Almost every industrial facility has at least one compressor that is used for hundreds of different tools, equipment and operations. While most applications for compressed air present no real problems, some do. Improper use can translate into unnecessary energy costs, high noise levels and dangerous exposure of personnel to high pressure air.
Reduce Energy Costs
The best way to cut energy costs is through proper maintenance and use of the compressed air system. Leaks and dirty filters require maintenance on a regular basis. Energy savings can also be realized when replacing outdated motors and controls with high efficiency models that often pay for themselves in a short period of time. The most important factor to dramatically boost efficiency is proper use. The Super Air Knife uses only 1/3 of the compressed air of typical blowoffs used in cleaning, cooling and drying operations and can be instantly cycled on and off.
Reduce Noise Levels
High noise levels are a common problem for many plants. Compressed air noise often exceeds OSHA (Occupational Safety and Health Administration) noise level exposure requirements, resulting in hearing loss to those working in close proximity. The sound level of the Super Air Knife is quiet at 69 dBA, even at high pressures of 80 PSIG (5.5 BAR). Using the Super Air Knife, it is possible to obtain hard-hitting force without the high noise.
|OHSA Maximum Allowable Noise Exposure*|
|Hours per day (constant noise) ||8 ||7 ||4 ||3 ||2 ||1 ||0.5|
|Sound level dBA ||90 ||91 ||95 ||97 ||100 ||105 ||110|
*OSHA Standard 29 CFR - 1910.95 (a)
Eliminate Harmful Dead Ended Pressures
Air can be dangerous when the outlet pressure of a hole, hose or copper tube is higher than 30 PSIG (2 BAR). In the event the opening is blocked by a hand or other body part, air may enter the bloodstream through the skin, resulting in serious or fatal injury. The Super Air Knife has been engineered for safety and cannot be dead ended. It is safe to operate at higher pressures and meets OSHA standard 1910.242(b).
Open Air Pipe or Copper Tube
Turbulent compressed air blasts straight out of the pipe or tube. It not only wastes huge amounts of compressed air but also violates OSHA noise and dead ended pressure requirements.
Replacement For Expensive, Noisy Blowers
Energy conscious plants might think a blower to be a better choice due to its slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of bearings, belts and filters. Here are some important facts:
Filters must be replaced every one to three months.
Belts must be replaced every three to six months.
Blower bearings wear out quickly due to the motor that must turn at 17-20,000 RPM in order to generate effective airflows.
Poorly designed seals that allow dirt and moisture infiltration along with environments above 125°F (52°C) decrease bearing life.
Typical bearing replacement is at least once a year at a cost near $1000.
Many bearings can not be replaced in the field, resulting in downtime to send the assembly back to the manufacturer.
Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often difficult to control since mechanical adjustments are required.