Being a Manufacturer Who Improves Manufacturing Has Benefits – For You

On many of occasions EXAIR has benefitted from our own products. One of the fertile areas for testing, product development, and customer feedback are our own manufacturing and assembly processes. Yes, EXAIR is a real factory in Ohio with employees, machinery, and equipment that uses our products everyday. Being a production facility leaves us best suited to understand the abilities, challenges, and opportunities of our customers. Today, I want to point out how two of our products have helped us to make Intelligent Compressed Air products that exceed your expectations. The Ultrasonic Leak Detector and Chip Trapper have both been studied at our facility to measure and understand the real benefits and capabilities of our products for our customers. Below is their story.

Leak Detector
Ultrasonic Leak Detector, Model 9061

 

Famously, one of the original case studies for our Ultrasonic Leak Detector took place at 11510 Goldcoast Dr Cincinnati, OH. (That’s EXAIR Corporation’s address). As the biggest rival against wasted compressed air, having it at EXAIR would be inconsistent with our own philosophy – we just can’t have it. Our President, Bryan Peters wrote about the benefits of the Ultrasonic Leak Detector in a blog “Free Money!…”. In the blog, he details the mystery of the compressed air costs during times when our plant was not running. Compressed air was so expensive that was costing us money while we were closed. Using the ultrasonic leak detector, EXAIR was able to find our leaks and fix them. The leaks in our system were miniscule compared to some old and very large compressed air systems. But even with our relatively small leaks we were able to save ONE MILLION CF per year of compressed air. This lost compressed air results in significant energy consumption as your compressors try to keep up with the demand caused by the leaky air lines. Please stop wasting money and energy on compressed air leaks. Find them today with EXAIR Ultrasonic Leak Detector.

EXAIR's new Chip Trapper
EXAIR’s Chip Trapper

At EXAIR, we also deal with a  variety of metalworking coolants as we manufacture aluminum, brass, and stainless steel parts. Before we started using our Chip Trapper, our water based coolant would last around 2 months. After those six weeks, we would vacuum out the coolant. After the coolant is pumped out, we would then shovel out the chips that had settled in the bottom of the sump. This task is time consuming, and the smell is awful from the rancid coolant. We found that by using a Chip Trapper weekly. We could extend our coolant life to six months. Some may say that cleaning the coolant sumps weekly is adding work. That is an old mentality though because by removing chips from the coolant weekly we save hours of labor we used to consume every two months and clean up our coolant in minutes not hours.  Here is a video to learn more. Our machinists loved our final prototype so much they kept it. You know how machinists are. Don’t mess with their tools.

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com

 

Identifying Reversible Drum Vac or High Lift Reversible Drum Vac

This summer we rolled out a new High Lift Reversible Drum Vac. Today, I received a phone call trying to figure out what Drum Vac the customer had. This led me to write a blog, “How can you tell the difference between a Reversible Drum Vac and a High Lift Reversible Drum Vac?”

The first identifier on the High Lift Reversible Drum Vac is the blue and black label attached to the muffler (pictured below), the label on our standard Reversible Drum Vac is silver and blue.

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High Lift Reversible Drum Vac Label

As time goes on the label may disappear from these rugged units after years of use. Our engineering team has had some forethought in this area, and we created a physical difference in the units that will not be removed, edited, or worn away. To confirm the identity of your Reversible Drum Vac, unscrew the body of the Reversible Drum Vac from muffler.

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High Lift Reversible Drum Vac (Left) Reversible Drum Vac (Right)

The High Lift Reversible Drum Vac will have a groove machined into the plug of the body. The Standard Reversible Drum Vac will be a smooth finish.

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The circled plug has the groove machined in it to identify the High Lift model.
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Close up showing machined groove

 

The High Lift Reversible Drum Vac doubles the lift of a Standard Reversible Drum Vac, which makes it great for any below grade liquid cleaning operations. The additional vacuum strength of the High Lift Reversible Drum Vac can be used to move viscous materials. Sludge, vegetable oil, and heavy motor oil can now be lifted from a coolant sump or trap at heights up to 15′ vertically. On top of this extra lifting capacity it features the same benefits as the Reversible Drum Vac. With no moving parts to wear out and no electricity required, it can operate safely and effectively for years.

Dave Woerner
Application Engineer
DaveWoerner@EXAIR.com
@EXAIR_DW

 

Chip Trapper Makes Coolant Last 6 Months Or More!

EXAIR's new Chip Trapper
EXAIR's new Chip Trapper

We’ve just been notified by “Plant Engineering Magazine” that their readers have named our new Chip Trapper “Product Of The Year”! That’s a very prestigious award and on behalf of all of us at EXAIR, thanks to all of you who voted for Chip Trapper. We also thank the people at “Plant Engineering” for their consideration.

Each year, “Plant Engineering” assembles a group of engineers and technical experts who review a long list of products that were made available in the past year. They narrow the list to come up with 112 finalists – companies they feel have offered something new and innovative. They show the 112 products in their November print and digital issues of the magazine and provide only the subscribers of the magazine a ballot to vote on their favorite product.  (Of course, companies with entries don’t receive ballots to keep it fair and honest.) Their circulation is almost 87,000 recipients!

If you haven’t seen Chip Trapper in action, please take a few minutes to watch our video.  Anybody who works in a machine shop understands why this product is a big deal. When the coolant that flows from those coolant nozzles slows to a trickle, you can easily end up having to take half a day (of lost production) to find the clog, clean the machine and replace the coolant. It usually ends up happening at a time when parts need to be finished by a deadline too! Using the Chip Trapper for only several minutes each week can make coolant that used to last only 6 weeks now last 6 months or more. Equally important, it gets rid of that nasty rancid coolant smell that can make you feel nauseous.

Are there other products out there that solve this problem? Not exactly! Most don’t work very well and can easily cost twice that of a Chip Trapper. We’ve tried a number of the other products in our own production and were never really satisfied with them. A lot of you who work in machining environments have probably arrived at that same conclusion. We took the problem into our own hands and developed the Chip Trapper to satisfy our own needs and those of our customers.

Is coolant management a big problem? To many we have spoken with, it is. The technical publications who have their fingers on the pulse of what is going on in industry understand this too. My January copy of “New Equipment Digest” just arrived and it has a large photo of the Chip Trapper on the front cover. They’ve also put a demo of it on their web site.  We appreciate their magazine getting the word out that EXAIR has solved a major coolant problem. If you know somebody who works with coolant, we’d appreciate it if you’d let them know too!

Kirk Edwards
Application Engineer
kirkedwards@exair.com