Growing up as a kid of the 80’s I remember wanting a Nintendo 64. This was very much a want due to the excellent advertising and having friends that got them when they first came out. So, like many kids of the times, I set forth to present my case to my parents and sell them on the benefits to me receiving this 64 bit wonder of the world. These benefits all revolved around me doing chores and “helping” to earn money to go towards the end goal. Thinking back now, I really should have started to learn more about negotiating earlier in life because my parents and older brother really made out on the deal. The point is, I had to make sure that they saw a return on their investment. Mainly, I would be entertained and they would get some stuff done around the house without complaints.
Well, flash forward to today and I still feel as though it is always an easy justification if I have supporting evidence of the benefits and even better, if there is some form of cost savings that will be had by spending money on a project or a tool. Often times the justification is the amount of time spent on a task. Well, here at EXAIR we completely embrace that justification culture and, in many cases, can provide you the information necessary to present to management or budget committee – the simple ROI your company will see when investing in EXAIR products. The best part is, this study is always free.
The way it works is pretty simple, we want to compare your current solution to our engineered products. EXAIR has a simple form that gets filled out (or you can call, e-mail or chat) explaining your application to us. We ask for a few key pieces of detailed information, and for you to send one of your current solutions (the nozzle, homemade device, or open tube for example). Then we run side by side tests in house to determine air consumption, noise, and force at the same pressure you are using at your facility. That’s right, this testing is all done here at EXAIR through our EXAIR Efficiency Lab. We document these performance characteristics and send a report showing a simple return on investment for you if you replace your device with an EXAIR engineered solution.
This information is then easily backed up by our 30 day guarantee on stock products. Get the EXAIR solution in, test it in your facility and see how the savings stack up. If there is anything that doesn’t stack up, you simply let us know and send the units back.
The entire Efficiency Lab and 30 day guarantee are offered to all of our customers that are within the US and Canada. If you would like to discuss what is possible for you and your team, please reach out to an Application Engineer.
If you’re a follower of the EXAIR Blog, you’re probably well aware that compressed air is the most expensive utility in an industrial environment. The average cost to generate 1000 Standard Cubic Feet of compressed air is $0.25. If you’re familiar with how much air you use on a daily basis, you’ll understand just how quickly that adds up. To make matters worse, many compressed air systems waste significant amounts of compressed air just through leaks. According to the Compressed Air Challenge, a typical plant that has not been well maintained will likely have a leak rate of approximately 30%!! Good luck explaining to your finance department that you’re carelessly wasting 30% of the most expensive utility. To make sure you get the most out of your compressed air system, it’s important to follow the Six Steps to Optimizing Your Compressed Air System.
Starting with Step 1: Measure the air consumption to find sources that use a lot of compressed air. In order to have an understanding of your compressed air usage across various processes and in your entire facility, you have to measure and produce a baseline. Without a measurement of usage, there’s no way to determine your actual costs or evaluate opportunities for savings. To do so, EXAIR offers a range of Digital Flowmeters from stock. The Digital Flowmeter provides a digital readout of the exact amount of compressed air being used. Many companies will install the DFM on each major leg of their air distribution system to allow for constant monitoring and provide a benchmark of compressed air usage.
Once you’ve measured your baseline, it’s time to explore another simple avenue of savings. Step 2 in the process is finding and fixing leaks in your current system. EXAIR offers our Model 9061 Ultrasonic Leak Detector to allow you to locate and fix any leaks within your distribution system. With an unmaintained system wasting on average 30% of the produced volume, this one seems like a no-brainer but is often overlooked. If you can hear the leak without the help of a device like the ULD, it’s a VERY bad leak. These should be located, tagged, and repaired ASAP!
After getting a baseline measurement of the air consumption in your facility of compressed air usage and locating and fixing leaks in your system, it’s time to begin implementing some changes. Step 3 of the 6 Steps to Optimizing Your Compressed Air System covers upgrading your blowoff, cooling, and drying operations using engineered compressed air products. EXAIR manufactures a variety of products that can help to ensure you’re using your compressed air in the best way possible. While it may seem simple, easy, and cheap to use something like an open-ended pipe or tube for blowoff, the fact of the matter is that the volume of air that these homemade solutions use quickly make them more expensive. Look no further than EXAIR when seeking a safe, efficient, and reliable engineered blowoff solution.
Step 4 may be the easiest of any of the others. TURN IT OFF! You can’t waste compressed air when it’s turned off. By strategically placing valves at various points throughout the distribution system, it allows you to isolate areas of the facility that may not require continuous compressed air usage. It isn’t exactly feasible to eliminate every single leak, so even if you’ve closely followed Step 3 it’s still beneficial to close some valves here and there to further reduce your consumption. In some applications, such as products traveling on a conveyor, it may be possible to utilize a product like EXAIR’s Electronic Flow Controller to ensure air isn’t wasted in between parts on the conveyor.
The 5th step in the 6 steps to optimizing your compressed air system highlights the use of intermediate storage of compressed air near the point of use. Receiver tanks are installed in the distribution system to provide a source of compressed air close to the point of use, rather than relying on the output of the compressor. Compressed air receiver tanks are an integral part to many compressed air distribution systems. Compressed air is stored at a high pressure after drying and filtration, but just upstream of point of use devices. The receiver tank is charged to a pressure higher than what is needed by the system, creating a favorable pressure differential to release compressed air when needed.
Think of a compressed air receiver tank as a “battery”. It stores the compressed air energy within a system to be used in periods of peak demand, helping to maintain a stable compressed air pressure. This improves the overall performance of the compressed air system and helps to prevent pressure drop. They should be placed strategically to provide a source of compressed air to intermittent high-volume applications.
