Friday, 4 August 2017

Super Air Knife-To avoid chips coming out from the work station, used as an air curtain

Recently, we worked with a Client, who has been involved mainly with fabrication of mild steel and stainless steel components and had a problem with workers being hit by chips coming out  from the work station. So you will have look to the below image. As there is no front end cover, so It was  tremendously unsafe and dangerous for workers to work in this circumstances.They contacted to Our company Vivek Engineers and our application engineers visited their place and after a case study,they reached to a solution to use Exair's 30" Super Air Knife.

As Exair's Super Air knife consists of a high intensity, uniform sheet of laminar airflow sometimes known as streamline flow across the entire length with hard hitting force.So, it easily blows away the chips which are coming out from workstation. Eventually,the workers are able to work with safe and the client is satisfied with 30"Super Air Knife to use in their application.

EXAIR offers the Super Air Knife in lengths from 3" to 108", with a 0.002" shim installed.  They’re ideal for most industrial and commercial blow off applications. If you have such an application, give us a call. 
Below Our 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, 3297 0358, 4170 1145
TeleFax : 080- 2648 1309.
E- mail : sales@vivekengineers.net , durga@vivekengineers.net

CONTACT PERSON :
Mr. Durga Madhab Praharaj - Sales & Operations Manager
Mob : 097404 39220. E -mail : durga@vivekengineers.net

Thursday, 27 July 2017

EXAIR Vortex Tubes: As Much Cold Air As You Need, As Cold As You Need It

Looking for a reliable, consistent flow of cold air, Vortex Tube is really the better way to produce it. There are no moving part, the air flow and temperature from a particular model, set to a specific cold fraction, is only influenced by the compressed air supply pressure & temperature.
Pressure is easy to control, all you need is a suitable regulator.  Temperature can be a variable, depending on your type of compressor, if you have a dryer system (and what type it is,) and sometimes, ambient conditions…if, for example, a long pipe is run through a very hot environment like a foundry or a blast furnace operation.  In cases where supply pressure and/or temperature can be limitations, a higher capacity Vortex Tube, set to a lower Cold Fraction, may be specified.  Which brings me to the user inquiry that inspired today’s blog…
This particular customer uses our Model 3215 Vortex Tubes (15 SCFM, 1,000 Btu/hr) to provide cooling to analyzer systems that monitor certain quality parameters in their manufacturing processes.  The ability to precisely control the temperature in these systems makes for repeatable and accurate measurement of these parameters.   Their compressed air supply in this area is regulated to 80psig, they have a refrigerant-type dryer and climate-controlled facility, so their supply temperature is a consistent 70°F.  You couldn’t ask for better conditions for a successful Vortex Tube application, and they’ve worked great, for years.

Now, due to a plant expansion, they’re installing some of these analyzer systems in a location where the compressed air supply is limited to 60psig.  The required cooling capacity is going to be the same, so the Project Manager reached out to us to see if they could get the same amount of cooling with this new pressure limitation.  Here’s how they’re doing it:
Exair publish the rated performance of Vortex Tube products for a supply pressure of 100psig.  The Model 3215 Vortex Tube consumes 15 SCFM @100psig and, when set to an 80% Cold Fraction (meaning 80%…or 12 SCFM…of the 15 SCFM supply is directed to the cold end,) the cold air will be 54F colder than the compressed air supply temperature.  Here’s the performance table, so you can follow along:
Now, their supply is at 80psig.  Since air consumption is directly proportional to absolute supply pressure (gauge pressure PLUS atmospheric, which is 14.7psi at sea level,) we can calculate their units’ consumption as follows:
(80psig + 14.7psia) ÷ (100psig + 14.7psia) = 0.83 X 15 SCFM (@100psig) = 12.4 SCFM (@80psig)
So, with a 50°F temperature drop (from a supply @70°F,) they were getting 12.4 SCFM of cold air at 20°F.
As you can see from the table above, they’ll only get a 46°F drop at 60psig…and the flow won’t be as high, either.  So…we’ll need to get more air through the Vortex Tube, right?  Let’s use a little math to solve for what we need.
We still need 20°F cold air from 70°F compressed air, so, at 60psig, we’re looking at a Cold Fraction of ~70%.  And we still need 12.4 SCFM, so:
12.4 SCFM ÷ 0.7 = 17.7 SCFM @60psig (required supply)
Our Model 3230 Vortex Tube uses 30 SCFM @10opsig…at 60psig it’ll consume:
(60psig + 14.7psia) ÷ (100psig + 14.7psia) = 0.65 X 30 SCFM (@100psig) = 19.5 SCFM (@60psig)
That’s about 10% more flow than they needed, theoretically, which was close enough to start.  From there, they “dialed in” performance by regulating the supply pressure and Cold Fraction
Vivek Engineers#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076.
Ph : 080 -  2648 1309, 3297 0358, 4170 1145
TeleFax : 080- 2648 1309.
E- mail : sales@vivekengineers.net , durga@vivekengineers.net

