How Exair Air Nozzles Save Money and Compressed Air ?

Industrial air nozzles are widely used in India across various industries for applications such as cooling, drying, blowing off debris, and cleaning. But it is really complicated to find out a proper nozzle based on quality and cost.

Now I am going to explain you how you can save Money and Compressed Air if you select EXAIR Engineered Air Nozzles in India.

One of the worst culprits for inefficient air use is open pipe blow-offs. This would include cheap air guns, drilled holes in pipes, and tubes. These are very inefficient for compressed air and can cost you a lot of money.  I will share a comparison to a 1/8” NPT pipe to an EXAIR Mini Super Air Nozzle.  (Reference below).  As you can see, by just adding the EXAIR nozzle to the end of the pipe, the company was able to save per year.  That is some real savings.

The table above shows the air consumption for typical homemade blow offs. The pages that follow give the air consumption and other data on EXAIR's Air Nozzles and Jets. Consider the following example where a Model 1102 Mini Super Air Nozzle replaces an 1/8" open pipe. The compressed air savings is easy to calculate and proves to be dramatic. Payout for Air Nozzles and Jets, including filter and installation cost is measured in weeks - not years, as is the case for other cost reduction equipment. Based on a 40 hour work week, 52 weeks a year.

Example: 

1. Existing blowoff is 1/8" open pipe at 80 PSIG (5.5 BAR) supply. 

Air consumption, from the table above, is 70 SCFM (1,981 SLPM). 

2. Use a 1/8 FNPT Model 1102 Mini Super Air Nozzle also at 80 PSIG (5.5 BAR) supply. Air consumption, from the image below, is 10 SCFM (283 SLPM). 

3. Compressed air saved = 70 - 10 = 60 SCFM (1,981 - 283 =1,698 SLPM) 

4. For this example, the blow off is continuous. If the duty cycle was 20%, then air saved would be 60 x .2 = 12 SCFM (1,698 x .2 = 340 SLPM).

 5. Most large plants know their cost per 1,000 standard cubic feet of compressed air (10,000 standard liters). If you don't know your actual cost per 1,000 SCF, Rs 29 is a reasonable average to use. 

(Cost per 10,000 standard liters is approximately Rs 10 )

 6. Money saved per hour = SCFM saved x 60 minutes x cost/1,000 SCF

                                            (SLPM saved x 60 min x cost/10,000 SL)

                                          = 60 x 60 x Rs 29 /1,000 

                                         (= 1,698 x 60 x Rs 10 /10,000)

                                             =Rs 104/hour that is =Rs 4160/week and Rs 216,320/year savings for one nozzle.

Now please Let me answer and explain  to a very common question, we are asked during presentation of Exair's Air Nozzles that Why Exair Air nozzles consume less compressed air. 

Well, we will discuss the working principle of Exair Air Nozzles and which is of course the realistic answer.

Air Nozzles use the Coanda effect to amplify compressed airflow up to 25 times or more. As illustrated on top, compressed air (black arrows) is ejected through a series of nozzles on the outer perimeter. As the air travels along the outer wall of the nozzle, surrounding air (blue arrows) is entrained into the stream. The airstream that results is a high volume, high velocity blast of air at minimal consumption. The air is always ejected so it can vent safely, well below OSHA dead end pressure requirements, should the nozzle end be blocked.

For more detailed information or to select the appropriate model for your specific needs, you can visit  official website of Vivek Engineers or contact the Application Engineers.

website www.vivekengineers.net

Padmalochan Nayak

Vivek Engineers #22, 1st Floor, 1st Cross,  Bilekahalli Indl. Area, Adj. IIMB Compound,  Bannerghatta Road, Bangalore - 560 076  Ph : 080 -  4170 1145 Email: sales@vivekengineers.net            p.lochan@vivekengineers.net

🔧 Introducing the Air Amplifier by Exair USA 🔧

  The Air Amplifier from Exair USA is an innovative solution designed to efficiently utilize compressed air up to 17 bar pressure for various industrial applications. This high-performance tool is engineered to optimize your operations while ensuring reliability and minimal maintenance.

Key Features and Applications:

Vent Welding Smoke: Efficiently remove welding smoke from the work area, ensuring a safer and cleaner environment for workers.
Cool Hot Parts: Rapidly cool down hot components, enhancing safety and productivity in your processes.
Dry Wet Parts: Effectively dry wet surfaces, preparing them for the next stage of production.
Clean Machined Parts: Maintain the integrity of machined parts by removing debris and contaminants.
Distribute Heat: Evenly distribute heat in molds or ovens, ensuring uniform temperature control.
Ventilate Confined Areas: Provide fresh air to confined spaces, improving air quality and worker safety.
Dust Collection: Collect and manage dust efficiently, maintaining a clean and compliant workspace.
Exhaust Tank Fumes: Safely exhaust harmful fumes from tanks, protecting both workers and the environment.

