Thursday, 13 June 2019

Comparison: EXAIR Cabinet Coolers vs. Air to Air Heat Exchangers

At EXAIR Cabinet Cooler System is for  industrial enclosure cooling solutions and in many cases those cooling solutions have remained in place for decades. In the time, in the market with industrial enclosure cooling solutions we’ve encountered a number of alternative means for enclosure cooling.  One of those methods is an air-to-air heat exchanger.

An air-to-air heat exchanger uses the temperature differential between the ambient air surrounding an enclosure and the hot air inside an enclosure to create a cooling effect.  A closed loop system exchanges the heat inside the enclosure with the outside air in an effort to maintain a set internal temperature.  The heat exchange of most air-to-air unit relies on a heat pipe, a heat-transfer device which converts an internal refrigerant liquid into vapor by placing one end of the pipe in contact with the hot environment.  The heated vapor travels to the other end of the pipe which is in contact with a cooler environment.  The vapor condenses back into a liquid (releasing latent heat) and returning to the hot end of the pipe and the cycle repeats.

But, this type of a solution does give some cause for concern, especially when considering their use in an industrial environment.  Here are the key points to keep in mind when comparing an air-to-air cooler to an EXAIR Cabinet Cooler.

Required temperature differential based on ambient air temp

An air-to-air heat exchange relies on the ΔT between the ambient air temperature and the internal enclosure air temperature to produce cooling.  If this ΔT is low, or the ambient temperature rises, cooling is diminished.  This means that as the temperatures in your facility begin to rise, air-to-air heat exchangers become less and less effective.  Larger air-to-air heat exchangers can be used, but these may be even larger than the enclosure itself.

EXAIR Cabinet Coolers rely on the ΔT between the cold air temperature from the Cabinet Cooler (normally ~20°F) and the desired internal enclosure temperature (normally 95°F).  The cold air temperature from the Cabinet Cooler is unaffected by increases in ambient temperatures.  The large ΔT and high volume cold air flow produced by a Cabinet Cooler results in more cooling capacity.  And, we can increase cooling capacity from a Cabinet Cooler without increasing its physical footprint, which is already much, much smaller than an air-to-air type of unit.
Cooling in high temperature environments

Due to their nature of operation, an air-to-air heat exchanger must have an ambient temperature which is lower than the desired internal temperature of the enclosure.  If the ambient air has a higher temperature, air-to-air units provide zero cooling.

Cabinet Coolers, on the other hand, can be used in hot, high temperature environments up to 200°F (93°C).

Cooling in dirty environments

Dirt in the ambient environment will impact cooling performance with an air-to-air heat exchanger.  In order for the air-to-air unit to effectively remove heat, the heat pipe must have access to ambient air.  With any exposure to the ambient environment comes the possibility for the ambient end of the heat pipe to become covered in ambient contaminants such as dust.  This dust will create an insulation barrier between the heat pipe and the ambient air, decreasing the ability for the heat pipe to condense the vapors within.  Because of this, most air-to-air devices use filters to separate the heat pipe from the ambient environment.  But, when these filters become clogged, access to ambient temperatures are reduced, and cooling capacity of the air-to-air unit reduces as well.

Size and time required to install

Air-to-air heat exchangers vary in size, but even the smallest units can have large dimensions.  Many applications have limited space on the enclosure, and a large, bulky solution can be prohibitive.  Couple this with the time and modification required to the enclosure to install a large air-to-air unit, and the “solution” may end up bringing additional problems.

Another key aspect of the Cabinet Cooler is its size.  Small, compact, and easy to mount on the top or side of an enclosure, Cabinet Coolers install in minutes to remove overheating problems.

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

Tuesday, 28 May 2019

Pulls chips and dusts into the Chip Vac

A company manufactures sintered metal parts using powdered metal. After the powdered metal is sintered and cooled the manufacturer performs a reaming application. this produces a small amount of chips and dust which has been a housekeeping issue. They were manually cleaning the mess and needed to eliminate the cleaning process. The customer ordered the Model 6193 Chip Vac to pull the small chips and dusts into the chip vac which can be emptied easily. This saves time and eliminates housekeeping issues.

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

Monday, 6 May 2019

Vacuum feeder, Conveying Food granules from ground level to machine top hopper

Exair Line Vac (Model .6081) has been designed & used to generate vacuum & made for conveying at economical cost compare to traditional Vacuum Pumps. In recent past one of our client in manufacturing cigarette filter had a requirement for vacuum loading system (Flavor Granules Hopper Loading) to automate the machine. The conveying distance is 2.5 m and conveying capacity is 30 thousand granules per hour .Please have a look of shared video showing the complete unit after assembly.

