Bottling Line Can Run Efficiently by Taking a Few Simple Steps

I recently visited a local customer who bottles a liquid drink.  They do two different sizes, single serve and gallon bottles.  The main issues they were having is the gallon bottles were not dry enough after they come out of a cooling / rinse tunnel.  They currently had three different blow off devices in place outside of this cooling tunnel.  The cooling tunnel had hundreds of spray nozzles to both rinse and cool the gallons of liquid.

On the exit of the tunnel there was a blower driven air knife that was being powered by a high maintenance motor that was also sucking in non filtered air to blow the moisture off thee gallon jugs.  The blower was not producing high velocity air and the knife position could not be adjusted for maximum effectiveness due to the hard piping from the blower.

The bottles come out of the blower and go from a 60″ wide conveyor to a 24″ wide conveyor in about five feet of travel. The bottles are then funneled down even further into a single file line and then sped up and sent through two 90 degree bends to try and knock any residual water off them before going into the casing machine.

There were no other blow offs on the gallon line because they were concerned with their compressed air use.  The other two blow offs they had in place were on the single serve bottling line. On that line there were two points that had six separate clusters of a metal flat nozzle that was approximately 1″ wide and were all pointed at a different point of the cap to try and eliminate some moisture that would get trapped under the lip.

The single serve bottles would come out spaced approximately six inches apart but the nozzles were blowing continuously.  This was a very large waste of compressed air.  They could have very easily installed an EXAIR EFC on these supply lines to cut their usage by more than 50% of their current demand.   They then went past an open pipe blow off to help dry the final labeling point.   This was also on continuously which was another opportunity for air savings.

I recommended installing two Electronic Flow Control (EFC) units and replacing their existing nozzles and open pipe with the EXAIR model 1126 1″ Flat Super Air Nozzle outfitted with swivels to allow them to be positioned properly to reach under the bottle cap. Proper positioning, in many cases, increases the effectiveness of the nozzles and can get the job done with fewer nozzles installed. In this application I am confident we can get that bottle cap area blown off with only 2 nozzles.

By eliminating excessive nozzles and cycling compressed air on and off only as needed, the customer saves compressed air. I estimated it was enough compressed air to install a 24″ Deluxe Super Air Knife Kit to blow down on top of the gallon containers, which is the primary reason they asked me to visit in the first place. This will not only give them the 24″ Super Air Knife, but it will also include the crucial EFC and a filter separator to clean the compressed air and a pressure regulator to adjust the pressure down to the minimum necessary for success. All of these factors contribute to optimizing compressed air and using it effectively within anyone’s plant:

  • Eliminate open pipes and ineffective blow offs
  • Turn off compressed air whenever possible
  • Keep it clean to reduce wear and maintenance
  • Adjust the pressure to a minimum level for success

This is just one location in the entire facility where implementing the Electronic Flow Control and EXAIR engineered nozzles will help the customer to optimize their compressed air use.

If you would like to learn more or have questions on any of the EXAIR products mentioned in this blog, feel free to contact us.

Brian Farno
Application Engineer

Once Again EXAIR Is First To Tackle The Impossible

That’s right folks, in case you haven’t seen, EXAIR is the first company to offer long length Super Air Knives in single piece construction.   You can now get up to a 108″ long Super Air Knife in Aluminum, 303 Stainless Steel, or 316 Stainless Steel as a single piece.

EXAIR's new 108 inch Super Air Knives

What does this mean for you, the customer? Well, a few of the benefits are a seamless airflow no matter how close your target is to the knife, easier plumbing of compressed air for uniform flow, easier mounting since no coupling brackets are needed to join the two halves together, and single piece shim construction for fewer parts overall.

We also offer these Super Air Knives with our Plumbing Kit Installed as well as with our Universal Air Knife Mounting System.  This means you can get from a 3″ to 108″ Super Air Knife in single piece construction ready to use and mount to your system from STOCK. These additional features will allow you time same time and resources upon receipt of your Super Air Knife.  If you have any questions on our long Super Air Knives or what product might fit your application, feel free to contact us.

Brian Farno
Application Engineer

Straight To The Source


This week I took a call from a bakery who was using an air knife to remove the left over crust in their silicone lined stainless steel baking pans. They purchased the air knife through a reseller who made the recommendation. They noticed there wasn’t much of an increase in velocity and little force coming from the exhaust side of the air knife so after several attempts at re-mounting the knife and adjusting the input air pressure, they still weren’t able to remove the remaining crust, so they returned the unit.

They called EXAIR looking for a recommendation and provided the part # for the air knife they had recently returned. It turns out that the air knife they returned was actually a 12” EXAIR Super Ion Air Knife. The Super Ion Air Knife provides a laminar sheet of ionized airflow, with a 40:1 amplification rate,  to remove a static charge from a process. I asked if the customer was needing to remove a static charge and their answer was simply, “No, we weren’t even using the ionizing feature”.