Monday, 3 July 2017

Cooling Gelatin Pills Using The Mini Cooler

Our Principal recently worked with an OEM on a cooling application for a gelatin pill forming machine they designed for their customer. In their machine design, the gelatin film leaves an extruding machine then travels between 2 punch rollers to form the pills. After the pills are formed, they are supposed to drop onto a chute feeding a conveyor to carry the pills to the bottling/packaging area.egree quick release elbow connection, 1 aluminium wand ( drum not included).

The problem they were having was the film was retaining heat which caused the pills to occasionally stick to the roller, resulting in rejects and lost production time. They were looking for an economical way to blow cold air across the rollers and film but were concerned about putting too much demand on their customer’s compressed air system.
After reviewing the photos and discussing the details, Our Principal recommended they use Exair's Model # 3308 Mini Cooler System with dual point hose kit. The Mini Cooler provides a 50°F temperature drop from the incoming supply air temperature and provides 550 Btu/hr. of cooling capacity. The system includes a swivel mag base for easy installation while the dual point hose kit would allow them to direct the cold air to blow across both rollers from a single device. Compressed air demand is minimal, at only 8 SCFM @ 100 PSIG, alleviating their concern for the customer’s compressed air system.
Vivek Engineers#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076.
Ph : 080 -  2648 1309, 3297 0358, 4170 1145
TeleFax : 080- 2648 1309.
E- mail : p.lochan@vivekengineers.net 

Tuesday, 30 May 2017

Internal Mix Atomizing Spray Nozzle Used In Feed Additive Process

An agricultural customer was looking to replace the spray nozzle used in their feed additive process. The soy oil/beeswax solution they are applying to the feed, is slightly viscous (close to 100 cP) which seems to be clogging the tight clearances inside the current nozzle, resulting in varying flow rates and an erratic spray pattern. They had tried to contact the current manufacturer several times for a solution but were unhappy with the lack of assistance they were receiving, not to mention the long lead times of 6-8 weeks for a replacement.

After further discussion, they confirmed they weren’t as concerned with the flow rate or spray pattern, as they were with the nozzle potentially getting clogged.  They were able to obtain some internal dimensions of the existing nozzle and after further review, Exair recommended they use Exair's Model # AF1030SS Internal Mix Flat Pattern Atomizing Nozzle as a replacement. This nozzle has larger inside diameters which would reduce the potential for clogging. The Internal Mix Atomizing Nozzles mix the liquid and air inside the air cap and produce the finest atomization. The flow rate can be changed by adjusting the control valve on the nozzle and/or by adjusting the liquid pressure. Internal Mix nozzles are capable of handling fluids up to 300 Centipoise. 

