EXAIR Internal Mix Atomizing Nozzles: Overview

Internal Mix Atomizing Spray Nozzles are the perfect choice for fine mist and precise control.

In today’s market, the cost of consumable products are on the rise; especially with paints, oils, and yes, even the cost of water.  You can help ease some of that cost by being more effective in spraying with less liquid.  The EXAIR Atomizing Nozzles  can accomplish these objectives.  By using compressed air to shear the liquid, small micron-sized droplets are produced.  As a reference, reducing the area of a particle by one-half will multiply the number of droplets by eight.  With smaller diameter particles, it will increase the surface area and the coverage; thus, requiring less liquid in your application.

In addition, with a variety of spray patterns, you can accurately target the liquid without having excess spillage around the product.  EXAIR manufactures three families of Atomizing Nozzles; Internal Mix, External Mix, and Siphon Fed.  In this blog, I will be discussing the Internal Mix Atomizing Nozzles.

The Internal Mix Atomizing Nozzles are designed, like the name suggests, to atomize the liquid inside the nozzle.  This means that the liquid and air streams will come together just before leaving the Atomizing Nozzle.  For this type of Atomizing Nozzle, the air and liquid supply are pressurized and independently controlled.

The Internal Mix Atomizing Nozzle can spray fluids with a viscosity below 300 CPS (similar to SAE40 oil).  EXAIR manufactures these nozzles with stainless-steel construction; making them compatible with many different kinds of liquids.  And they are used in many applications like washing, coating, cooling, quenching, and dust control.

Atomizing Nozzle

EXAIR carries three different body sizes in 1/8” NPT, ¼” NPT, and ½” NPT inlet ports; so, you can create a light mist or a monsoon.  Each body size has different air caps and liquid caps to control the largest liquid flow rates.  This will allow you to have finer adjustments of your liquid spraying.  These caps are easily interchangeable to change the spray patterns, spray amounts, and to reduce downtime if cleaning is needed.

Other features for the Atomizing Nozzles are the mechanisms to precisely regulate the amount of liquid being sprayed.  The liquid adjusting stem can  control the liquid flow into the Atomizing Nozzle.  Along with inlet air pressure and liquid pressure, you can “dial in” the exact amount of fluid to end any waste or excess. They have a compact design to mount inside tight areas, and we carry mounting brackets for easy attachment and positioning.   Versatility is very important in saving, applying, and spraying costly fluids, and the Internal Mix Atomizing Nozzles have it.

No Drip Atomizing Family

To help reduce excess fluid even more, EXAIR has a No Drip option.  This patented option is used to keep the expensive liquid from dripping out of the Atomizing Nozzles during off cycles.  A valve inside the body will create a seal on the liquid side when you turn off the compressed air.  For delicate and sensitive applications, the unwanted drips will not occur with the No Drip option to ruin the finish of your product. This option also enhances the Internal Mix Atomizing Nozzle for intermittent spraying processes.  It will keep the liquid inside the body of the nozzle; so, when you apply air pressure, the Atomizing Nozzle will give an instant spray.

Unlike some manufacturers, there is no need to run a separate compressed air line or have a liquid solenoid valve to stop the dripping.  The Internal Mix Atomizing Nozzles with the No Drip options can give you the best performance in efficiency, effectiveness, and flexibility without any drips.

If you need to maximize the liquid dispersion and reduce consumption, the EXAIR Atomizing Nozzles are the products to use.  The Internal Mix Atomizing Nozzles can shear the drops into micron-sized particles, saving expensive consumable oils and liquids.  If you have a spraying application, an Application Engineer at EXAIR can help you to decide the correct model.

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

Engineered Air Nozzles vs. Commercial vs. Open Air Line

How much does your compressed air cost?  If you don’t know, there are some handy tools, like this one, that will help you calculate it precisely.  For estimating purposes, the U.S. Department of Energy estimates that compressed air costs about $0.25 per 1,000 Standard Cubic Feet of mass to generate.  Again, this is an estimate based on different electric power consumption costs from around the country, varying efficiencies of different types & sizes of air compressors, etc., so, as the automobile folks say, “your mileage may vary.”

