Thursday, 2 February 2023

What is the Unique Design of Exair Vortex Tube and Cold Fraction?

  In various industries, it is a very common issue, that is increase of temperature of a particular spot or small tools/ parts of machines during production process. Literally we can say a small issue can affect whole production process.

Also it is really uneconomical to facilitate air conditioning entire factories and workshops. If do so, then the main problem will arise as  their sizes and other problems will be the various heats generated by production processes. Also it will be really uncontrollable to stop the cold air escaping through windows,  open doors and loading bays. Of course the industry will need a  high capacity air conditioning system i.e. expensive to purchase and also not cost effective to operate.


To resolve this problem EXAIR-USA has produced some Industrial spot cooling products . In this article I will discuss about EXAIR Vortex tube  and the Cold Fraction generated by it which can produce cold air to a temperature as low as -46°C (-50°F) and most interesting matter is that it has no moving parts, so no tear and wear and made up of stainless steel which is wear resistance, as well as its resistance to corrosion and oxidation. So Exair provides a Industrial spot cooler i.e. Vortex Tube which will provide years of reliable, maintenance-free operation.

EXAIR Vortex Tubes are available in three sizes such as small, medium, and large. These sizes can produce a range of cooling capacities from 135 BTU/hr to 10,200 BTU/hr (34 Kcal/hr to 2,570 Kcal/hr).A generator plays vital role inside each Vortex Tube to provide such cooling effect. When the compressed air enters into the vortex tube, then it is controlled by the generator that can enter the Vortex Tube and initiating the spinning of the air.  

As an example, a medium-sized Vortex Tube, model 3240, will only allow 40 SCFM (1,133 SLPM) of compressed air to travel into the Vortex Tube at 100 PSIG (6.9 bar).  While a small-sized Vortex Tube, model 3208, will only allow 8 SCFM (227 SLPM) of compressed air at 100 PSIG (6.9 bar).  EXAIR manufactures the most comprehensive range, from 2 SCFM (57 SLPM) to 150 SCFM (4,248 SLPM).

After the compressed air goes through the generator, there will be a pressure drop to slightly above atmospheric pressure.  (This is the “engine” of how the Vortex Tube works).  The air will travel toward one end of the tube, where there is an air control valve, or Hot Air Exhaust Valve.  This side of the Vortex Tube will blow hot air.  This valve can be adjusted to increase or decrease the amount of air that leaves the hot end.  The remaining portion of the air is redirected toward the opposite end of the Vortex Tube, called the cold end.  By conservation of mass, the hot air and cold air flows will have to equal the inlet flow as shown in Equation 1:

Equation 1:


Q = Qc + Qh


Q – Vortex Inlet Flow (SCFM/SLPM)


Qc – Cold Air Flow (SCFM/SLPM)


Qh – Hot Air Flow (SCFM/SLPM)


The percentage of inlet air flow that exits the cold end of a vortex tube is known as the Cold Fraction.  As an example, if the Hot Air Exhaust Valve of the Vortex Tube is adjusted to allow only 20% of the air flow to escape from the hot end, then 80% of the air flow is redirected toward the cold end.  EXAIR uses this ratio as the Cold Fraction; reference Equation 2:


Equation 2:


CF = Qc/Q * 100


CF = Cold Fraction (%)


Qc – Cold Air Flow (SCFM/SLPM)


Q – Vortex Inlet Flow (SCFM/SLPM)


EXAIR created a chart to show the temperature drop and rise, relative to the incoming compressed air temperature.  Across the top of the chart, we have the Cold Fraction and along the side, we have the inlet air pressure.  As you can see, the temperature changes as the Cold Fraction and inlet air pressure change.  As the percentage of the Cold Fraction becomes smaller, the cold air flow becomes colder, but the amount of cold air flow becomes less.  You may notice that this chart is independent of the Vortex Tube size.  So, no matter the generator size of the Vortex Tube that is used, the temperature drop and rise will follow the chart above.


