HEPA Vac Improves Cleaning Process AND Keeps Operators Safe!

On a recent visit with our Hungarian Distributor, I had the pleasure of visiting an automotive leather manufacturing plant. They process and cut to order a wide variety of different styles of leather used in the manufacturing of European automobiles. In one of their machines, a grinding process is performed that smooths out the cut edges of the material before they’re stitched together.

The grinding process itself is self-contained within the machine, but the significant amount of leather dust created needs to be periodically cleaned out. If not, it ends up accumulating on some of the internal components and increasing the downtime and maintenance required on the machine. Due to this, they implemented a 2x per shift cleaning operation.

The machine has several tight spaces inside where the dust accumulates. They’d shut off the machine and blow out the dust. Then, sweep up all of the dust into a dustpan and dump it in the trash. This entire process took approximately 30 minutes each time for 1-hr/shift. With three shifts operating 24/7, that’s 3-hrs/day of lost production time for this particular cleaning process, still less than what they were experiencing as a result of the machine downtime when they weren’t regularly cleaning it.

HDHEPAVac559

However, the primary concern of theirs was that they were now blowing dust all over the shop causing a potential health hazard to their operators. They wanted a solution that would allow them to clean the machine, without presenting an additional hazard. We tested with a Mini Chip Vac first, but the dust was a bit too fine and was still passing through the filter bag.

For fine dusts such as this, the Heavy Duty HEPA Vac is the more suitable option. After testing the Heavy Duty HEPA Vac, it was clear that this was the solution they were hoping for. The high-powered vacuum made quick work of the dust inside, while keeping it contained inside of the drum by the HEPA filter.

They still need to stop and clean the machine out 2x/shift, but now the process only took 10 minutes. They reduced their overall downtime on this machine per day by 2/3 to just 1hr, while keeping their operators safe. While this wasn’t the reason for looking at new solutions, it was definitely an added benefit. If you’re looking for a maintenance-free vacuum system for cleaning up in your facility, EXAIR has a wide range of Industrial Housekeeping solutions available from stock.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Video: EXAIR Drum Vacs Selection For Solid Materials

EXAIR Corporation has engineered compressed air solutions for Industrial Housekeeping…among them, a full line of drum mounted vacuums for dry/solids cleanup.

If you’d like to find out more, please give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Compressed Air Vacuums and Their Advantages Over Electric Vacuums

EXAIR‘s line of Industrial Housekeeping Products consist of liquid and dry vacuums that utilize compressed air to operate. They do not have loud electric motors which most ‘all purpose’ electric vacuums rely on.  In industrial settings with harsh conditions and rugged use, EXAIR’s Industrial Housekeeping Products are better suited for the everyday wear and tear of typical manufacturing, commercial and construction environments.

When you look at EXAIR vacuums, you’ll notice there is not an electrical cord.  Because the EXAIR Industrial Housekeeping Products utilize compressed air for operation. This means they do not have the same maintenance issues of an electric motor which breakdown and fail when dirt, dust and temperature take their normal toll on moving parts. With EXAIR vacuums there are no moving parts: no motors to burn up, no bearings to wear out, and no impellers to clog in the vacuum units. They also run quieter than a typical electric vacuum.

They are maintenance free, just supply clean and filtered air, and they can operate for many, many years.

 

EXAIR’s liquid vacuums, there is a built in pressure/vacuum relief device and auto safety shut-off to prevent over-filling.

The Reversible Drum Vac is a two-way liquid pumping system, also made for mounting on standard steel drums…closed top drums, in this case.  They can fill or empty a 55 gallon drum in 90 seconds.  Options include 5, 30, and 110 gallon drum sizes, and a High Lift model – increased suction head for deep wells, underground tanks, or higher viscosity liquids, up to 1,400 cP.

hlrdvhowworks

The heart of our popular coolant filtration system: the EXAIR Chip Trapper.  A Filter Bag in the “fill” line traps chips, swarf, and shavings.  The liquid passes through, and is able to be immediately pumped back out.  Not only is coolant life extended, regular cleaning of the coolant sump prevents loss of coolant flow due to clogging of the supply lines.  The Chip Trapper is available in 30, 55, and 110 gallon sizes, and also in the High Lift version.