The system is fabricated considering  the user's  requirement and integrated with our Exair Line Vac, Output is routed to the hopper top extending a drop point assembly with an exhaust which helps in keeping up granules quality. To automate the process it has level sensing capability which is mounted on top hopper body and controlled.

These systems are designed based on user's requirement & can be developed to suit various other such requirements. Feel free to let us know in case you have any such requirement.

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

Thursday, 2 May 2019

Clean Quickly and Quietly! No Moving Parts to Clog or Wear Out!

The heavy use, 24/7, dusty environment of a typical factory often proves too challenging for ordinary electrical vacuum cleaners. In trying to clean up the heavy debris produced by many machining processes, their motors and impellers will often clog, drastically lowering their lifecycle.
Every EXAIR vacuum is specifically engineered to withstand the rigors of operating in an industrial environment. They use compressed air as their power source, removing clog-prone motors and impellers altogether. EXAIR vacuums are also designed to consume small amounts of air and produce low noise levels, often lower than electrial vacuums. All of EXAIR's industrial vacuums are CE and OSHA Compliant.
Chip Trapper™
Our award winning Chip Trapper™ offers a fast, easy way to clean solids such as chips, swarf and shavings out of used coolants and other liquids. It vacuums debris filled liquid into the included 30, 55, or 110 gallon drum. Only clean liquid pumps back out. Expensive coolant that used to last only six weeks can now last six months!
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High Lift Chip Trapper™
The newest member of EXAIR's Industrial Housekeeping family is the compressed air powered High Lift Chip Trapper™. It recycles used coolants and other liquids like the Chip Trapper but produces even more power to reach deep pits, sumps, and wells. It is so powerful that it's able to pull even thick liquids up 15 feet!
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Reversible Drum Vac™
The Reversible Drum Vac™ is a stainless steel pump that does what traditional vacuums can't. After vacuuming the liquid, a simple turn of a knob lets you pump it back out of the drum. Coolant sumps can be easily refilled, floor spills vacuumed, or contaminated liquids transferred to filtration tanks in minutes. It attaches quickly to any 30, 55 or 110 gallon drum. A 5 gallon Mini Reversible Drum Vac is available for small cleanup jobs.
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The High Lift Reversible Drum Vac™ is specially designed with extra vacuum power to move thicker liquids (up to 1400 cP) or pull liquids from below grade work areas, sumps or tanks up to 15 feet! It attaches quickly to any closed head 30, 55 or 110 gallon drum. Like all of EXAIR's industrial vacuums, the High Lift Reversible Drum Vac uses no electricity and has no moving parts, assuring maintenance free operation.
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Chip Vac™ is an industrial duty vacuum that can vacuum chips directly into an ordinary 30, 55 or 110 gallon drum. Dusty materials are trapped by the 0.1 micron filter bag. The Chip Vac is ideal for cleaning chips from fixtures, floors and work surfaces of machining centers, lathes, saws, mills, etc. For small cleanups, a 5 gallon Mini Chip Vac is available.
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EXAIR's compressed air operated Heavy Duty HEPA Vac™ attaches to an ordinary 30, 55 or 110 gallon open top drum to turn it into a powerful, HEPA (High Efficiency Particulate Air) quality, industrial vacuum cleaner. It has been engineered to filter contaminants to HEPA requirements in dusty environments where frequent cleaning is needed.
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EXAIR's Heavy Duty Dry Vac™ is built for rugged, industrial duty clean-ups! The hardened alloy construction resists wear, making the Heavy Duty Dry Vac suitable for the clean-up of abrasive materials like steel shot, garnet, metal chips, and sand while also useful for quick, general purpose applications. Available for 30, 55, and 110 gallon drums.
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Vivek Engineers#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076.
Ph : 080 -  2648 1309, 4170 1145
Mob : 097404 39220
E- mail ,