How do you use this chart?  As an example, we can select a model 3230 Vortex Tube.  It will use 30 SCFM (850 SLPM) of compressed air at 100 PSIG (6.9 Bar).  We can determine the temperature and amount of air that will flow from the cold end and the hot end.  For our scenario, we will set the inlet pressure to 100 PSIG, and adjust the Hot Exhaust Valve to allow for a 60% Cold Fraction.  Let’s say the inlet compressed air temperature is 68°F.  With Equation 2, we can rearrange the values to find the Cold Air Flow, Qc:


Qc = CF * Q


Qc = 0.60 * 30 SCFM = 18 SCFM of cold air flow


The temperature drop shown in the chart above is 86°F.  If the inlet temperature is 68°F, the temperature of the cold air is (68°F – 86°F) = -18°F.  So, at the cold end, we will have 18 SCFM of air at a temperature of -18°F.  For the hot end, we can calculate the flow and temperature as well.  From Equation 1,


Q = Qc + Qh or


Qh = Q – Qc


Qh = 30 SCFM – 18 SCFM = 12 SCFM


The temperature rise shown in the chart above is 119°F.  So, with the inlet temperature at 68°F, we get (119°F + 68°F) = 187°F.  So, we have 12 SCFM of air at a temperature of 187°F coming out of the hot end.

With the Cold Fraction and inlet air pressure, you can get specific temperatures for your application.  For cooling and heating capacities, the flow and temperature can be used to calculate the correct Vortex Tube size for your application. 

Padmalochan Nayak



Vivek Engineers
#22, 1st Floor, 1st Cross, 
Bilekahalli Indl. Area, Adj. IIMB Compound, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.



Monday, 30 January 2023

Blowing Loose Onion Skins by EXAIR Super Air Nozzle

 It is difficult and messy to pack onions with loose onion skin. Everyone wants fresh and clean vegetables, especially onion. So in onion packaging farm, the EXAIR Super Air Nozzle can be used to blow loose onion skin from onions before packaging.


An onion farmer used a 
Model 1100 Super Air Nozzle (from our principal EXAIR-USA) to blow loose onion skin from onions before packaging to improve aesthetics perceived by customers.

Model 1100 Super Air Nozzle


Exair Engineered Air Nozzles and Jets reduce noise levels and air costs. If you have  any blow off, cooling and drying operation in your industry, kindly contact us at below contact details.

Padmalochan Nayak



Vivek Engineers
#22, 1st Floor, 1st Cross, 
Bilekahalli Indl. Area, Adj. IIMB Compound, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220




Monday, 23 January 2023

Convey parts, materials, waste - with no moving parts!

Exair Air Operated Conveyors

Exair Line Vacs use a small amount of compressed air to generate a vacuum by a Venturi effect.The unique design generates a high velocity to create a powerful vacuum on one side.  Once the product reaches the throat area of the Line Vac, the compressed air will carry the product the rest of the way. We can reach horizontal distances up to 100 feet (30 meters) and vertical heights up to 20 feet (6 meters).  EXAIR manufactures a variety of Line Vacs in different sizes, styles, and materials.  Here is an overview of the Line Vacs that EXAIR offers.

Line Vac: Exair standard Line Vac is the most versatile product in this family. Exair has two types of connections, slip-on ends for hose connections (Line Vac) and threaded ends for pipe connection(Thraeded Line Vac).  EXAIR can also mix the connection types on each end.  They range in diameters from 3/8” (10mm) up to 5” (127mm).  Exair manufactures the Line Vacs in aluminum, 303SS, and 316SS; but don’t let that deter you from asking for special types of materials. Exair has a high temperature version that can withstand temperatures up to 900°  F (482° C). These Line Vacs work great in applications for loading plastic pellets in hoppers, discarding scrap pieces, trim removal and transferring material. If an operator has to place a bag of dry material on his shoulder to climb stairs, a Line Vac would be a much better alternative.

Heavy Duty Line Vacs:  They are made from a hardened alloy steel for abrasion resistance. The generators inside these Line Vacs are more powerful than the standard models; so, that they can convey heavier materials at higher conveyance rates.They can reach conveying rates as high as 40 lbs./min. (18.2 Kg/min) of material.With the hardened alloy construction, they are great for sand blasting materials, ceramic, glass and steel shot.They are manufactured with inlet and outlet connections for ship-on hoses or threaded pipes.  EXAIR stocks the Heavy Duty Line Vacs in the range from ¾” (19mm) to 3” (76mm) for both hose and NPT connections.These Line Vacs are our most powerful design with great wear resistance. 

Light Duty Line Vacs On the other end of the Line-Vac spectrum, EXAIR created the Light Duty Line Vac.   They use much less compressed air than the other Line Vacs which is great for moving lightweight materials over short distances.  They can also be used for removing smoke and fumes from a work area. The Light Duty Line Vac ranges from ¾” (19mm) up to 6” (152mm) diameter for slip-on hose connections.  This two-piece design provides an effective way of moving material at a lower cost. It can be used in applications like hopper loading, fiber tensioning, filling operations, and smoke removal. For moving material within a short distance, the Light Duty Line Vac could be the proper product to use. 