Chip Trapper Family
30 gallon, 55 gallon, and 110 gallon Chip Trapper

EXAIR’s dry vacuums provide many pickup and filtration options. They withstand harsh environments, have many filtration and power options and run quieter than electric vacuums.

The EXAIR Chip Vac and Heavy Duty Dry Vac is a powerful industrial vacuum for use on wet or dry chips. Both are for use with 30, 55, or 110 gallon drums, and the Chip Vac can also be used on a 5 gallon drum. The Heavy Duty HEPA Vac has the added benefit of the HEPA quality filter system.  Filtration per IEST-RP-CC-007 to 99.97% minimum filtration at the 0.3 micron level ensures performance meets the needed criteria.

The Chip Vac is also 50% quieter than a comparable electric vacuum at only 77 dBA!!

Chip Vacs-all
From left to right: 5 gallon, 30 gallon, 55 gallon, and 110 gallon Chip Vacs are sized for any cleanup need.

If you would like to talk about Industrial Housekeeping products or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact  myself or one of our Application Engineers we can help you determine the best solution.

Jordan Shouse
Application Engineer
Find us on the Web http://www.exair.com/28/home.htm
Follow me on Twitter
Like us on Facebook

Built to Last Liquid Vacuum Systems Made by EXAIR

Baseball season is in full swing, temperatures are climbing, and there’s pollen in the air. It must be spring!! The coming of spring means it’s time to start opening up the windows and tidying up around the house. It also means an increase in rain showers. To those of you out there that have experienced the joy of walking down into the basement only to find a nice pool of water I feel your pain. A crack in our foundation allowed a significant amount of water to seep inside, of course all over the brand-new carpet!!

I went out to the garage and grabbed the ol’ trusty shop vac and began vacuuming up as much residual water as I could. Shop vacs are a great tool for cleaning up a variety of messes in your home. However, the very same shop vac is not suitable for use in an industrial environment. EXAIR manufactures a variety of compressed air operated industrial vacuum systems. For the purpose of this blog, I’m going to highlight the systems suitable for use with wet materials.

Electric vacuums have impellers that can clog or break, the motor will eventually burn out, not to mention the risks associated with using electrical products near liquid. With no electricity and no moving parts to wear out, EXAIR’s Industrial Housekeeping products are much better suited to withstand a harsh industrial environment.

The Reversible Drum Vac attaches quickly to any closed head 30, 55, or 110 gallon drum. It’s capable of filling a 55 gallon drum in as little as 90 seconds! With a simple turn of the knob, it’s able to quickly pump the liquid back out of the drum. Coolant sumps can easily be refilled, floor spills contained, or contaminated liquids can be transferred to filtration tanks in minutes.

The High Lift Reversible Drum Vac operates just the same as the standard, but provides a higher-powered vacuum for use with thicker liquids or for applications that need to lift the liquid from below grade work areas up to 15’ deep. Both the standard and High Lift Reversible Drum Vacs have an automatic safety shutoff valve to prevent the drum from overfilling.

CTR_dirtychiptrapperfamily

The Reversible Drum Vac is also the heart behind our award-winning coolant filtration system: the Chip Trapper. The Chip Trapper is a fast and simple way to clean chips, swarf, and shavings suspended in the coolant sump of your CNC machines. The liquid and suspended solids are vacuumed up into the drum. A filter bag inside traps the debris, chips, and shavings and allows you to pump clean liquid back out of the drum. The filter bag can be removed and cleaned for repeated use. Each system will come with (2) bags to get you started. Not only does this extend the life of your coolant, but can also eliminate the potential for chips and shavings to get clogged in the coolant system and reducing coolant flow. It, too, is available as a High Lift Chip Trapper System for thicker liquids or sumps that are below ground.

If you’re looking for a vacuum system that’s Built to Last, EXAIR has the right tool for you. All of our vacuum systems have no moving parts to wear out and are maintenance-free when supplied with clean and dry compressed air. With all systems available in stock and same day shipment for stock items, you can have one just in time for your annual spring cleaning!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

The EXAIR Chip Trapper™ System Extends Machine Coolant Life

Have you realized that you spend too much time cleaning out your CNC machine?  Do you find that It is messy and backbreaking work?  Do you spend too much money replacing the coolant in your system?  If you answer yes to any of these, EXAIR has a product for you; the Chip Trapper System.

EXAIR created this product to reduce the down time and extend the life of your coolant.  This device will save you money and time with productivity, coolant, and repairs.  In this blog, I will go over some of the features and benefits with the Chip Trapper Systems.