Tuesday, 12 March 2019

Choosing the Right Vortex Tube – Max Refrigeration vs. Max Cold Temperature

The Vortex Tube is a low cost, reliable, maintenance free way to provide cooling to a wide variety of industrial spot cooling problems.
There are two (2) popular uses for the Vortex Tubes. One is to spot cool a warm item as fast as possible. The other is to chill an item to as low a temperature as possible. Because these are very different requirements, different Vortex Tube configurations exist to handle each.
For those applications of spot cooling, we recommend the 3200 series of Vortex Tubes. They are designed to be most efficient at providing maximum refrigeration, which is a function of high cold air flow rate and moderate temperature differential of the cold air to the warm item.
And for those applications of chilling an item to a very low temperature at low flow rate , we recommend the 3400 series of Vortex Tubes. They are designed to be most efficient at providing maximum cold air temperatures, but with a lower cold air flow rate.
An important parameter for the Vortex Tubes is the Cold Fraction. By adjusting the hot valve on a vortex tube, the amount of air that is discharged through the cold end changes. When expressed as a percentage of the total compressed air that is supplied to the vortex tube, we get the Cold Fraction. For example, if the hot valve is adjusted so that for every 10 parts of compressed air supplied, we get 7 parts of cold air, then we have a 70% Cold Fraction. When you know the Cold fraction setting and the compressed air supply pressure, you can use the Vortex Tube Performance tables and get the cold air discharge temperature.
Using the table below left, at 100 PSIG compressed air pressure and a 70% Cold Fraction, we can expect the cold air discharge temperature drop to be 71°F. With 70 ° compressed air temperature, the cold air will be at -1°F.

The 3200 series of Vortex Tubes are for use in the 50-80% Cold Fraction range, and the model 3400 series is designed for use in the 20-50% Cold Fraction ranges, to maximize the performance of each.
In summary, the selection of the Vortex Tube that best meets the application needs is based on the desired cold air flow rate, and the temperature of air desired. Once these are known, using the tables can provide the information needed to select the best option.
For those applications where we are unsure what will work best, we offer the EXAIR Cooling Kits, that include a Vortex Tube (small, medium, or large) and an array of Generators, to allow the configuration of the full range of Vortex Tubes within each size family.
  • Model 3908 – Small Vortex Tube Cooling Kit – build models 3202, 3204, 3208, and 3402, 3404, 3408
  • Model 3930 – Medium Vortex Tube Cooling Kit – build models 3210, 3215, 3225, 3230, 3240, and 3410, 3415, 3425, 3430, 3440
  • Model 3998 – Large Vortex Tube Cooling Kit – build models 3250, 3275, 3298, 3299, and models 3450, 3475, 3498, 3499


Thursday, 21 February 2019

Removing machine dust by Exair 120022 2" Aluminium Super Air Amplifier

Company manufactures welded tubing. Shavings are building up at the cutoff operation causing missed locations and tubes cut off to wrong length. Using the Model 1100 Super Air Nozzle to direct the shavings towards the  Model 120022 2"(51mm) Super Air Amplifier, the cut off area was vacuumed clear so the next part could be located properly. This eliminated short pieces.

Super Air Amplifier Performance at 80 PSIG (5.5 BAR)

Monday, 18 February 2019

Siphon Fed Atomizing Nozzles Selection

When we recommend an Atomizing Nozzle for a particular application, we try to obtain as much general information as possible about the application, such as:

What type of spray pattern do you need?
How wide of an area needs to be covered?
What kind of flow rate needs to be achieved?
Is the liquid source pressurized?
What is the viscosity of the liquid?
While all of this information is going to help simplify the selection process, when we get a reply that the liquid isn’t pressurized, the choice becomes a little less complicated.

Exair Siphon Fed Atomizing Nozzles are the preferred solution in applications where a pressurized liquid source isn’t available. With a steady supply of compressed air, these nozzles are able to draw the liquid into the nozzle with suction heights up to 36″ for our 1/8″ NPT and 1/4″ NPT nozzles, and up to 24″ for our larger 1/2″ NPT Models. They can also be gravity fed as well.

These nozzles mix the fluid internally and are capable of handling viscosity up to 200 centipoise. Depending on the size of the nozzle and supply air pressure, flow rates can range from 0.4 GPH up to 60 GPH with either a round or flat fan spray pattern. There is also an adjusting valve for more or less liquid flow as needed to fit the demand of the application.

Exair also offers these nozzles with the patented No Drip feature which positively stops the liquid flow when the supply air pressure drops below 30 PSIG, eliminating the need for any additional valves or supply lines.
If you have an application requiring a fine mist of atomized liquid, please contact us in below contact details.
Vivek Engineers#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076.
Ph : 080 -  2648 1309, 4170 1145
Mob : 097404 39220
E- mail : ,