Sanitary Flange Line Vacs Exair latest engineering design within the Line Vac family is the Sanitary Flange Line Vacs.  They can convert pipes into a useful conveyor for bulk material and waste removal.  They use an ISO2852 flange for easy disassembly and cleaning to reduce bacterial entrapment.  They ae made from 316 stainless steel material for superior corrosion resistance.They come in four different sizes to fit the sanitary flanges from 1 ½” up to a 3” flange. For sensitive applications where cleanliness is a major requirement, the Sanitary Flange Line Vac are manufactured for these conditions. 

With all of the EXAIR Line Vacs above, they can be sold as kits.  A kit will include a filter, regulator and a bracket. (Bracket are not sold with all types and sizes.)  The filter will help keep the Line Vac clean as well as the product that it being conveyed.  The regulator is a great tool to vary the conveyance rates for better control. The bracket helps to mount the Line Vac to a sturdy base for support. 

Please Contact us @ below address.....

Padmalochan Nayak



Vivek Engineers
#22, 1st Floor, 1st Cross, 
Bilekahalli Indl. Area, Adj. IIMB Compound, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220



Friday, 20 January 2023

Finding Your Perfect Static Elimination Solution

  Static electricity can disrupt multiple different manufacturing processes affecting product quality, production speeds, and cause harmful shocks to employees. 

Though different processes deal with static in unique ways, one thing they have in common is the adverse effect it has on production. No matter what your static situation may be, EXAIR offers a line of diverse static eliminators that are tailored to handle any static issue efficiently and effectively.

EXAIR's line of patented Intellistat products are engineered for sensitive processes. The handheld 

Intellistat® Ion Air Gun and the hands-free 

Intellistat® Ion Air Nozzle are made for laboratories, clean rooms, medical or electronic applications and carry a Class 5 cleanroom rating per ISO 14644-1. 

For applications needing wide area coverage, EXAIR’s Super Ion Air Knife is available up to 108” wide. 

The Super Ion Air Wipe offers 360° blowoff for cables, wires, and extruded shapes. 

The Ion Air Cannon is excellent for remote mounting or static elimination at a distance on rapid production lines. 

The Ion Air Gun and Ion Air Jet are for hand-held, manual applications. 

For applications where the surface may be sensitive to airflow, Exair Ionizing Bar or Ionizing Point don’t require the use of compressed air and still remove static charges. 

Please Contact us @ below address.....

Padmalochan Nayak



Vivek Engineers
#22, 1st Floor, 1st Cross, 
Bilekahalli Indl. Area, Adj. IIMB Compound, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220



Friday, 6 January 2023

EXAIR’s Cabinet Cooler® Systems have an overwhelming advantage than Refrigerant-Based Panel Coolers

In India the hottest period generally runs from April to mid-June, i.e. before the arrival of the monsoon, when the temperature can reach 45 °C (113 °F) in inland areas. While the temperatures begin to heat up, this can be a problem for the sensitive electronics located in control panels throughout your facility. This downtime arises not only due to heat but also due to dirt and moisture.

One solution for keeping the panel cool is an A/C refrigerant-based cooling system. While these can work to keep the conditions cool inside the panel, they come with their own set of maintenance issues and added costs. Some of these aren’t always readily apparent when you’re looking to solve a problem stemming from a heat-related shutdown. You need a solution, and you need it FAST. Installing a refrigerant-based panel cooler is going to take a MINIMUM of 3 hours and oftentimes an entire shift to complete. This means that you’re going to be subjected to additional downtime before you’re back up and running smoothly. In comparison, EXAIR’s Cabinet Cooler Systems are on the shelf and installed in an hour or less.

Generally speaking, air throughout an industrial facility is riddled with dirt, dust, and even oil. A/C panel coolers do have to draw in ambient air which means these filters can become clogged, restricting airflow and preventing the unit from operating at peak capacity. In many cases, it’s not discovered that the filters are clogged until AFTER the alarms have sounded and your panel is overheating. Maintenance is going to be necessary for any A/C panel cooler installed in an industrial facility.

This maintenance doesn’t stop just at the filters. It’s reasonable to consider around 4 hours of time per quarter cleaning/replacing filters, changing refrigerant, checking for leaks, etc. While this maintenance is performed, the systems have to be shut down and locked/tagged out. Not only is downtime required to install, but there will also be downtime associated with the regular maintenance necessary for these systems to operate effectively.