EXAIR offers two types, the Chip Trapper and the High Lift Chip Trapper.  They are designed to move fluid into the drum to be filtered, and to allow the clean fluid to be placed back into the sump.  The Chip Trapper works great for quick coolant cleaning at the floor level.  The High Lift Chip Trapper is ideal for cleaning viscous fluids as well as for reservoirs below the floor level.

Both types use a pneumatic two-way pump to move the fluid.  They come in three different drum sizes, 30 Gallon (114L), 55 Gallon (208L), and 110 Gallon (418L). So, you can clean large sump tanks with only one cycle through the cleaning system.  They come standard with a 5-micron bag filter that can hold over 5 gallons of material.

EXAIR can also offer filter bags in 5 other micron ranges from 1 micron up to 200 micron.  And if you are not sure on the other filtration ranges, EXAIR offers a filter sample pack, model 901060-SP, that includes one of each type.

Chip Trapper Cut Away

The Chip Trapper System includes the drum, the two-way pneumatic pump, a drum dolly, a directional flow valve, 10 feet (3m) of vacuum hose, 20 feet (6m) of compressed air hose, a chip wand, a shut off valve, and two additional filter bags.  All you need to do is to attach the Chip Trapper System to a filtered compressed air source.

The High Lift Chip Trapper offers a more powerful pneumatic pump which can fill a 55 gallon (208L) drum in 85 second from 15 feet (4.5m) below.  And, instead of the 10 feet (3m) vacuum hose, it will come with a  20 feet (6m) vacuum hose.

The unique features with the Chip trappers are the abilities to clean the CNC sump very quickly and with less mess.  Also, by using compressed air to pump the coolant in and out of the drum, it will aerate the coolant.  This will reduce bacteria growth and extend the life of the coolant. Thus, saving you money with those more expensive coolants.

Another benefit is that the pneumatic pump does not have any moving parts to wear out.  So, it will last you a long time without worrying about motor failures or loud noises.

You can watch the video of the operation here:

A list of some benefits that you will see if you purchase the Chip Trapper System is as follows:

  • The number of complete coolant change-outs are reduced.
  • The speed to get the CNC machines back operational to make parts.
  • Reduce the number of barrels of coolant concentrate per year.
  • Bacterial growth dramatically reduced as the Chip Trapper aerates the coolant.
  • Filter bags will remove the chip fines and some tramp oils keeping the coolant fresh.
  • Quiet and long lasting
  • A complete system that is easy to use.

As an added note, some CNC machines come with a spindle coolant feature.  This new technology helps in the need to increase speeds and feed rates.  The coolant is pumped to the top of the machine and fed directly through the spindle.  This type of spindle uses a rotary union which allows the coolant to the spindle as it spins at a high rate of speed.  The rotary unions are very expensive and costly to replace.

These spindles are very susceptible to dirty coolant.  If a seal within the rotary union begins to leak inside the machine, you will not be able to diagnose the problem until they have a machine failure.  The Chip Trapper with help eliminate this chance and keep your machine from an extreme expensive breakdown.

When your machine is not operating, your productivity is lost.  The EXAIR Chip Trapper Systems can be that product for you to get you back up and running is a short period of time, extend your coolant life, and keep the area clean and safe.  A win-win proposition in saving money and time.

For U.S. and Canadian customers, EXAIR offers a 30-day unconditional guarantee to try.  And, for a limited time.  an end-user will get a free EXAIR Vac-u-Gun, a $112.00 value, with any purchase of a Chip Trapper or High Lift Chip Trapper.

If you want to learn more about the EXAIR Industrial Housekeeping Products, you can contact an Application Engineer.  We will be happy to help you.

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

 

EXAIR’s Powerful Chip Vac for Keeping Your Plant Clean and Safe

March brings with it the first day of spring and April seems to have brought that first day where I believe spring could actually be here consistently. I don’t know about you, but boy am I ready for some warmer temperatures!! Naturally, spring is the time of year that we roll up our sleeves and do some of the deep-cleaning we’ve been putting off all winter.

Though, for any manufacturer or processor, “spring cleaning” is a year round affair.