Advantages:
Maintenance-Free: The Air Amplifier is designed with no moving parts, making it completely maintenance-free and ensuring long-term reliability. 🔩
Durable Construction: Made from either high-quality stainless steel or aluminum, it offers exceptional durability and resistance to harsh industrial environments. 🛠️
Efficient Operation: Harnessing the power of compressed air, it delivers efficient and cost-effective performance. ⚙️
Whether you need to cool, dry, clean, or ventilate, the Air Amplifier by Exair USA is your go-to solution for a variety of industrial applications. Its robust construction and maintenance-free design make it a valuable addition to any facility.
✨ Experience the Excellence of Air Amplification with Exair USA ✨

For more information contact us at below contact details or visit our website www.vivekengineers.net

Vivek Engineers #22, 1st Floor, 1st Cross,  Bilekahalli Indl. Area, Adj. IIMB Compound,  Bannerghatta Road, Bangalore - 560 076  Mob: 9740439220 Ph : 080 -  2648 1309, 4170 1145 Email: sales@vivekengineers.net           durga@vivekengineers.net           p.lochan@vivekengineers.net

USB Data Logger Available for Digital Flowmeter

EXAIR’s Digital Flowmeter provides an excellent way to monitor compressed air consumption and waste. Now, with the addition of EXAIR’s new USB Data Logger, you can also maintain a history of the Digital Flowmeter’s measurements for analysis.Use the included software to configure the Data Logger to record your flow rate. Record from once a second (about nine hours of data) up to once every 12 hours (over 2 years!).

Regular monitoring of compressed air usage makes it possible for companies to save thousands of dollars per year in compressed air waste by identifying costly leaks or inefficient air products. When the Data Logger is removed from the Digital Flowmeter and plugged into a computer, the data can be viewed in the included software or exported directly into Microsoft Excel®. This allows you to track flow rate easily on your computer.

The Data Logger is available pre-installed on the Digital Flowmeter.Summing Remote Displays, that make it easy to monitor compressed air consumption from a convenient location, are also available.

Vivek Engineers,E- mail : sales@vivekengineers.net ,Website: www.vivekengineers.net

CE Compliant Air Nozzles Increase Efficiency

EXAIR’s family of Air Nozzles-- from the tiny new Model 1108SS Atto Super Air Nozzle at 2.0 ounces (56.7 grams) of blowing force to the high powerModel 1120 Large Super Air Nozzle at 23 pounds (10.4 kg) of strong blowoff force -- have always provided safe, economical performance. Independent laboratory tests now certify that EXAIR’s entire Air Nozzle family hasalso met the rigorous safety, health, and environmental standards of the European Union in order to attain the CE mark.

By entraining high volumes of room air, EXAIR’s Super Air Nozzles use less compressed air and less energy to provide superior performance to other blowoff products. Unlike open pipe and nozzles that haven’t been optimized, none of EXAIR’s large selection of Super Air Nozzles can be blocked, meeting OSHA’s standard for dead-end pressure 29 CFR 1910.242(b). All of EXAIR’s Super Air Nozzles also fall within OSHA’s noise requirement 29 CFR 1910.95(a).

Vivek Engineers

E- mail : sales@vivekengineers.net ,Website : www.vivekengineers.net

Cold Gun Increases Tool Life

Cold Gun Increases Tool Life

A Company manufactures intricate machined parts for the automotive, motorcycle and aerospace industries. One of their machinists had a frequent problem rough-milling pocket in type 410 stainless steel when using a two flute 3/8" carbide cutter on their Okuma vertical machining center. Coolant produced thermal shock, resulting in micro cracking of the carbide inserts. Without coolant, thermal cracking of the inserts was almost immediate. They were constantly changing inserts.

The company installed a Model 5215 Cold Gun System. The 20°F cold air kept the inserts cool and allowed all the heat to be carried away on the chips. Tool life increased by 50%.

The Cold Gun incorporates a vortex tube to convert an ordinary supply of compressed air into two low pressure streams, one hot and one cold. The hot airstream is muffled and discharged through the hot air exhaust.  The cold air is muffled and discharged through the flexible hose, which directs it to the point of use.  The magnetic base provides easy mounting and portability. 

Heat buildup can ruin expensive tooling as well as the part being machined. In this situation, it would have been easy to constantly ruin a Rs.9000 cutter. When asked how others solve this problem, the machinists replied, "We've seen companies go so far as to defeat the safety interlocks so the machine runs with the doors open - just to blow a little compressed air at the part to cool it. For us, the Cold Gun keeps the tooling cool and allows us to immediately handle the part since the heat blows away with the chips.

www.vivekengineers.net