EXAIR’s Cabinet Cooler systems have absolutely NO maintenance required when supplied with clean, dry air (a suitably sized filter is included in our Cabinet Cooler system kits). Once they’re installed, they’ll operate darn near forever without any intervention at all. In fact, Exair Cabinet Cooler systems that have been out in the field operating for 20+ years without a problem.

Cabinet Cooler systems were designed specifically for operating in the harshest of conditions where A/C systems will be problematic. Thermostatically controlled systems are available to ensure that you’ll maintain the desired internal temperature of the panel without using any unnecessary compressed air. High Temperature Cabinet Cooler systems are also available for applications where ambient conditions could be higher than 125°F. Refrigerant-based panel coolers must be de-rated by 65% at 90°F and by 95% at 115°F, meaning they’ll need to either be oversized or operate longer to match the performance from a similarly sized Cabinet Cooler system.

Summer is coming!
Better we should be ready to stop electronic control downtime due to heat, dirt, and moisture!

Please Contact us @ below address.....

Padmalochan Nayak



Vivek Engineers
#22, 1st Floor, 1st Cross, 
Bilekahalli Indl. Area, Adj. IIMB Compound, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220



Sunday, 1 January 2023

Super Ion Air Knives Remove Static, Improve Bottle Cap Production

Static electricity is an imbalance of electric charges within or on the surface of a material or between materials. The charge remains until it is able to move away by means of an electric current or electrical discharge.

Recently our principal MS Exair, USA solved this static charge problem in the US division of a global manufacturer of bottle caps. A machine that sorts & orients plastic caps was particularly prone to static charge problems last winter, causing a marked decrease in their production, and they wanted to resolve this static issue to archive goal in their production.

As the caps travel horizontally (white arrows), they pass under a static bar (supplied by the machine manufacturer) which provided some reduction in static charge, but was unable to keep up with the higher magnitudes of static charge experienced during the lower humidity winter months. Bottle caps (right) would pile up, slowing production.

Model 112230 30″ Gen4 Super Ion Air Knife Kit replaced the OEM static bar, resulting in dramatic improvement…no more piling up of bottle caps.
 
The increased static charge (beyond the OEM static bar’s ability to handle) reduced production by 1/3. The Super Ion Air Knife restored operation to full capacity for this machine…and three others, once they saw the results of the first one.

If static charge is causing you problems with dust clinging to your product, your product clinging to itself, sheets mis-feeding, materials jamming, tearing, or curling, or nuisance shocks to operators, Vivek Engineers (Authorized distributor of EXAIR-USA) has a variety of safe and efficient Static Eliminator solutions. Please contact us soon @ below details.
Also please visit our website www.vivekengineers.net



Vivek Engineers
#22, 1st Floor, 1st Cross, 
Bilekahalli Indl. Area, Adj. IIMB Compound, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220





Tuesday, 25 October 2022

New TurboBlast Safety Air Gun for Heavy Duty Jobs Requiring Powerful Blowoff

 EXAIR's new TurboBlast® Safety Air Gun is the latest addition to the EXAIR line of Safety Air Guns. This dynamic air gun is capable of producing up to 23 pounds of force with a simple press of a button trigger and is the ideal solution for blow off applications requiring maximum force such as removing stubborn or heavy debris like slag and flash, part drying or cooling from a distance, as well as heavy duty cleanup in busy facilities.


 The TurboBlast features a cast aluminum handle with a rugged elastomer grip that’s not only comfortable, but UV resistant, chemical resistant and insulated from heat or cold. The light touch activation trigger creates a powerful blast of air and also includes a “Dead Man's” grip that turns air off if the air gun is dropped. All models include an integrated nozzle guard for safety. Models are available with an adjustable gate valve to control blowing force on the fly, or without the gate valve.

The TurboBlast is available in multiple different flow rates and extensions up to 6 feet long to provide ease of reaching into difficult to reach areas. The TurboBlast Guns are the most powerful air guns from EXAIR and complement our VariBlast Precision, VariBlast Compact, Soft Grip and Heavy Duty Safety Air Guns. All EXAIR Safety Air Guns are CE compliant and meet OSHA  
standards.
To get idea of more Pneumatic Products, please visit our website www.vivekengineers.net




Vivek Engineers
#22, 1st Floor, 1st Cross, 
Bilekahalli Indl. Area, Adj. IIMB Compound, 
Bannerghatta Road, Bangalore - 560 076 
Ph : 080 -  2648 1309, 4170 1145.
Mob : 097404 39220