Lucky for you, EXAIR has an entire line of Industrial Housekeeping Products that’ll get your shop tidied up for spring. In this blog, I’d like to dive into the Chip Vac. With its powerful suction, it’s an ideal solution for fast and efficient cleaning.

premcv400
Chip Vac cleaning up a floor spill

EXAIR’s Chip Vac is a compressed air operated industrial duty vacuum designed specifically for vacuuming up chips and shavings. The powerful vacuum is suitable for use with metal, wood, or plastic chips and is designed to thread into the 2” NPT bung on standard drum lids. The Chip Vac can handle dry or wet chips from fixtures, floors and work surfaces of machining centers, lathes, saws, mills, and a variety of other industrial equipment.

Electrically powered vacuums or shop vacs are not designed to be operated in a rugged industrial environment. Filters clog, motors wear out, and you find yourself frequently replacing them. EXAIR’s Chip Vac has NO moving parts to wear out, doesn’t require maintenance, and needs nothing but a source of compressed air to operate. In addition, the sound level produced is half of that produced by an electric vacuum.

The Chip Vac is sold in systems both with and without the drum. EXAIR has 5, 30, 55, and 110 gallon systems available for a wide range of applications. If you already have spare drums in your facility, the Chip Vac is also available with just the lid assembly, Chip Vac, 10’ hose, tools, and filter bag to attach to the top of your own drums.

All systems will include a drum lid with a locking ring that easily fits onto the top of a standard open top drum. It’s easy to remove and place onto another drum so that different materials can be easily kept separate for recycling. Recycling companies will pay a premium price for pre-sorted chips and shavings. With the Chip Vac, it’s as easy as removing the lid and placing it onto a new drum in between jobs.

Don’t waste your time this spring fooling with and replacing electrical vacuums. Get yourself a vacuum designed for the job. One that’ll last year after year! With these systems in stock, ready to ship with an order by 3:00 ET, an unconditional 30 day guarantee and backed up by our 5-Year Warranty, there’s no reason not to give one a try!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

EXAIR Reversible Drum Vac Fills A 55 Gallon Drum in 90 Seconds Flat, And Empties It Just As Fast

There are a few ways to get the liquid out of a drum:

  • You can use a pump.  Some pumps are even made to mount straight onto the lid of the drum.
  • You can siphon the liquid out, if you can get the drum higher than where you want to put the liquid.  And if you have the time.
  • You can turn the drum over.  I used to do field service in chemical plants…some of them had drum handlers on fork trucks that could pick up and tilt the drum to pour the liquid out.  Some of them pushed the drum over and simply let the liquid spill into a pit or below-grade sump.

But pumps break down.  Siphoning is finicky and slow.  I’m loath to knock the skills of the fork truck operator that can pour out a drum like a sommelier pours a fine wine.  And I’ll never forget the first time I saw an operator half-roll/half-dance a drum to the edge of that pit and let the liquid dump as he dropped it precisely where he wanted it…however, even in the context of the inner recesses of a chemical plant, it was simple, but inelegant.

EXAIR has an engineered solution that preserves the simplicity, though: the Reversible Drum Vac.  Thread the standpipe into the bung connection and the RDV itself into the vent, and that drum is now a two-way pumping system, able to be emptied via a 10 foot long Vacuum Hose in as little as a minute and a half.  Turn the knob on the RDV to switch modes, and you can fill that same drum just as fast.

With a simple turn of the knob, the Reversible Drum Vac can fill or empty a 55 gallon drum in 90 seconds!

 

 

 

 

 

 

The EXAIR Reversible Drum Vac Systems come with a variety of configurations and options:

  • Made to fit an existing 30, 55, or 110 closed top steel drum in good condition.
  • Mini Reversible Drum Vac System comes with a 5 gallon drum.
  • Deluxe Systems add a Drum Dolly and a set of tools.
  • Premium Systems add a drum (30, 55, or 110 gallon,) an upgrade to Heavy Duty Aluminum Tools, and a 20ft compressed air supply hose with shutoff valve and pressure gauge.
  • High Lift Reversible Drum Vacs generate a suction head of 180″H2O for maximum lift.  They’re also specified for higher viscosity liquids.

Below is a great video that showcases just how easy it is to from installing the Reversible Drum Vac to using the Reversible Drum Vac and just how fast the RDV operates.

If you’re looking for a fluid handling solution for liquids in drums, give me a call and we’ll talk about which Reversible Drum Vac System is right for you.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook