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

Customizing Blow-off Applications

EXAIR Blowoff Systems are a combination of EXAIR air Nozzles, mag bases and Stay Set hoses. They are available in single or dual outlets and can change the length of the Stay Set Hose and/or the type of nozzle. The flexibility of this product comes in handy when an application require multiple point blowoff or requires different force values from each nozzle. Customizing allows you to fit the nozzles directly to the need of the application.

Example of an EXAIR Blowoff System – these can be customized with different nozzles or length of hose to suit your application best.

One example of this came from a customer who was running a 1950’s era Benchmaster OBI press to stamp out copper lamination and spring steel. There current set-up which can be seen bellow was not really that effective, was loose/floppy, and had been glued together. All of this made it hard for the Technician to line everything up to eject the parts. The technician reached out to us to see if we could substitute some nozzles on our dual Blow-off system with the stay set hose and dual port magnetic base (as seen above). We were able to piece together a special kit for them to swap out one of the 1103 Mini Super Air Nozzles with a 1126 1″ Flat Super Air Nozzle to match the current set-up.

The Customer’s current ejection set-up in the punch press

Customizing the nozzles in Blow-off systems can allow for better coverage on awkwardly shaped parts that might have a mix of both smooth surfaces and crevices. Also changing out the length of the Stay Set hoses that come with the kits can allow you to reach all sides when centrally located mounting is not applicable. Using two different length stay set hoses can also allow for two different blow off points to share the same mounting and air line; this means your maintenance team wont have to bring in multiple drops which I’m sure they will appreciate.

Not only can we customize blowoff systems for you, since we manufacture the products here in Cincinnati, OH, we can provide custom features and performance characteristics for you. Our wonderful team of Engineers (just don’t tell them I said that) can design special air knives, nozzles, and even air amplifiers to fit your needs. The image below shows custom Air Amplifiers (with customer specified flanges) that we have built. We can customize our products to fit your needs.

Custom Stainless Steel Sanitary Flange Air Amplifier
Special Curved Super Air Knife

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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Measuring And Adding Sound Levels Together

What sound level do you get when you feed an EXAIR Super Air Nozzle at 80psig? What if there are two of them?  Or three?  Grab your scientific calculators, folks…we’re gonna ‘math’ today!

But first, a little explanation of sound power & sound pressure:

Strictly speaking, power is defined as energy per unit time, and is used to measure energy generation or consumption.  In acoustics, though, sound power is applicable to the generation of the sound…how much sound is being MADE by a noisy operation.

Sound pressure is the way acoustics professionals quantify the intensity of the sound power at the target.  For the purposes of most noise reduction discussions, the target is “your ears.”

The sound levels that we publish are measured at a distance of 3 feet from the product, to the side.  The units we use are decibels, corrected for “A” weighting (which accounts for how the human ear perceives the intensity of the sound, which varies for different frequencies,) or dBA.  Also, decibels follow a logarithmic scale, which means two important things:

  • A few decibels’ worth of change result in a “twice as loud” perception to your ears.
  • Adding sources of sound doesn’t double the decibel level.

If you want to know how the sound level from a single source is calculated, those calculations are found here.  For the purposes of this blog, though, we’re going to assume a user wants to know what the resultant sound level is going to be if they add a sound generating device to their current (known) situation.

Combined Sound Level (dBA) = 10 x log10[10SL1/10 + 10SL2/10 + 10SL3/10 …]

Let’s use an EXAIR Model 1100 Super Air Nozzle (rated at 74dBA) as an example, and let’s say we have one in operation, and want to add another.  What will be the increase in dBA?

10 x log10[1074/10 + 1074/10] = 77.65 dBA

Now, there are two reasons I picked the Model 1100 as an example:

  • It’s one of our most versatile products, with a wide range of applications, and a proven track record of efficiency, safety, and sound level reduction.
  • We proved out the math in a real live experiment:

Why do I care about all of this?  My Dad experienced dramatic hearing loss from industrial exposure at a relatively young age…he got his first hearing aids in his early 40’s…so I saw, literally up close and very personal, what a quality of life issue that can be.  The fact that I get to use my technical aptitude to help others lower industrial noise exposure is more than just making a living.  It’s something I’m passionate about.  If you want to talk about sound level reduction in regard to your use of compressed air, talk to me.  Please.

Russ Bowman
Application Engineer
EXAIR Corporation
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Reduce Sound Levels In Less Than A Minute

Okay, I will admit, the title may be a tad bit leading.  The fact is, it can be done.  I speak to customers almost daily who are struggling with the noise levels produced from open pipe blowoffs.  With Noise Induced Hearing Loss (NIHL) a significant problem among manufacturing workers, reducing the noise form compressed air can be a simple solution and contribute toward reducing overall noise exposure levels. Many of these calls and emails revolve around reducing these exact noise levels, sometimes the open pipes have existing threads on them to install the solution immediately.

To reduce these noise levels, we need to simply reduce the amount of energy that is being expelled through the pipe. How do we do this you might ask?  The use of an air nozzle will reduce the energy being dispersed from an open pipe.  This will result in lower air consumption as well as lower sound levels while actually increasing velocity as the pipe will maintain higher operating pressures. Be cautious about the air nozzle you choose, however, they are not all created equal. EXAIR’s engineered air nozzles are among the quietest and most efficient air nozzles available.

Family of Nozzles

What size pipes can we fit nozzles to?  That’s a great question.  We have nozzles that range from a 4mm straight thread all the way up to 1-1/4″ NPT thread.  This also includes nearly any size in between especially the standard compressed air piping sizes.  For instance, a 1/4″ Sched. 40 pipe that has 1/4″ MNPT threads on it can easily produce over a 100 dBA noise level from 3 feet away.  This can easily be reduced to below 80 dBA from 3′ away by utilizing one of our model 1100 Super Air Nozzles.  All it takes is a deep well socket and ratchet with some thread sealant.

This doesn’t just lower the sound level though, it reduces the amount of compressed air expelled through that open pipe by creating a restriction on the exit point.  This permits the compressed air to reach a higher line pressure causing a higher exit velocity and due to the engineering within the nozzle, this will also eliminate dangerous dead-end pressure and complies with OSHA standard 29 CFR 1910.242(b).

Easy Install

All in all, a 30-second install can make an operator’s work station considerably quieter and potentially remove the need for hearing protection.  If you would like to discuss how to lower noise levels in your facility, contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF