. The  hose they sent in was actually designed to be used with liquid coolants and was a very large consumer of compressed air.

A flexible blow off with .495" openings. Designed for liquid but used for compressed air. Enormous waste of air and a huge safety risk.

A flexible blow off with .495″ openings. Designed for liquid but used for compressed air. Enormous waste of air and a huge safety risk.

The hose shown above was being used at 40 psig inlet pressure.  The device is not OSHA compliant for dead end pressure, nor does it meet or exceed the OSHA standard for allowable noise level exposure.   The hose was utilizing 84.64 SCFM of compressed air and was giving off 100.1 dBA of sound.

OSHA Noise Level

As seen in the chart above, an employee is only permitted to work in the surrounding area for 2 hours a day when exposed to this noise level.   The amount of force that the nozzle gave off was far more than what was needed to blow chips and fines off the part.   The EXAIR solution was a model 1002-9230 – Safety air Nozzle w/ 30″ Stay Set Hose.

The EXAIR products were operated at line pressure of 80 psig which means they utilized 17 SCFM of compressed air and gave off a sound level of 80 dBA.  On top of saving over 67 SCFM per nozzle and reducing the noise level to below OSHA standard, the EXAIR engineered solution also meets or exceeds the OSHA standard for 30 psig dead end pressure.   In total this customer has replaced 8 of these inefficient lines and is saving 541 SCFM of compressed air each time they activate the part blowoff.

If you would like to find out more about the EXAIR Efficiency Lab, contact an Application Engineer.

We look forward to testing your blow off and being able to recommend a safe, efficient, engineered solution.

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

 

Not All Suppliers Are The Same

Just last week I received a package on my front porch.  This was a replacement part for a tool which I purchased used, knowing it needed the part.  The trick is, I needed it a few months ago.  I ordered the part from the manufacturer directly on July 2, 2015.  This part was said to be in stock and would ship to my home from their location which was also in the United States.  I heard good things about the company and I bought the tool with confidence I could have the part and the tool fixed quickly. I thought, no big deal I will get it within a week, fix it, and then use it.

After not receiving a shipping notification and nothing showing up at my door for two weeks I decided to call the company.  I finally got hold of a customer service representative after I had to wade through the automated phone attendant.  The person explained that they had in fact received my order and they would try to ship it out the next day so watch my email.   Well, the next day came and when it was nearing the end of the day I decided to call in again since I had still yet to receive a shipping confirmation.  This time I got in touch with a different customer service rep who explained there had been a fire in their warehouse and that nothing was shipping that day or even that week.   The fire didn’t happen that day, it had happened over 2 weeks prior to that.   Instead of notifying me when I placed my order, or even when I called in the first time I was simply told incorrect information.   I gave them the benefit of the doubt and after discussing the issue the customer rep. told me they are doing their best to get items lined up and out as quickly as they can.  It should only be a few more weeks.

I accepted the explanation and began the waiting period.  a few weeks came and I received a back-order notification in the mail, still no notification of any sort stating they are not shipping any products out.  Few more weeks and another post card.   After the third post card I had almost forgotten about it.  Finally I received an e mail, my item had shipped.  Two days later it was on my porch and packed like any other shipment.  No explanation for the delay, no apologies, and as if it was just normal business for them.

I ordered the part on July 2nd,   I received the part on October 13th.  Needless to say, the quality is good but the customer service communication is fairly lacking.

I began to think about what we do at EXAIR, and came to the realization that if something like this had happened here we would have sent out an E-News, a simple e-mail, tell customers who call in, and other forms of communication to every last customer that had an order in and we would be notifying every customer that was placing new orders.  We would be up front with the information and we would not hesitate to apologize for the inconvenience.   We have had disruptive incidents in the past which we handled this way, this is just good business etiquette.  This goes hand in hand with the fact you speak to a human when you call in to our office, all stock products (and we stock it ALL) ship same day on orders received by 3 PM ET when shipping in the US, and we will give you updates via e-mail or phone however you prefer.   Then to top it all off, we will give you a 30 day guarantee and a 5 year built to last warranty on pneumatic parts.

30 Day Guarantee

30 Day Guarantee

So if you want to be informed, treated right, get the products you need in a timely manner, and get your problem solved, you have zero reason to go with anyone else.

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

 

Calculating Compressed Air Cost & Savings Made Easy

If you have ever looked through our catalog, website, blog, twitter feeds, or even our Facebook page, you will see that we can almost always put a dollar amount behind the amount of compressed air you saved by installing EXAIR’s Intelligent Compressed Air Products.   No matter which platform we use to deliver the message, we use the same value for the cost of compressed air which is $.25 per 1,000 Standard Cubic Feet of compressed air. This value is derived from average commercial and industrial energy costs nationwide, if you are on either coast this value may increase slightly. On the positive side, if your cost for compressed air is a bit more, installing an EXAIR product will increase your savings.

