Benefits of Air Nozzles Replacing Coolant Lines used for Air

Over the years, EXAIR has come across many different types of blow-off devices.  We have seen copper tubes, pipes with crushed ends, fittings with holes drilled into them, and modular flex lines.  For compressed air use, these are very dangerous and very inefficient.

A plastic machining center was looking for a better way to blow compressed air.  They were using modular flex lines, similar to Loc-line, which are mainly designed for spraying coolant.  They had 14 blow-off lines in their plant that were about 18” (457mm) long and operated 8 hours a day at 40 PSIG (2.8 bar).  They liked the positioning feature of the flex line, but they could tell by the loud noises that they were wasting compressed air.  So, they contacted EXAIR.

When EXAIR started to manufacture compressed air products in 1983, we created a culture in making high quality products that are safe, effective, and very efficient.  With our Super Air Nozzles, we engineered a way to entrain the ambient air to add mass to the air stream to use less compressed air with a strong force.  This is done by the Venturi method.  We create a high velocity which will make a low pressure at the exit.  The surrounding air is drawn into the compressed air stream increasing efficiency.  We also engineered fins to support OSHA compliance in noise levels and dead-end pressure.  So, if your skin comes in contact with an EXAIR nozzle, the end will not be able to be blocked and allow air to penetrate the skin membrane; even above 30 PSIG (2 bar).  I went over the cost savings and safety solutions that EXAIR’s products could give.

EXAIR Super Air Nozzle entrainment

Since the modular flex lines had a ¼” (6mm) opening, I recommended the model 1100 Super Air Nozzle with a Stay Set Hose.  This recommendation is from experience with these types of blow-off devices.  The Stay Set Hoses will give them that possibility of manually adjusting and re-adjusting the Super Air Nozzles.  The hoses have a “memory” function and will not creep or droop until you physically move it.  They work well to direct air flows at specific target areas like the flex lines above.  For the company above, I recommended the model 1100-9218 which is a model 1100 Super Air Nozzle with an 18” (457mm) long Stay Set Hose.  It was easy to remove the flex line and replace it with a safer and more efficient product

Model 1100-9218

Now, let’s look at the savings.  The Super Air Nozzle with the 18” Stay Set Hose cost $92.00 each.  The flex line is generally around $10.00 each.  But this is not the total cost of ownership.  As an efficiency comparison, the model 1100 Super Air Nozzle will only use 8 SCFM (227 SLPM) of compressed air at 40 PSIG (2.8 bar); and, the noise level is reduced to 70 dBA for each nozzle.  At 40 PSIG (2.8 bar), the flex line had a noise level of 97 dBA and an air usage of 19 SCFM (538 SLPM).

For the annual savings and the payback period, I will look at the electrical cost.  (Since the Super Air Nozzle is using less compressed air, the maintenance and wear on your air compressor is reduced.)

  • The air savings is calculated from the difference in air usage; 19 SCFM for flex line – 8 SCFM for Super Air Nozzle = 11 SCFM savings per blow-off device.
  • With 14 flex lines, the total compressed air savings will be 11 SCFM * 14 = 154 SCFM.
  • To get into the cost, an air compressor can produce 5.36 SCFM/KW of electricity at a cost of $0.10/KWh.  For an annual savings, we have the figures from the information above; 8 hours/day * 250 days * 154 SCFM * $0.10/KWh * 1KW/5.36 SCFM = $5,746.27/year.
  • For a payback period, the model 1100-9218 has a price of $92.00 each, or $1,288.00 for 14 systems.  The flex lines were $10.00 each, or $140.00 total.  The payback period will be ($1,288 – $140) / ($5,746.27/year) * (12 months/year) = 2.4 months.  Wow, what a savings!

Not all blow off devices are the same.  With the customer above, they were able to cut their noise levels, remove the dead-end pressure concerns, and save $5,746.27 a year in compressed air.  If your company decides to select an unconventional way to blow off parts without contacting EXAIR, there can be many hidden pitfalls; especially with safety.  Besides, if you can save your company thousands of dollars per year as well, why go with a non-standard nozzle?  If you are using compressed air for blowing, cooling, cleaning or moving material; you should contact an Application Engineer at EXAIR.  What do you have to lose?