Regardless of whether you calculate it exactly or just estimate it, it’s going to come as no surprise that it isn’t cheap.  That’s why efficient use HAS to be taken seriously.  Luckily, there are steps you can take (six, specifically, see below,) that can help.

Step 3, dear reader, is the subject of today’s blog.

This is a common inquiry here at EXAIR Corporation.  It’s not hard to find a blog about them -like this one, or this one, or even this one.  Before we go any further….yes, this is ANOTHER one.

I recently had the pleasure of helping a caller who was using the male ends of pneumatic quick connect fittings to blow off steel tubes:

Cheap and easy…but loud & wasteful. Don’t let this happen to you.

They were operating these, for the most part, 24/7, as their production was continuous, although there were actually spaces between product at times.  They were using over 74 SCFM…that’s 750,000 Standard Cubic Feet of compressed air PER WEEK, or over 39 MILLION SCF per year…over $9,700.00* in generation cost.  After a brief discussion, they ordered & installed two Model 1101 Super Air Nozzles, which threaded right in to their existing fittings:

This was a “slam dunk” – no system modification was even required.

Not only were the Super Air Nozzles markedly quieter (sound level went from 90dBA to 72dBA,) air consumption was reduced to just 20.90 SCFM…a 72% reduction, which translates to an annual cost savings of over $7,000.00*.  But wait…there’s more.

See, that was just “step 3” – they also installed a solenoid valve in the supply line, actuated from their process control.  This turns off the compressed air in between cycles, roughly estimated at about half the time.  This gets them additional savings of almost $1,400.00* per year.  But wait (again)…there’s STILL more.

This is one of five lines that were (mis)using the pneumatic fittings.  With the dramatic improvements of the first line, they ordered Super Air Nozzles for the remaining four.  So, to recap…an investment of $440.00 (2019 List Price for the Model 1101 is $44.00,) plus their solenoid valves, they’re saving almost $42,000.00* per year in compressed air generation costs.

*using the DoE thumbrule of $0.25/1,000 SCF referenced in the first paragraph.

Engineered compressed air products like the Super Air Nozzles are a clear winner all day, every day, over any open-end type device.  If you’d like to find out how much EXAIR’s Intelligent Compressed Air Products can save you, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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EXAIR Nano Super Air Nozzles for Science and Industry!

A few weeks ago I was on vacation with my family. My wife and I had taken our three daughters to Columbus, OH for three days after camping in a tent for a few days. One of the focal points to the trip was COSI, the Center of Science and Industry. In case you live anywhere near Columbus, OH and have not heard of how amazing this interactive museum is, you should definitely check it out. This isn’t your normal museum.

While the Mythic Creatures exhibit and the Jim Henson exhibit were both absolutely amazing for my 9, 6 and 4 year old daughters, it was also entertaining for my wife and myself. Now you may be asking what does this interactive science place and trip with kids have to do with EXAIR.

Well, while my daughters and I were watching this enormous pendulum that knocks ball bearings off boxes every few minutes I could hear that all too familiar, gentle sound of compressed air blowing every now and then. I couldn’t however see where the noise was coming from.

COSI Pendulum

As we wandered through the different sections I saw several examples of compressed air use but none were the exact sound or display I had heard. When we were walking through the Space exhibit just above where the pendulum was located and that gentle sound was getting closer. All of a sudden I saw it. Next thing I know I look up and my 6 year old was using a joystick to control a scaled down Lunar Lander propelling it in circles. This was where the sound was coming from.

Propelled Lunar Lander

While I was amazed by this interactive piece I could tell they were using compressed air and I was curious as to how it was working. That’s when I noticed the distinct design of our Nano Super Air Nozzle on the bottom of the Lander. Here’s a close up picture, well as close as the handrail would allow me to get without over reaching.