So where does this number come from?   I can tell you this much, we didn’t let the marketing department or anyone in Accounting make it up.   This is a number that the Engineering department has deemed feasible and is accurate.

To calculate the amount we first look to what the cost per kilowatt hour is you pay for energy.  Then we will need to know what the compressor shaft horsepower  of the compressor is, plus the run time percentage, the percentage at full-load, and the motor efficiency.

If you don’t have all of these values, no worries.   We can get fairly close by using the industry accepted standard mentioned above, or use some other general standards if all you know is the cost of your electricity.

The way to calculate the cost of compressed air is not an intense mathematical equation like you might think.  The best part is, you don’t even have to worry about doing any of the math shown below because you can contact us and we can work through it for you.

If you prefer to have us compare your current compressed air blow off or application method to one of our engineered products, we can do that AND provide you a report which includes side by side performance comparisons (volume of flow, noise, force) and dollar savings. This refers to our free Efficiency Lab service.

EXAIR's Efficiency Lab is a free service to all US customers.

EXAIR’s Efficiency Lab is a free service to all US customers.

If you already know how much air you are using, you can use the Air Savings Calculators (USD or Euro) within our website’s knowledge base. Just plug in the numbers (EXAIR product data is found on our website or just contact us) and receive air savings per minute, hour, day and year. We also present a simple ROI payback time in days.

Now, back to the math behind our calculation.
Cost ($) =
(bhp) x (0.746) x (#of operating hours) x ($/kWh) x (% time) x ( % full load bhp)
——————————————————————————————————————————
Motor Efficiency

Where:
bhp
— Compressor shaft horsepower (generally higher than motor nameplate Hp)
0.746 – conversion between hp and KW
Percent Time — percentage of time running at this operating level
Percent full-load bhp — bhp as percentage of full load bhp at this operating level
Motor Efficiency — motor efficiency at this operating level

For an average facility here in the Midwest $0.25/1,000 SCF of compressed air is accurate.   If you would like to attempt the calculation and or share with us your findings, please reach out to us.   If you need help, we are happy to assist.

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

 

Minor Adjustments, Advice From An Expert Source

It’s not every day that we hear a customer say that our products aren’t consuming ENOUGH air, but that’s exactly what happened to me yesterday. I received a call from one of our long-standing customers who was experiencing reduced air consumption with our Model # 3202 Vortex Tube. The Vortex Tube uses compressed air to create a stream of cold air and a stream of hot air, providing a temperature range from -50°F to +260°F and cooling capacity up to 10,200 Btu/hr. Also, these units have no moving parts and are virtually maintenance free, making them the ideal choice for a variety of industrial spot cooling applications.

Vortex Tubes

This particular customer has been purchasing this model for several years, so they are pretty familiar with the performance and operation of the unit. They advised they were used to seeing air consumption at approximately 60 liters/minute or 2 SCFM (exactly what the Model # 3202 is designed to consume at 100 psig inlet pressure) but were starting to experience about a 50% drop to 30 liter/minute or 1 SCFM. We discussed the common troubleshooting:

  • Low supply pressure? (measuring at the inlet of the Vortex Tube during operation)
  • Compressed air inlet temperature? (warmer than ambient air – reducing performance)
  • Reduced cold flow? (possible clog from contaminants in the compressed air supply)
  • Unit seeing any back pressure? (up to 2 PSIG is acceptable, 5 PSIG will reduce approximately 5°F)
  • Over-tightened Cold Cap or Cold Muffler? (is it too tight?)

The customer advised they were using a push-to-lock fitting, where they drilled out the center and then would install it in the Cold Cap of the Vortex Tube. Their operator would hold the body of the Vortex Tube, by the air inlet, then take a wrench and thread the fitting into the ¼” NPT female opening on the Cold Cap. Without realizing, the operator was also turning the Cold Cap which was causing it to become over-tightened.  This in turn would reduce the consumption of the unit because it would shrink the internal air chamber.

Vortex Tube Exploded View

 

I made the suggestion to my customer to slightly loosen the Cold Cap and see if that didn’t fix the consumption issue. They called me back about an hour later and were very pleased to advise that now the unit was “working great!”.

We want to help you maximize our products, while optimizing your compressed air system. If you have a similar performance issue or would like to discuss your application, please contact us.

Justin Nicholl
Application Engineer
justinnicholl@EXAIR.com
@EXAIR_JN

New Computer = New Problems

droll_500x439At home, my wife and I have had the same laptop for quite some time.  The computer is on its third hard drive and has started showing signs that it will be needing a fourth.  So, the hunt began for a new computer. As always, I started my research and tried to find something that would fit our requirements for a new family computer.