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

Process Improvement, ROI and Safety from One Air Nozzle

Process improvement projects can be detailed, complex, expensive, and take a long time to prove their worth.  Today, I want to tell you about one that WAS NOT ANYTHING like that.

A metal stamping company used compressed air to blow their products from their dies.  They did what many do – they ran some copper tubing, and aimed it at the platen so it would properly eject the parts as they were stamped.  They KNEW it was loud, and they suspected it was inefficient as well.

After discussing the setup and seeing a picture of it (the one on the left, below,) I recommended installing a few engineered Super Air Nozzles to lower the noise levels considerably.  Boy, was I wrong.  About “a few” nozzles, that is…turns out, they only needed one Model 1122-9212 2″ Flat Super Air Nozzle with 12″ Stay Set Hose.  The copper tubes come from a manifold that already had 1/4 NPT ports – installation took a matter of minutes.  Nothing detailed, complex, or expensive about it:

This loud & inefficient copper tubing blowoff was just a compression fitting (and a Model 1122 2″ Flat Super Air Nozzle) away from being quiet and efficient.

It didn’t take much longer than that to prove its worth either: as soon as they noticed how much the noise level went down on THIS press, they ordered them for the other eighteen presses in their facility as well.

The 1/4″ copper tubes blew continuously from a pressure regulator set @60psig…the three of them theoretically consumed a total of ~80 SCFM.  The Model 1122, at 60psig supply, consumes only 17.2 SCFM.  Simple return on investment was as follows:

  • 80 SCFM was costing them $48.00 a week
    • 80 SCFM X 60 min/hr X 8 hr/day X 5 days/week X $0.25/1,000 CFM = $48.00
  • 17.2 SCFM, using the same formula, only costs $10.32 a week (I’ll let you do the math; it’s good practice.)
  • They saved $37.68 a week.  The Model 1122-9212 costs $116.00 (2020 pricing) – that means that each of them paid for themselves in just a hair over three weeks.
  • $37.68 x 50 work weeks per year = $1884.00 saved annually per nozzle
  • $1884 x 18 (the number of presses) = $33,912 saved annually 

Considering they also didn’t have to listen to those very loud open ended copper tube blowoffs, I think you’ll have to agree it made for a very good investment.  They did. The new nozzle runs at 77 decibels, a comfortable level and well below the OSHA standard [29 CFR – 1910.95(a)] for allowable noise exposure.

If you’d like to find out how EXAIR Intelligent Compressed Air Products can save you money on compressed air – and save everyone’s hearing – give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Swivel Fittings: Adjusting Their Way Into Your Application

Ever had that spot that you needed to blow off but no matter how hard you tried you couldn’t reach the spot with piping? Well here at EXAIR we’ve got a solution for you; Introducing the swivel fitting! When blowing off various parts it is better to have an angled sweep of air rather than blowing directly across or directly down onto the part. EXAIR’s Swivel fittings provide a movement of 25 degrees from the center, meaning a total of 50 degrees.

EXAIR’s Swivel Fittings Adjusted
Regardless of size of the air nozzle we can provide a swivel fitting to fit all of our nozzles starting at an M4 Thread up to a 1” NPT. The M4 (4mm), M5 (5mm), and M6 (6mm) swivel fittings come with a Female NPT to screw the nozzle into and a Male NPT to attach to the swivel fitting to the pipe. For our 1/8” Fitting up to the 1” Fittings a male NPT is used to connect the Nozzle and a female NPT is used to connect to the pipe. The swivel fittings can easily be adjusted by either loosening or tightening the center hex nut.
EXAIR’s Family of Swivel Fittings
If the swivel fitting doesn’t give you the adjustment that you need, they can be coupled with our Stay Set Hoses to give extra adjustment and positioning. Our stay set hoses come in lengths of 6” all the way up to 36” and provide easy positioning for your application. Of course, these hoses can also be used without a swivel fitting. 
EXAIR’s Family of Stay Set Hoses
Swivel fittings are not used with just air nozzles, in many cases swivel fittings have been used with our smaller Air Amplifiers and our 3” Air Knifes.

For more information on EXAIR’s Swivel Fittings, Stay Set Hoses, or any EXAIR‘s 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.

Cody Biehle
Application Engineer
EXAIR Corporation
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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