When considering an Atomizing Nozzle for an application, there are some general parameters that can be helpful in making the best selection.
  1. Do you have a pressurized liquid source?
  2. What is the fluid viscosity?
  3. What spray pattern best fits the process?
  4. How much flow (GPH/LPH) do I need?
If you have an application requiring a fine mist of atomized liquid spray, please contact an application engineer for assistance.
Vivek Engineers#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076.
Ph : 080 -  2648 1309, 3297 0358, 4170 1145
TeleFax : 080- 2648 1309.
E- mail : sales@vivekengineers.net , durga@vivekengineers.net

CONTACT PERSON :
Mr. Durga Madhab Praharaj - Sales & Operations Manager
Mob : 097404 39220. E -mail : durga@vivekengineers.net

Beat the Heat with EXAIR Cabinet Coolers!

As we begin to approach the heat of summer , we begin to break out the flip-flops, swimsuits, and warm weather attire. If you’re not a fan of the warmer temperatures, this may not be your favorite time of year. For me, I can’t wait to spend some time outdoors and enjoy all of the activities that summer has to offer. Whether you like the heat or not one thing is certain, the electrical enclosures within your facility most certainly do not.


EXAIR’s Cabinet Cooler Systems were designed specifically to rectify these issues within your facility. Utilizing Vortex Tube technology, the Cabinet Cooler produces cold air from an ordinary supply of compressed air. This cold air keeps the enclosure free of debris and moisture and is easily installed in minutes through a standard electrical knockout. The Cabinet Cooler Systems are available with Nema 12 (IP54) ratings and are also available in Aluminum, 303 Stainless Steel, and 316 Stainless Steel construction for Nema 4 (IP66) rated enclosures. For systems that are not able to be mounted on top of the cabinet, we also have Side Mount Kits available in Aluminum, 303 Stainless, and 316 Stainless.


These systems are available with cooling capacities of anywhere from 275-5,600 Btu/hr. To make things much easier for you, Exair offers a Cabinet Cooler Sizing Guide that will allow us to recommend the most suitable model for your cabinet. With a few quick measurements, we’ll be able to determine the exact heat load that we’ll need to dissipate and offer you a quick and easy solution. If you’re experiencing heat related issues somewhere within your facility or remember the troubles that they caused you last year, contact an Application Engineer today and we’ll see to it that this summer your cabinets remain cool!

Vivek Engineers#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076.
Ph : 080 -  2648 1309, 3297 0358, 4170 1145
TeleFax : 080- 2648 1309.
E- mail : sales@vivekengineers.net , p.lochan@vivekengineers.net

Wednesday, 17 May 2017

Super Air Amplifiers for Cooling Injection Mold

When working with a cooling application, many customers will immediately look to the Vortex Tube and Cold Gun product lines. While this may be the best solution for some applications with smaller areas to cool, cold air from a Vortex tube based solution is not the best method for large parts or larger areas that exceed a footprint of approximately 2″ x 2″. For larger areas, we have other options for many cooling applications. EXAIR’s Super Air Amplifiers and Super Air Knives are also very effective at reducing the temperature of a part without requiring cold air.

Cooling is a relative concept based on the starting and finishing temperature. What feels “cool” to a human being does not necessarily mean the same thing as “cooling” a part or material. Due to the ability of the Super Air Knives and Super Air Amplifiers to entrain large amounts of ambient temperature air, we can move a lot of air volume across the surface of the target part and quickly lower the temperature.

A simple example I like to use is blowing on a hot cup of coffee just as its been brewed. The temperature of the air coming from your mouth is around 98.6°F, the same as your body temperature. Coffee can be as hot as 185°F when fresh. Due to the temperature differential between your breath and the hot coffee, we’re able to achieve a reasonable amount of cooling just by simply blowing across the surface. Typically, when the target temperature of the part or material needs to be around ambient temperature or higher; the best solution for cooling is going to be either a Super Air Amplifier or Super Air Knife.

To illustrate the above concept even more, recently I was working with a customer that needed to cool a silicon injection mold. The mold had two sides and the customer was looking for a method of cooling it down between cycles. The mold cavity surface was approximately 400°F and they wanted to get it down to around 150°F. They were familiar with the EXAIR Cold Gun as they use them across their facility in various secondary or post-molding drilling operations. They had a spare and decided to hook it up and blow the cold air across the face of the mold to see what happens. The volume of air from the Cold Gun was not enough to sufficiently cool the entire mold, so he reached out to EXAIR for assistance.