EXAIR Model 1110SS-NPT – Nano Super Air Nozzles

The interesting part to this is how this setup gives an idea of the amount of thrust given off by a nozzle that only consumes 8.3 SCFM of compressed air when powered at 80 psig inlet pressure. These nozzles can easily be fitted to blast debris or moisture out of small pockets or hard to reach areas. They also can be used to help direct product that may be getting diverted to a new conveyor. And, obviously, they can be used to propel scale models of lunar landers. 

If you would like to discuss any application for point of use compressed air, and I do mean ANY, give us a call. If I can’t help with the application we will at the very least do our best to send you in the right direction.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

EXAIR Air Nozzles – Here’s Their Simple ROI

Return on Investment, or ROI, is the ratio of profit over total investment.  Many people use it to check stocks, financial markets, capital equipment, etc.  It is a quantitative way in determining the validity for an investment or project.   You can use the ROI value to give a measurable rate in looking at your investment.

For a positive ROI value, the project will pay for itself in less than one year.  Any negative values would represent a high-risk investment.  In this blog, I will compare the ROI when replacing a ¼” NPT open pipe with a model 1122 2” Flat Super Air Nozzle.  Let’s start by looking at Equation 1 to calculate the Return on Investment:

Equation 1:  ROI = (Total annual savings – Total Project Cost) / Total Project Cost * 100

The second part of the equation, Total Project Cost, is the cost of the nozzles plus the labor to install them onto the machine.  The model 1122, 2” Flat Super Air Nozzle, has a price of $70.00 each.  The cost of a ¼” NPT Pipe that is roughly 2” long is around $1.50 each.  What a difference!  How could EXAIR been in business for over 35 years?  Let’s continue on with the Return on Investment…

The amount of time required to install the nozzles to the end of a pipe is 1/2 hour (generously).  The labor rate that I will use in this example is $75.00 per hour (you can change this to your current labor rate).  The labor cost to install a nozzle is $35.00.   The Total Project Cost can be calculated as follows: ($70 – $1.50) + $35.00 = $103.50.  The next part of the equation, Total annual savings, has more complexity in the calculation, as shown below.

As a reference, EXAIR Super Air Nozzles for compressed air would be considered like LED light bulbs for electricity.  The open pipes and tubes would represent the incandescent light bulbs.  The reason for this parity is because of the amount of energy that the EXAIR Super Air Nozzles can save.  While LED light bulbs are a bit more expensive than the incandescent light bulbs, the Return on Investment has a high percentage, or in other words, a short payback period.  On the other hand, the open pipe is less expensive to purchase, but the overall cost to use in your compressed air system is much much higher.  I will explain why.

To calculate the Total Annual Savings, we need to generate a blow-off scenario (You can use your actual values to calculate the ROI for your project).  In this example, I will compare the ¼” NPT open pipe to the 2” Flat Super Air Nozzle.  (The reason behind this comparison is that the model 1122 can screw directly onto the end of the 1/4” NPT pipe.)   The amount of compressed air used by a 1/4” NPT open pipe is around 140 SCFM (3,962 SLPM) at 80 PSIG (5.5 Bar).  The model 1122 has an air consumption of 21.8 SCFM (622 SLPM) at 80 PSIG (5.5 Bar).  At an electrical rate of $0.08 per Kilowatt-hour, we see that the cost to make compressed air is $0.25 per 1000 standard cubic feet, or $0.25/1000SCF.  (Based on 4 SCFM per horsepower of air compressor).

To calculate an annual savings, let’s use a blow-off operation of 8 hours/day for 250 days a year.   Replacing the ¼” NPT open pipe with a model 1122, it will save you (140 SCFM – 21.8 SCFM) = 118.2 SCFM of compressed air.  To put this into a monetary value, the annual savings will be 118.2 SCFM *$0.25/1000SCF * 60 Min/hr * 8hr/day * 250 day/yr = $3,546/year.  Now if you have more than one blow-off spot in your facility like this, imagine the total amount of money that you would save.

