More And More Award Winning Products From EXAIR

As you might expect, a LOT of things have changed at EXAIR Corporation since 1983. Most of our current senior management had yet to graduate high school, and a fair number of current employees had yet to BE BORN. According to our computer system (another BIG change since 1983), our first ten customers were here in southwest Ohio (#11 was in Michigan), and now, we sell direct across the US & Canada, and our worldwide distributor network offers representation on six continents. One thing that hasn’t changed, though, is our founder’s vision of manufacturing quiet, safe, & efficient compressed air products for process improvement in just about any industry that uses compressed air. And THAT, dear reader, continues to gain high profile attention. The photo above shows the seven awards that our products have recently won, which were announced in 2021 or early 2022. Here’s a rundown:

Plant Engineering 2020 Product of the Year (Fluid Handling) GOLD AWARD:
1/2 NPT No Drip External Mix Air Atomizing Spray Nozzles

No Drip External Mix Atomizing Spray Nozzles

The 1/2 NPT models are the latest addition to our newest product line. The External Mix version offers the highest liquid flow rate, and largest pattern coverage. Among the applications where they’ve excelled so far are:

  • Snack food provider – applying flavoring to bulk snack materials.
  • Commercial bakery – spraying cooking oil onto pans used in a conveyor oven.
  • Sporting goods manufacturer – applying adhesive to the tops of skateboard decks to glue the grip tape on.

Plant Engineering 2020 Product of the Year (Material Handling Systems) GOLD AWARD:
2-1/2 NPT 303SS Threaded Line Vac

EXAIR's Threaded Line Vac Family
EXAIR Threaded Line Vac + Your Pipe + Compressed Air = Instant Conveyor System

For bulk material conveyance, it really doesn’t get any simpler than EXAIR Air Operated Conveyors. Stainless Steel models are especially popular when the environment – or the product – is corrosive, or hot…they’re good to 400F (204C), and can even be modified with High Temperature components for exposure up to 900F (482C). The Threaded versions have been successfully used to:

  • Recycle sprinkles applied to wafers into a return hopper in a candy production facility.
  • Replacing an auger conveyor to allow for homogenous mixing of grains & supplements in feed stock at an agricultural mill.
  • Providing a low cost solution to convey product into a hopper at a grain processing plant.

Plant Engineering 2020 Product of the Year (Maintenance Tools & Equipment) SILVER AWARD
Occupational Health & Safety 2021 New Product of the Year (Industrial Hygiene-Dust Control) WINNER
Occupational Health & Safety 2021 New Product of the Year (Health & Safety/Cleanup) PLATINUM

EasySwitch® Wet-Dry Vac

Like our Spray Nozzles product line, our Industrial Housekeeping Products line has also grown considerably over the years. The Deep Hole Vac-u-Gun and Heavy Duty HEPA Vac were real game changers when they came along, and the EasySwitch® Wet-Dry Vac Systems are likewise making an impact. Switching from wet to dry operation is, as advertised in the name itself, INCREDIBLY easy. Among our satisfied customers are:

Occupational Health & Safety 2021 New Product of the Year (Lab Safety) WINNER
Intellistat® Ion Air Gun™

The newest innovation in a long line of EXAIR static elimination solutions, the Model 8500 Intellistat® Ion Air Gun is made for laboratories, clean rooms, medical & electronic applications, and carries an ISO 14644-1 Class 5 rating for clean room use. Because of their rapid decay rates and lightweight construction, they’re used in a diverse range of applications and areas, including:

  • A supplier of fiberoptic parts uses an Intellistat® to remove dust and static charge from product prior to packaging.
  • A medical device manufacturer has one in a Class 7 clean room for silicone parts cleanliness.
  • A nutritional supplements maker uses their Intellistat® to remove static charge & powder residue from the tops of plastic bags before sealing them. The excess/residual powder causes them not to seal correctly.

Machine Design 2021 Big Idea! (Electrical Components) BRONZE AWARD
Gen4® Static Eliminator Power Supply

All EXAIR Gen4 Static Eliminators use one of two Power Supplies – your choice of the 2-port Model 7960, or the 4-port Model 7961.

EXAIR Static Eliminators produce ionized air via a Corona discharge, which requires high voltage, low current electricity. The Gen4® Static Eliminator Products feature armored & shielded cables with an internal ground, for safety and reliability. The ground path is completed through the cable and the Power Supply port, eliminating the need for an external ground connection. Faults in external ground connections result in the majority of the problems with those devices, so the internal ground is a “Big Idea!” indeed. The Gen4® Static Eliminator Power Supplies are switchable for 115VAC or 230VAC voltages, and are offered in 2, or 4 outlet designs, which can power any 2, or 4 EXAIR Static Eliminator Products. Like most EXAIR Intelligent Compressed Air Products, they’re used for a wide range of applications, in a wide range of industries:

If you’d like to find out more about these, or any of our other engineered compressed air products (we’re pretty proud of them all), give me a call. I can talk about them all day long…and sometimes I do!

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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5 Important Factors When Selecting an Atomizing Spray Nozzle

The most recent EXAIR Webinar is up and ready to be viewed as an on demand video. This presentation showcases five important factors when selecting an atomizing spray nozzle. Throughout the webinar you will gain several key takeaways that are outside of the five factors as well. If you have a liquid spray application and are not sure where to start, this video has a wealth of information for you. As always, the Application Engineer department is also here and ready to assist as needed. We can walk through any application with you and help right over the phone, through email, or even live chat.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

NEW 1/4″ HollowStream™ Cone Liquid Atomizing Nozzle – IN STOCK And Ready To Ship!