Based on the dimensions of the mold and understanding the target temperature to be 150°F, we settled on a system of (2) 120224 4” Super Air Amplifier Kits. One was placed above each side of the mold. As soon as the mold opened, they activated the Super Air Amplifiers and were able to pull the surface temperature of the mold down to an acceptable level. Time is money in any manufacturing operation. Companies that produce injection molded parts will look for any way to improve their process. By implementing a procedure to cool the mold more quickly, they are able to boost their productivity gains and become more profitable.

The Super Air Amplifier Kit comes with an Auto-Drain Filter to keep the air clean and dry, a pressure regulator to allow you to dial in the precise level of airflow, and a shim set that allows you to make gross adjustments to the flow. The Super Air Amplifier is available in (5) different sizes with ¾” up to 8” diameter outlets and flow rates from 219 SCFM to 9,000 SCFM 6″ from the outlet. They are capable of achieving an amplification ratio of up to 25:1 from the compressed air supply. The laminar airflow from the unit minimizes wind shear to produce sound levels that are typically three times quieter than other air movers.
Vivek Engineers#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area,
Bannerghatta Road, Bangalore - 560 076.
Ph : 080 -  2648 1309, 3297 0358, 4170 1145
TeleFax : 080- 2648 1309.
E- mail : sales@vivekengineers.net , p.lochan@vivekengineers.net

CONTACT PERSON :
Mr. Durga Madhab Praharaj - Sales & Operations Manager
Mob : 097404 39220. E -mail : durga@vivekengineers.net

Monday, 15 May 2017

Replacing Unsafe Open Pipes with High Pressure Air Nozzles


   (Open pipes present unsafe working conditions and continuous pressure drops in compressed air systems)

Let’s talk for a minute about pressure drops. Normally when the topic of pressure drops is raised, it comes in a context related to proper plumbing and volume supply.  (If there are significant pressure drops within a compressed air system, especially those which reduce volume flow, problems will arise with compressed air driven devices.)
But, there is another important aspect of pressure drops which relates to open pipe blow-off, a common homemade remedy for blow-off applications. This aspect has to do with the available compressed air pressure at the exhausting point from the pipe or nozzle.  In the case of an open pipe, it requires so much compressed air volume that, there can be a continuous pressure drop from the compressor to the open pipe.  However, when a nozzle is installed onto a compressed air pipe, there is a restriction to the flow and the entire pressure drop takes place across the nozzle.
What this means for the blow-off solution is a higher velocity blow-off and a more powerful force from the airflow, with less compressed air consumption.

To think of it another way, imagine the flow of water from your garden hose. If the hose is open-ended and the water is fully on, the flow will be high and the force will be low.  But, when you install a nozzle onto the end of the hose the flow reduces and the force increases.  This is because the pressure drop in the system is taking place across the nozzle rather than the entire system.

This type of a scenario was taking place in the image shown at the top of this blog. The plastic lines connected to the aluminum manifold were fully open on the end, providing a continuous pressure drop and poor blow-off performance.  This, coupled with the maximum operating pressure of similar types of hose being 35 PSI, led to a poor performance in this application.

The solution for this customer was to replace these open pipe blow-offs with EXAIR model 1126 Flat Super Air Nozzles and 12″ Stay Set Hoses, model 9262. The flat airflow of the 1126 Super Air Nozzles provide a highly efficient and forceful blow-off, and the Stay Set Hoses allow for articulation of the nozzles into any position needed.
By replacing these open pipes this customer saved compressed air, added safety (open pipes present an operating hazard per OSHA Standard CFR 1910.242(b)), and improved the performance of their operation.
Vivek Engineers#22, 1st Floor, 1st Cross, Adj. to IIMB Compound, Bilekahalli Indl. Area, 
Bannerghatta Road, Bangalore - 560 076.
Ph : 080 -  2648 1309, 3297 0358, 4170 1145
TeleFax : 080- 2648 1309.
E- mail : p.lochan@vivekengineers.net