Compressed Air: Only as Intelligent as Your Accessories

How often have you seen a compressed air system functioning at 100% efficiency? Do you have the right accessories to provide a source of clean air at the proper pressure? Even with the right accessories, have they been maintained in good working order? Chances are that some of your components are in fact in need of attention such as a clogged filter, improper regulator or maybe undersized hoses. Your air compressor is only as intelligent as the weakest component in your system.

This is why you need to make sure all of your EXAIR accessories are properly fitted and located in the most efficient locations. Your compressor is capable of producing compressed air but your accessories will allow it to function the way it is meant to function. Using accessories and using them in the right manner is the intelligent choice, it will minimize your maintenance while increasing your energy efficiency for the life of your compressor. Let’s review a few of the most important compressed air accessories you should consider.

Filter Separators: Filters remove and separate water, dirt and scale from your compressed air system to keep your air clean and output pure. Clean air keeps your air products and machines more efficient and reduce the frequency of maintenance. Filter Separators will accumulate particulate matter naturally so they will need cleaned and/or replaced filter elements regularly depending on your operating environment. EXAIR provides Filter Separators and recommend they be installed prior to an Oil Removal Filter, pressure regulator or valve.

Filter Separators

Oil Removal Filters: Many air compressors use oil to lubricate therefore the risk of oil in your air lines is imminent. Although oil may not affect the compressed air system itself it can become a problem with products which do not require oil and have small air gaps. It can also be problematic if oil is blowing on to packaging or the final product. Keep this in mind and remember that oil should be removed from compressed air lines in certain instances. EXAIR’s oil removal filters will remove oil and solid particulate found in many compressed air systems.

Pressure Regulators: Regulators adjust the air pressure being supplied by your air compressor to the level that you require at the point of use. For instance your compressor generates 150 PSI but your compressed air product only requires 80 PSIG, the regulator can adjust the pressure to the desired setting and also relieve undue pressure on fittings, hoses and tools. Reducing pressure at the end-use product will also reduce the air consumption. Almost every compressed air application will use tools with varying pressure ratings making EXAIR Pressure Regulators a must-have accessory.

Hoses & Fittings: Hoses and fittings wear with time. Common issues are kinking, bending, leaks and contaminants, they should be checked often and replaced when required. Another common problem with hoses is that they are either too long and not as efficient or too short which can cause your employees reduced productivity. EXAIR offers STAY SET Hoses, Conveying Hose, Coiled Hoses and Compressed Air Hoses of different sizes and lengths. Our selection of compressed air fittings insures you can get all you need from one location.

Receiver Tanks: The use of receiver tanks can improve your overall system efficiency. Storage receivers can be placed near equipment that consume short duration of high flows of compressed air that might cause localized low pressure. EXAIR’s 60 Gallon Receiver Tank placed near the point of use can smooth out the high flows so as not to cause the start of an extra air compressor or cause localized low pressure.

If you would like more information regarding how proper use of EXAIR’s accessories can make your compressed air consumption more intelligent please contact me or any of our qualified Applications Engineers to discuss your applications.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK

 

EXAIR Celebrates Manufacturing Day With A Win For A Manufacturer

In 2012, the National Association of Manufacturers organized an effort to proclaim the first Friday in October (hey, that’s today!) as Manufacturing Day.  According to the Advanced Manufacturing National Program Office (a division of NIST, the National Institute of Standards & Testing,) the purpose of MFG Day is “to raise awareness among students, parents, educators and the general public about modern manufacturing and the rewarding careers available.”

Today is kind of a big deal around here.  Not only is EXAIR Corporation a manufacturer, but many of the companies that use our products are as well.  A lot of us have a rich story, woven into the cloth of the history of American manufacturing (which, in turn, is woven into the larger cloth of American history.)  Have you heard the one about the motivated inventor with an idea to make innovative products who started an operation out of his home that, with inspired direction & vision, became a worldwide leader in their industry?

Yeah; that’s us.  Today, we’re honoring Roy Sweeney’s legacy (he founded the company in October 1983,) and celebrating MFG Day, by publishing a new Case Study, proving out the benefits of the use of EXAIR Intelligent Compressed Air Products in regard to the monetary savings associated with the reduction in compressed air use, and the noise level reduction from the implementation of our engineered products.