Lately, around the globe, we are all getting a little too used to hearing this from vendors. “Okay, so I have your order for one piece, and that is going to be on hold for 8 weeks until we can get parts in.” At EXAIR, we are able to state our products are in stock and ready to ship same-day on orders received by 2 PM ET that are shipping within the US or Canada. There is no exception when it comes to our brand new 1/4″ NPT HollowStream™ Cone Liquid Atomizing Nozzle.

1/4″ NPT HollowStream Liquid Atomizing Nozzle

Since introducing our first liquid only nozzles (no air required) we have been working to add these hollow cone pattern nozzles add to our liquid spray nozzles (complimenting our full cone spray nozzles). There are six flowrate capacities with a 1/4″ NPT inlet. These capacities will range from .06 GPM (.23 LPM) up to 2.5 GPM (9.45 LPM) flow rates. The HollowStream provides a ring of liquid upon your target that can be used for cooling, cleaning, rinsing, or suppression of dust. By only using the outer ring to cover a similar space as a full cone spray the amount of liquid is reduced. This is all done by a pressurized liquid supply.

Spray Dimensions and Pattern

The small footprint of the nozzle matched with the spray volume and pattern is ideal for tight-fitting areas or areas where manifolds of multiple nozzles are required. The maximum through passage is also large enough to permit some slurries and particulate to pass through when recycling the rinse or wash water is needed.

If you would like to discuss your spray application and determine if the 1/4″ NPT HollowStream Cone Nozzle is right for you, contact us. We look forward to helping you determine the correct product that will make the most efficient use of your resources.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Liquid Spray Nozzles Improve Gummy Candy Production

One of the more popular treats for kids and adults are gummies.  They can be sweet, sour, and in different shapes and colors.  A candy company that makes gummy bears was looking for a better way to spray food-grade oil onto their product.  They contacted EXAIR about our Air Atomizing Spray Nozzles. 

We discussed their setup and process for making the gummy candies; or in this case gummy bears.  The sugary mixture is poured into molds that are coated with corn starch.  The corn starch helps to keep the gummy from sticking to the mold.  Once hardened, the bears will be released from the molds and travel through a stainless-steel spinning drum.  In here, they apply a light food-grade oil onto the bears.  This process will hide the starch and give the candy that glazed and colored feature.  The drum was near 60” (1.52 meters) long and spun at 19 RPM.  The gummy bears would tumble along the length of the drum at a designed production rate of 2000 Kg/hr. (4,400 Lbs./hr.).  They used drip tubes along the top to apply the food-grade oil onto the gummy bears.  They noticed that the color was not as good and the coverage was spotty.  The oil pump was metered in a range of 0.35 – 3 gal/hr. (1.32 – 11.3 l/h).  The temperature inside the drum could reach up to 150oF (65oC), and the viscosity of the food-grade oil ranged between 190 – 400 cps.  In order to get the best results for quality, they had to reduce their production rates to about 1,700 to 1,800 Kg/hr. 

To determine the correct solution, we had to dive a bit more into their application.  The details of the EXAIR Atomizing Nozzles are measured with water as the liquid.  Since they are using an oil at different temperatures, the specific gravity will change slightly.  For their oil, the specific gravity is 0.92 at 20oC and 0.89 at 65oC.  We can use Equation 1 to convert the required flow rate from the food-grade oil to water.

Equation 1:

Q1 = Q2 * SQRT (SG2 / SG1)

Q1 – Flow of water (gph)

Q2 – Flow of oil (gph)

SG1 – Specific Gravity of water

SG2 – Specific Gravity of oil

The Specific Gravity of water is 1.  With the range of specific gravity for the oil, we can calculate the range that is needed as indicated by water.  Then we can make a selection as referenced by our data in the catalog.  Since we want to make sure that we can cover the range of the metered oil pump, we will use the maximum flow rate of 3 gph.  In adding the values, we get the following:

@20oC  Q1 = 3 gph * sqrt(0.92) = 2.88 gph

@65oC  Q1 = 3 gph * sqrt(0.89) = 2.83 gph  

Since the viscosity ranges above 300 cps., I recommended the External Mix Atomizing Nozzles to be mounted along the length of the rotating drum.  The External Mix can handle viscous liquids up to 800 cps.  Unlike the drip method, the EXAIR Liquid Atomizing Spray Nozzles use compressed air to shear the oil into small droplets and to disperse the oil in a wide pattern.  With the smaller particle size, we can get more coverage area which will allow them to use less food-grade oil.  The coverage area on the gummy bears was near 15” (38cm) as they rolled down the drum.  I also recommended the No-Drip option to allow for versatility in their process.  The No-Drip option for the Atomizing Nozzles is a very nice option which will stop the liquid solution from dripping when not in use.  When they needed to apply the oil, they would just turn on the compressed air to the Atomizing Nozzle.  It made it very easy to control.  This was important to reduce excess usage and non-conforming parts. It also keeps the inside of the drum oil free during cleaning cycles.   

EB2010SS

From the data above, I recommended three pieces of the model EB2010SS, No Drip External Mix Wide Angle Flat Fan Pattern.  The spray pattern was 14” (35.6cm) wide to cover part of the 60” (1.52m) length of the drum.  With an estimated 1 gph for each nozzle, we would be able to spray the maximum requirement as calculated above (2.88 gph).  After installation, they were able to get a consistent deep color of the gummy bear at the maximum production rate of 2,000 Kg/hr.  They also noticed that with the fine particle spray, they were able to use less oil.  With the three pieces of the model EB2010SS, they were able to reach maximum production rates with less food-grade oil and reduce scrap rates.

If you have a liquid that you would like to spray evenly, efficiently, and effectively; EXAIR Atomizing Nozzles can do that for you.  You can contact an Application Engineer for help.  For the customer above, they were able to create those gummy treats for kids and adults.  Yummy.

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

Picture: Giant Gummy Bear by Alexas_FotosPixabay licence.