The last step, Step 6, discusses the use of pressure regulators at the point of use. Pressure regulators are available to control the air pressure within the system and throttle the appropriate supply of air to any pneumatic device. As the last of the six steps to optimizing your compressed air system, controlling air pressure so that you’re only consuming as much as necessary can have a dramatic impact. EXAIR sells a variety of systems that will include a suitably sized pressure regulator to ensure you’re operating as efficiently as possible.
Follow these 6 steps and make sure you get the most out of your compressed air system!
There are six steps in optimizing your compressed air system. This entry will focus on Step 2 “Find and Fix leaks in your compressed air system”. Each of the six steps make an impact toward optimizing your compressed air system but finding and repairing your leaks will save you hundreds if not thousands of dollars every year. Major leaks can be felt or heard as you walk around and are somewhat easy to identify. The smaller leaks, which can not be heard or felt, can be found using EXAIR’s Ultrasonic Leak Detector (ULD).
EXAIR Model 9061 will help you find all the smaller leaks that go unnoticed yet add up to become a significant portion of air loss within any air savings program. This Ultrasonic Leak Detector (ULD) is a hand held, high quality instrument that can locate costly leaks in your compressed air system. The person using the ULD need only aim it in the direction of a suspected leak. When a leak is present, an audible tone can be heard with the use of headphones, and the LED display will light. Testing the various unions, pipes, valves and fittings of a complete installation can be done quickly and effectively at distances up 20 feet ( 6.1 m) from a leak.
Compressed air systems that are not maintained can easily waste up to 30% of the compressor output through leaks that go undetected. Compressing air is an expensive operation. Saving the wasted compressed air reduces overall operating costs. Smaller insignificant air leaks may not be a problem but when you add up and repair the multiple smaller leaks it will lead to significant annual savings.
If you have a compressed air system and want to find and repair your leaks EXAIR Model 9061 is a must have for finding all your leaks. If you have questions or need help please contact any one of our Application Engineers for assistance.
Compressed air can be one of the more expensive utilities to use in a facility, but a compressed air system is full of simple opportunities to increase efficiency and minimize the cost. Much like how you can take multiple steps to save electricity at your house there a few simple steps you can take to save your compressed air. These steps include finding and repairing leaks, compressor maintenance, minimizing pressure at the point of use, and turning the compressed air off when not in use. Implementing these steps and using the right tools to achieve them can lead to significant dollar savings – in fact our website case studies, other blog articles and catalog are filled with example after example of air (and dollar) savings success! And let’s be honest here, who doesn’t like saving money.
First off is finding your leaks. Leaks are one of the major wastes of compressed air in a system that could happen. Leaks in a compressed air system can account for wasting 20-30% of a compressors output. These leaks can commonly be found in pipe joints, devices that use the compressed air, quick connect fittings, and storage tanks. All of this compounds to wasting air much like a leaky faucet wastes water – little by little it grows until it simply needs to be addressed. One of the ways to help find leaks in your system is EXAIR’s affordable Ultrasonic Leak Detector. This leak detector uses ultrasonic waves to detect where costly leaks can be found so that they can be patched or fixed.
Choose efficient end-use products. Engineered air knives, air amplifiers, air nozzles and safety air guns can dramatically outperform (use less air) than commercial air nozzles and in-house solutions such as drilled pipes, open air lines and other creative “fixes”. We have seen some very nice in-house solutions from customers who have put in some significant time and effort, but they all have one thing in common – they use more air than any of EXAIR’s engineered solutions.
Minimizing your pressure can also save you money by limiting the amount of compressed air that is being used. Pressure and volume go hand and hand, the higher the pressure the higher the volume of air and vice versa. By minimizing the pressure that you are using you are also minimizing the amount of air that is being used which means savings. Each CFM used can be associated with a certain price value so the less you use the more you save. You also cut down on the amount of work the compressor has to do and how often the compressor has to cycle. Pressure can be minimized using one of EXAIR’s Pressure Regulators to cut down on the amount of air being used.
Turn off the compressed air when it is not in use. Just like how you wouldn’t leave the faucet running or lights on in a room that is not being used, don’t leave your compressed air running (insert bad dad joke). Constantly using compressed air even when not in use will cause the compressor to cycle more often wasting money. Each CFM has a price to it so don’t waste CFM’s blowing it back into the air and doing nothing. This can simply be done by adding one of EXAIR’s ball valve or solenoid valves to turn off when you are done using it. Also, if you want to take it another step farther you can look at using one of EXAIR’s Electronic Flow Controllers (EFC). The EFC uses a photo eye attached to a timer that will open a solenoid valve for a set amount of time when it detects an object within 3’ of the photo eye. This will turn the air on only when your product is in the air path and turn it off during any spaces in between.
Compressor maintenance is another important step to minimizing the cost of compressed air. Neglected air compressors can cause a lot of issues ranging from expensive repairs to a decreases in efficiency. Wear and tear placed on the motor of an air compressor can cause the compressor to produce less compressed air (SCFM) at the same power consumption. This means you are paying the same amount of money and getting less out of it. Making sure that your compressor or any machine is always running at its optimal performance and should always be a priority for any facility.
There are many different ways to save on compressed air, these are just a few of them. Reducing air use will save money and reduce the demand on your compressor which in turn can prolong the life of your air compressor. If you have questions about how to save on compressed air or any of our engineered Intelligent Compressed Air® Products, feel free to contact EXAIR or any Application Engineer.
Cody Biehle Application Engineer EXAIR Corporation Visit us on the Web Follow me on Twitter Like us on Facebook