You can download the complete Case Study here, but while we’re on the subject, here’s a basic rundown:

  • A roll forming operation used to blow off their product with a combination of loud and inefficient devices: copper tubing and modular flexible hose which is designed primarily for machine tool coolant, but often misapplied for use with compressed air.
  • It worked just fine, but an engineering study noted it as a potential wasteful use of compressed air.  That’s when they called us.
  • By replacing those blow offs with Model 1100 Super Air Nozzles and Model 1122 2″ Flat Super Air Nozzles, their noise levels dropped from 107 dBA to 83.8 dBA.  To put that in perspective, it went from the approximate sound level of a rock concert to that of a leaf blower. (ref: Centers for Disease Control & Prevention: What Causes Hearing Loss?)
  • Compressed air consumption dropped by more than half, from 190 SCFM to 86.8 SCFM…an annual savings of over $3,200.00.  All for an investment of $654.00 (2020 pricing) for those engineered Air Nozzles, Stay Set Hoses, and Magnetic Bases.  That means they’ll have paid for themselves in just under two months.
  • In addition to that, for participation in this Case Study, we’re giving them a generous credit on their order.  Happy Manufacturing Day!

And frankly, I think the engineered products just look better too.

Last but certainly not least, this reduction in compressed air usage decreases the load on their air compressors, reducing the electrical power consumed.  Product impact, along with our own consumption of resources and waste recycling, is a key component of EXAIR Corporation’s Sustainability Plan.  We’re making the world a better place, by making products that make the world a better place, using methods that make the world a better place.  I can’t think of a better way to celebrate Manufacturing Day.  If you want to get in on it, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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MFG Day logo courtesy of nist.gov

Are EXAIR’s Hoses and Tubes Right For You?

Are you tired of ducking and dodging hard pipe everywhere? Do you need something more mobile for your compressed air? Then EXAIR Hoses and Tubes might be a solution for you. EXAIR offers a variety of hoses and tubes in different styles designed to work with our products without affecting performance. These products simplify the use, setup, and integration of our various products into your process. Normally if you were to buy hoses you would need to determine the proper diameters, pressure ratings, and/or end fittings to best fit the item in use. This is all unnecessary when purchasing EXAIR’s Hoses and tubes for EXAIR products since everything is sized and properly rated to be used with our products. So, ask our Application Engineers if EXAIR Hoses and Tubes are right for you.

 Products may include the following.

Line Vac air operated conveyor hose
Conveying Hoses:

These hoses are used with our Air Operated Conveyors or Line Vacs which are used to convey material from point A to point B. The hose can be mounted on either side of the Line Vac using the properly sized hose clamp that comes with it. The Conveyance hose is made out of a durable PVC semi-flexible material in sizes from ¾” I.D. to 3” I.D. to match our Line Vac sizes. They also come in lengths up to 50’ in increments of 10’.

Coiled hose
Coiled Hoses:

When it comes to getting compressed air to our safety air guns, we offer a series of abrasion-resistant nylon Coiled Hoses. The coiled hose comes in a 12’ long length and comes in 3 sizes; these sizes are 1/8” NPT, ¼” NPT, and 3/8” NPT to attach right to EXAIR’s Safety Air Guns. The hoses also include swivel fittings to make for easier uncoiling. The coiled design makes it easy to reach around the work area and retract back to the substation. With the right size hose Coiled Hoses can supply the required amount of compressed air with minimal amount of pressure drop.

Compressed air hose
Compressed Air Hoses:

Compressed Air Hose can be used to reach equipment from overhead or near equipment. These hoses are made with synthetic rubber and comes in 3/8” I.D. and ½” I.D… Lengths up to 50’ long can be provided and the hoses are rated for up to 250 psig air pressure. These hoses can provide lasting protection from ozone, weathering and temperatures up to 158oF. They also come with two male ends in ¼” NPT or ½” NPT.

Stay Set Hoses
Stay Set Hoses:

Bendable and flexible, the stay set hose allows for manual positioning of your compressed air product. Equipped with “memory” function, the hose will not creep or droop until it is physically moved. The Stay Set Hose comes in lengths from 6” to 36” in length, and they offered in a combination of 1/8” and ¼” MNPT connections. These hoses are rated for 250 psig and are made of a reinforced rubber.

E-Vac Tubing

Vacuum Tubing:

When it comes down to our E-Vac product line, EXAIR offers vacuum tubing to be used along with the unit. This tubing is made from polyurethane and comes in 1/8” O.D. and 3/8” O.D. up to 50’ in length in increments of 10’.

If you have any questions about compressed air systems or want more information on any of EXAIR’s products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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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