The customer mentioned the crust falls right out if a pan is turned over, the need for static elimination was most likely unnecessary. I recommended the same solution as the reseller, but without the static elimination qualities, the EXAIR Super Air Knife  can get the job done. After troubleshooting the lack of performance they experienced, I determined they were using quick disconnects and tubing, which per my previous blog titled “(Im)Proper Infeed Pipe Size For The Super Air Knife”, was incorrect.


The customer is going to re-pipe their supply line so I recommended re-ordering our 12” Super Air Knife. Since they already have an account with the supplier, they wanted to order through them. Of course this was perfectly fine but I reminded them we also sell factory direct and we make placing your order easy.

Regardless if you order your EXAIR product direct or from another source, we are always here to help troubleshoot your application to ensure you are achieving optimal performance.

If you have a current process or a new application that requires assistance, please do not hesitate to contact an Application Engineer.

Justin Nicholl
Application Engineer

Everybody Wants Options II

Justin Nicholl, I hear you loud and clear about how Everybody Wants Options. I would go so far as to say a lot of people NEED options. This was evident in an application that I had the pleasure of assisting a caller with recently. They make plastic parts for the automotive industry, and manually remove them from a conveyor line, where the operators experience a nuisance static shock. This static charge also presents a problem when the parts are packaged for shipping, so there are two great reasons for getting rid of it right there.

On to the options: they weren’t sure if they wanted to mount something over the conveyor (like a Super Ion Air Knife or Ion Air Cannon,) or if they wanted to have manual, precise control (as with an Ion Air Gun.) I recommended that they try the Ion Air Gun…for ease of setup, it can’t be beat: you can literally go from opening the box to blowing ionized air in a matter of minutes, provided you’ve got a compressed air line and an electrical outlet within reach. If it is indeed successful in eliminating the static charge (and this is a VERY common & successful application,) then the only question is: Will the operator want to have another hand free? If so, they can return the Ion Air Gun for full credit per our 30 Day Unconditional Guarantee, and get either the Super Ion Air Knife or Ion Air Cannon; whichever they choose. In fact, it’s very likely that using the Ion Air Gun for a little while will better inform their decision.

EXAIR Static Eliminators: Mount in place, or hold in your hand.

EXAIR Static Eliminators: Mount in place, or hold in your hand.

EXAIR product lines, across the board, are rife with options. I wrote a while back about a purchasing agent who got a request for “the largest, most powerful air gun they’ve got” and ordered a 6′ Super Blast Safety Air Gun (with a 1-1/4” NPT connection, 6 foot extension, and a whopping 23lbs of force) when they just wanted to blow off some chips from their machine tools. Again, we used the 30 Day Unconditional Guarantee to get them a 6″ Heavy Duty Safety Air Gun (3/8” NPT connection, 6 inch extension, and a very usable 13oz of force.)

1218-6 1310-6 blog

Another user recently tried a Stainless Steel Line Vac – the product they needed to convey was too abrasive for an aluminum Line Vac – but they just weren’t getting the conveyance rate they wanted. No problem…the Model 150200 2” Heavy Duty Line Vac is made of an abrasion resistant hardened alloy, and boosts conveyance performance dramatically. The dimensions were the same, so the new one dropped right in, saving them from exploring the option of re-plumbing their lines.

all lv blog

Regardless of your compressed air product needs, EXAIR is the most likely solution:

*Super Air Knives are available in lengths from 3” to 108”. They come in aluminum, 303 or 316 grade Stainless Steel, and PVDF plastic (with Hastelloy-C fasteners and Teflon shims for the most aggressive installations.) This is, by far, the most options you’ll find in the industry. And they’re all in stock…waiting until next week doesn’t have to be an option.

*Cabinet Cooler Systems come in capacities from 550 BTU/hr to 5,600 BTU/hr. Whether your enclosure needs NEMA 12 (oil tight, dust tight, indoor duty), NEMA 4 (splash resistant) or NEMA 4X (corrosion resistant,) we’ve got it. And yes, they’re in stock.

*If you need to move a lot of air, or draw a vacuum, our Adjustable Air Amplifiers and Adjustable E-Vacs, respectively, offer you infinite options in range of performance with the simple twist of a locking ring.

You want options? We’ve got them. You want help narrowing them down? Call us.

Russ Bowman
Application Engineer

Posted in Air Amplifier, Air Knife, Cabinet Cooler, Compressed Air Optimization, Customer Service, Industrial Safety Air Guns, Line Vac, Safety Air Gun, Static Elimination, Super Air Nozzle, Vacuum, Vacuum Generators. Tags: , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , . Leave a Comment »

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