Engineered air nozzles can have a dramatic effect on plant air consumption, especially when used in place of homemade blowoffs. Consider an example where an Exair Model 1001 Safety Air Nozzle replaces a 1/8-in. open pipe. At 80 psig, both provide about 9 oz of force at a 12-in. distance.

The 1/8-in.-diameter open-pipe blowoff at 80 psig consumes 70 scfm of compressed air. A Model 1001 nozzle, on the other hand, consumes only 10 scfm, a 60-scfm savings. For noncontinuous applications, multiply this number by the duty cycle to determine actual air savings.

Managers of most large plants know their costs per 1,000 standard cubic feet of compressed air. If actual costs are not known, $0.25/1,000 scf is a reasonable average. Cost savings in this example are

60 scfm x 60 min x $0.25/1,000 scf = $0.90/hr. Annual savings amount to $1,872 for a single nozzle.

Calculating compressed-air savings shows that engineered nozzles, including filter and installation costs, often pay for themselves in a matter of weeks, not years.