With the Total Annual Cost and the Project Cost known, we can insert these values into Equation 1 to calculate the ROI:

ROI = (Total annual savings – Total Project Cost) / Project Cost * 100

ROI = ($3,546 – $103.50) / $103.50 * 100

ROI = 3326%

With a percentage value that high, we are looking at a payback period of only 9 days.  You may look at the initial cost and be discouraged.  But in a little over a week, the model 1122 will have paid for itself.  And after using it for just 1 year, it will save your company $3,546.00.  Like with any great idea, the LED light bulb clicked on in my mind.  What could be the total savings if you looked at all the blow-off applications in your facility?

EXAIR Nozzles

In my experience, a loud blowing noise from your equipment is generally coming from an open pipe or tube.  With these “cheap” ways to blow compressed air, it will cost your company a lot of money to use as shown in the example above.  If you would like to team up with EXAIR to set up ways to increase savings, improve productivity, and increase safety, you can contact an Application Engineer to get started.  It can be as simple as screwing on a Super Air Nozzle.

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

Magnetic Bases and Stay Set Hoses: Adding Flexibility to EXAIR Products

EXAIR manufactures a variety of intelligent compressed air products that can cool, clean, coat, convey, and conserve.  They’re designed specifically with enhanced efficiencies, OSHA safety, and high quality in mind.  What could make them perform even better?  Making them movable!  EXAIR offers Magnetic Bases and Stay Set Hoses to achieve this.  In this blog, I will cover the features and benefits of both products.

Stay Set Hoses:

The Stay Set Hose gives you that possibility of manually adjusting and re-adjusting smaller EXAIR products like Super Air Nozzles and Air Jets.  The hose has a “memory” function, and it will not creep or droop until you physically move it.  They work very well in directing the air flows at specific target areas.

The Stay Set Hoses come in lengths from 6” (15cm) to 36” (91cm), and they have threaded connections with either ¼” NPT male on both ends or with a 1/8” NPT female and a ¼” NPT male types.

The hoses are made from reinforced synthetic rubber and have a pressure rating of 250 PSIG (17 bar).  They can add versatility to our Safety Air Guns and Blowoff Stations.  If you need positioning for precise blowing or adjustments for different targets, the  Stay Set Hoses would be a nice addition to include with your EXAIR products.

Magnetic Bases:

If you need a solid mount to steel surfaces or to move your blow-off system to different locations, the Magnetic Base will allow you to do these functions.  It has a 100 lb. (45.5Kg) pulling force to keep the blowing device attached firmly until you want to move it.  They can be mounted in a vertical or horizontal position.

EXAIR offers a single outlet Magnetic Base or a dual outlet Magnetic Base (for multiple blowing products). We also have a Magnetic Base with a swivel to help angle the blowing force.  The bases come with a ¼ turn shut-off valve to easily turn on and off the compressed air to the EXAIR products.

If you want to combine the Stay Set Hoses and Magnetic Bases with your EXAIR Air Nozzles and Air Jets, we can create this with the EXAIR Blowoff System.  We can combine multiple devices into a single model number.  At EXAIR, we pride ourselves with great customer service and an “easy to do business” philosophy.  You can contact a friendly Application Engineer to build an efficient, safe, and movable system just for you.

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

Upgrade Blowoff Applications with Engineered Products to Increase Safety and Efficiency

At EXAIR, it’s our business to make sure that you get the most out of your compressed air system.  We’ve got a Six Step plan to help you do just that, and one of those steps is the topic of today’s blog:

We have a couple of ways to help with step #1.  You can use a Digital Flowmeter to measure your total compressed air usage, and take advantage of our Efficiency Lab service to determine the consumption of individual compressed air devices that may be running up the total.  Based on our performance tests of those devices, we can recommend suitable EXAIR Intelligent Compressed Air Products to replace them with, along with the expected reductions in air consumption & noise levels…quieter is always better too.