Once I was done with the online research, we went to two big box stores and looked at the computers.  The sad thing was the amount of knowledge we were met with from the sales staff.  At one retailer the employee simply read the tag on the computer line for line. ( I had already read the same tag).  The other retailer, we couldn’t even get help.  Granted, I never asked for help  but when someone is walking through looking at every laptop and writing notes down then you might think they could have questions or the potential to purchase.

So, we went on our way and (without a salesperson’s help) narrowed it down to 3 computers with additional research and investigation.  Went and physically looked at them and came up with one winner.  So we bought it.  I got it home, installed some software and the very next day it started showing problems.  It was to the point of calling the manufacturers support line.  The guy there was great, but the problem came back.  So I took the computer back and got another one, same PC just a new machine.  Took it home and found out I couldn’t install a piece of software because the software key was already used on the old PC.  So I started to try and find a contact number or chat for the company. After spending an hour on their website in an endless loop of links that said support, I finally found a way to reach them.

Once I dialed the phone and it rang I was greeted by an automated service, finally reached a real human being and spent the next 2 hours troubleshooting and getting the problem resolved. Once I reached a person the service was pretty decent, and the problem was resolved.

homepage

The point to this story is that you will never have those issues when dealing with EXAIR.  As soon as you go to our home page you see several ways to contact us including the phone number right on the page.  Not only that, we offer you to contact us via live chat, fax, email, or even snail mail if you want.  If you choose to call in, you will be greeted by a real live person, not an automated system or an automated recording of a live person. I know I have mentioned it time and time again, but here at EXAIR we try to make sure we set ourselves apart from other companies with the level of service and products we provide.  After working here for close to four years it is growing harder and harder to see how some businesses can stay alive with the level of service they provide. EXAIR has already done the research and investigating necessary to answer your questions, we are available at your call and we are eager to assist.

Contact us, we’ll get you taken care of.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Experience Is What Matters

Collectively EXAIR’s application engineers have 45 years with the company and 100 years of industrial experience. Each application engineer comes to us with “shop” experience and a college education. Between the two disciplines (real world and college experience), we can marry the practical with the hypothetical to find  the best answer to your compressed air challenges.

eng group

For me, I have industrial engineering and business management degrees. I’ve been a machine shop manager, manufacturing engineering manager, and a marketing product manager. Kirk comes from a family of industrial distributors and sold mechanical power transmission equipment for years, he also has a masters degree. Brian has mechanical engineering technology degree and was a service tech for a machine tool builder. Russ is schooled by the U.S. Navy in nuclear technology and has years of experience in the pump industry. Dave has a degree in mechanical engineering and worked as an application engineer prior to coming to us. Neal has a degree in industrial technology and worked his way through the ranks in the injection molding industry prior to EXAIR. Lee has an electro-mechanical engineering degree which he finished while working as an automotive technician and is also a six sigma black belt.

All this knowledge and experience is not confined to one individual.  Our cubicles are arrange so as to be in ear shot of one another. When you call in for technical support, you not only have the expertise of the engineer you are talking with,  but the entire engineering staff.

Being on the technical support line, we come into contact with hundreds of engineers from most every facet of manufacturing.  Be it industrial, textile, automotive, mining, power generation, paper/pulp, pharmaceutical or medical, we have had experience in serving these customers and more.

Need to update your compressed air system? Are you wanting to save energy by reducing you compressed air consumption? We would sincerely welcome the opportunity to serve you. Call one of our application engineers at 1-800-903-9247 [list of engineers ]

Joe Panfalone
Application Engineer
Phone (513) 671-3322
Fax (513) 671-3363
Web: http://www.exair.com
Twitter: http://www.twitter.com/exair_jp
Facebook: http://www.facebook.com/exair

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A Special Build

machining

The number of calls and emails that come in every week always seem to have something new.  Looking through my emails this afternoon I saw an product integration walk-through for a Line Vac, but with a twist.  This particular application had been mimicked in another facility and in looking at the specs, the requested model didn’t seem to fit quite right.  After a few emails and a sketch of the installation, everything was worked out with a safety margin to ensure proper application performance.

I also noticed the telltale signs of summer, which was an abundance of Cabinet Cooler Sizing Guide assistance forms.  There were a number of others dealing with Cabinet Cooler Side Mount Kits, Air Nozzles, Air Knives, Reversible Drum Vacs, etc.  In short, there hasn’t been a shortage of fresh applications to keep me on my toes and asking questions.

One of the questions that stood out to me this past week was whether we are able to offer our Threaded Line Vac products with BSPP threads, and the answer is yes.  Unsurprisingly the request came from an overseas source, and also unsurprisingly we are stepping up to fill the need.  We pride ourselves on building reliable products and having them in stock, but we also pride ourselves in being able to step out of the production manufacturing zone and modify our designs when you need a custom solution.

If you’re involved with our product and see the need for a BSPP thread, or another modification to suit the market, drop me an email and I’ll see what we can do.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

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