Home > Blog > 5 Ways to Improve Plant Productivity with Air Solutions

5 Ways to Improve Plant Productivity with Air Solutions

13/08/2024
Operating at maximum production efficiency is a goal many manufacturers strive for. Whether you are a new operation or you have been around for decades, you should always be on the lookout for new ways to improve efficiency and reduce costs. Below are five ways you can implement air solutions to improve your overall plant productivity.

Investigate your workflow to identify shortcomings or gaps in production

It is imperative to never assume you are operating at peak efficiency. Investigating workflows to identify shortcomings is the best way to spot gaps or issues in production before they cost you unplanned downtime. A common problem many manufacturers face is unplanned downtime due to overheated electrical panels. When electrical panels overheat, the production line is halted until the electrical components are cooled, reset or even replaced. Identifying this issue and installing enclosure coolers on these panels is a simple and cost-effective way to ensure your electronics will not overheat and halt production.

Reduce costly downtime with preventative maintenance

Performing preventative maintenance is also a great proactive habit to ensure as little downtime as possible. The frequency of the preventative maintenance is dependent on the operating conditions of the equipment.   For example, with the use of Cold Air Guns, workers can extend their tool life by up to 50% by keeping the tool at a lower temperature. This results in less downtime and cost in replacing and maintaining tools. Additionally, by using cold air cooling instead of liquid coolant, you eliminate the mess and the need for secondary parts cleaning in machining.

Increase operating speeds without sacrificing quality

While reducing downtime is important in improving overall plant efficiency, increasing operating speeds is also a key strategy to improve productivity. With the use of Cold Air Guns, manufacturers can increase machining rates by up to 36% while improving the quality of the product that is being manufactured. In this case study, discover how a paper company was able to increase their production rates while simultaneously improving the quality of the paper they were cutting with the use of a Cold Air Gun.  

Additionally, Air Flow Amplifiers and Air Knives can be utilized to increase production rates. Air Flow Amplifiers can be used to increase production by removing smoke, dust and debris for critical operating areas. And for quick and thorough blow off, Air Knives can be installed to improve finish quality of products.

Identify operating costs that can be reduced

Ensuring optimum efficiency by reducing operating costs is another factor that comes into play in manufacturing. By being aware of your operating costs and how they can be reduced can make a large difference in your bottom line. For example, by installing Air Nozzles into your production line, you can greatly reduce your compressed air consumption and therefore reduce your overall operating costs. In this case study, a bottle cap manufacturer was able to reduce their compressed air consumption by 70% after installing Vortec Engineered Air Nozzles, when compared to non-engineered nozzles. This resulted in saving the company $300,000 a year in compressed air costs.

Ensure safe working conditions for employees to stay productive

A happy and safe employee is a productive employee. In extreme temperature environments, employees are likely to take more breaks or work slower due to heat stress. Ensuring employees are comfortable and safe in even the most extreme temperatures can greatly improve their productivity. Vortec Cooling Vests offer personal cooling while keeping the employee comfortable while reducing heat stress and fatigue.  
Home > Blog > Compressed Air Cooling Helps to Advance Manufacturing Technology

Compressed Air Cooling Helps to Advance Manufacturing Technology

13/08/2024
In the weeks leading up to the International Manufacturing Technology Show (IMTS) this September, manufacturers from around the globe are preparing to travel to Chicago, IL to share and discover the latest innovations and technologies to advance traditional manufacturing practices. For the first time in decades, Vortec, an ITW company, will be exhibiting their compressed air cooling technology in a tradeshow format.

Vortec became the first company to develop technology for converting the vortex tube phenomenon into practical, effective industrial cooling solutions over 60 years ago. Since then, Vortec has continued to refine and expand vortex tube applications, as well as develop air amplification products for more efficient use of compressed air in cleaning and conveying applications. Vortec cooling works by inputting compressed air into a vortex tube where the air cools, and exports cold air to cool a variety of manufacturing processes and technologies, such as electrical cabinets, tools, blades, products and more!

Some of the Vortec products that will be on display at IMTS this year are:
  • Vortex A/C Enclosure Coolers
  • Cold Air Guns
  • Vortec Cooling Vests
  • Blow Off Solutions
    1. Energy Saving Air Nozzles
    2. Air Jets
    3. Air Amplifiers
    4. Air Knives


Vortex A/C Enclosure Coolers: 

All of Vortec’s Enclosure Air Conditioning units keep Electrical and Electronic Enclosures cool, clean and protected and are a low cost alternative to expensive, high maintenance air conditioners; and avoid contamination with dirty, humid air caused by fans. Vortex cabinet air conditioners maintain a slight pressurization in the cabinet to keep electrical and electronic components clean and dry; and most are thermostatically controlled to maintain enclosure temperatures within a specified temperature range.

Cold Air Guns:

Cold Air Guns use vortex tube technology and filtered compressed air to produce sub-freezing air as low as -30 deg F for numerous industrial spot cooling applications. With no moving parts to wear out, Cold-Air Guns require no electricity at the target, just a compressed air source.

Cold Air Guns are most often used for cooling of metal parts, in the machining and repair of metals, plastics, wood, ceramics and other materials. Cold air machining outperforms mist coolants and substantially increases tool life and feed rates on dry machining operations. The effective air cooling from a cold air gun is an energy saver and can eliminate the growth of heat-related parts while improving part's tolerance and surface finish quality. Vortec air gun nozzles have adjustable temperature and flow settings; and some models have a frost-free nozzle to eliminate mess from frost and condensation.

Vortec Cooling Vest:

Workers in extreme temperatures wear Vortec Cooling Vests (VCVs) to stay cool by minimizing heat stress and fatigue.  The VCV's improve comfort and productivity. Vortec personal cooling vest systems have two components: a cooling tube that generates cold air to provide air flow to the worker and a perforated cooling vest through which the cold air flows to lower the worker's body temperature
VCVs are available in two cooling capacities; 1500 BTUH and 2500 BTUH.   All models can achieve temperature differentials of +/- 45 – 60 deg F from the inlet compressed air temperature using vortex tube technology. These models are adjustable by the worker using an integral temperature adjustment knob.

Blow Off Solutions:

Whether your application needs pin-point blow off, flat curtains of air for wide blow off, or adjustable air amplifiers for a variety of blow off needs, Vortec has the solution for you. Our line of blow off products includes: air nozzles, air jets, air amplifiers, and air knives. These products meet your various blow off needs while helping reduce compressed air consumption, meeting OSHA dead head standards, and reducing noise levels.
 
We are excited to be exhibiting our line of cooling and blow off products this year to those in the manufacturing industry. Stop by Booth #135680 to see these cooling products in action or to even try the cooling vest on for yourself! Our experts will be available to discuss how these innovative products can help you better achieve your manufacturing goals.