We’re going to skip right over Step #2…just for now…but if you can’t wait, click on the picture above for more on finding & fixing leaks.

Once you get our recommended replacements in (I mean, why wouldn’t you?), they’re going to be part of your compressed air system, so naturally, we want to make sure you get the most out of them as well.  Key considerations are suitable supply lines, and proper installation.

In the case of a Super Air Nozzle or Air Jet, these are oftentimes one and the same.  They’re all small enough, and lightweight enough, to be adequately supported by compressed air piping (assuming the piping is adequately supported,) metal tubing (via a compression fitting adapter,) or even mounting solutions like our Stay Set Hoses.

Just a few ideas for installing an EXAIR Super Air Nozzle

Sometimes, though, you need a firm, vibration-resistant mounting…that’s where we recommend our Swivel Fittings.  A hex retainer tightly locks the ball in position, but allows for easy repositioning when loosened.  They come in standard NPT sizes from 1″ NPT down to 1/8″ NPT, and we even have them for the M4, M5, and M6 metric threads for our Atto, Pico, and Nano Super Air Nozzles.

Typical threaded fittings are limited in the angles you can achieve. EXAIR Swivel Fittings provide 50° of adjustability.

Even a highly efficient blow off needs to be aimed well in order to do its job well.  If you’d like to discuss how to get the most out of your compressed air system – or our products – give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Reduce Sound Level in your Factory, Improve Worker Safety and Comfort

Checking the sound level in your processes is an important aspect of ensuring a safe working environment for your employees. Loud noises and the exposure time can lead to significant health concerns. Permanent hearing loss, increased stress levels due to the uncomfortable work environment, and potential injury due to lack of concentration or inability to hear the surroundings are all examples of some risks associated with a noisy environment.

The Occupational Safety and Health Administration, known by most simply as OSHA, introduced Standard 29 CFR 1910.95(a) as a means of protecting operators from injury associated with high noise levels. The chart below indicates maximum allowable exposure time based on different noise levels. At just 90 dBA, an operator can operate safely for 8 hours. Open end pipe blowoffs and some air guns fitted with cross drilled relief holes will often result in noise levels in excess of 100 dBA. At 110 dBA, permanent hearing loss can be experienced in just 30 minutes!

OSHA Chart

The first step to lowering your sound level is to take a baseline reading of your various processes and devices that are causing the noise. EXAIR’s Sound Level Meter, Model 9104, is an easy to use instrument that provides a digital readout of the sound level. They come with an NIST traceable calibration certificate and will allow you to determine what processes and areas are causing the most trouble.

SoundMeter_new_nist225

From there, EXAIR has a wide range of Intelligent Compressed Air Products® that are designed to reduce compressed air consumption as well as sound levels. For noisy blowoffs where you’re currently using an open-ended pipe or a loud cross-drilled nozzle, EXAIR’s Super Air Nozzles are the ideal solution. Not only will they pay for themselves over time due to compressed air savings, but your operators will thank you when they’re able to hear later on in life!!

Drilled pipe is another common culprit of high noise levels. Rather than purchasing an engineered solution, the idea is that a simple drilled pipe is just as effective right? Not at all!! Not only does a drilled pipe produce exceptionally high sound levels, but the amount of compressed air used is also very inefficient. EXAIR’s Super Air Knife is available in lengths ranging from 3”-108” and has a sound level of just 69 dBA at 80 PSIG. At this sound level, operators won’t even require hearing protection at all!

SAK vs drilled pipe
EXAIR’s Super Air Knife is the ideal solution for replacing noisy, inefficient drilled pipe

With all of these products available in stock, EXAIR has the tools you need to reduce sound level in your processes. If you’d like to talk to an Application Engineer about any applications that you feel could benefit from a sound reduction, give us a call.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD