Greeting Cards saved by 1″ Flat Super Air Nozzle

A greeting card manufacturer used a liquid coolant plastic nozzle to provide an air assist to divert greeting cards to an auxiliary straight conveyor. Without the air assist the cards would bounce and fly from the conveyor leading to a loss of products and more maintenance.  They used what they had on hand which was a coolant nozzle pictured below.

Coolant Type Nozzle
Liquid Coolant Nozzle uses 32 SCFM at 40 PSIG and 57 SCFM at 80 PSIG.

This nozzle was run at a fairly low pressure of 10 PSIG, but still used 7.8 SCFM at 10 PSIG.  The nozzle worked well, but if run for 24 hours over 250 working days, it costs $702 to supply air to the nozzle. The customer utilized (40) nozzles in their plant which cost them $28,080.  Also, the nozzles were incredibly noisy, since they were designed for liquid flow.

Our customer decided to upgrade to an engineered air nozzle after some time. They needed to cut their air consumption, but still get the job done.  They tested our 1″ Flat Nozzle, but with the standard 0.015” shim it used 5.7 SCFM of compressed air at 10 PSIG. This would be a savings, but after a quick conversation with our Application Engineers, the customer decided to install a 1″ Flat Super Air Nozzle with only a 0.005″ shim. This nozzle 1126-.005 only used 0.9 SCFM of compressed air at 10 PSIG of inlet pressure.  Replace their 40 liquid coolant nozzle would save them 6.9 SCFM per nozzle. 276 SCFM if all 40 nozzles were replaced. Saving 276 SCFM lowered energy bill for their air compressor by $24,840 anuually. Which would mean the simple ROI for $41, 1″ Flat Super Air Nozzle would be 17 days!

1″ Flat Super Air Nozzle model number 1126-.005 on a Stay Set Hose

Call an Application Engineer today to see how we can help you save thousands of dollars.

Dave Woerner
Application Engineer

Line Vac Removes Debris In Fuse Manufacturing

Over the last few months I’ve had the pleasure of working with an automation house headquartered in the U.S.  This company provides automation solutions to businesses from the states and abroad, and has a variety of applications, particularly for the Line Vac.  We began our discussions about transferring plastic pellet material into a multi-stage hopper atop a large machine, and progressed into other potential applications.

One of those applications was in the evacuation and reuse of sand used during a filling process for semiconductor fuses.  Fuses often contain high purity quartz sand as a granular filler.  The grain size distribution of the sand is of particular importance, as it provides room for vapors and gases to expand in the event of an arc.  So, making the most of the specified sand is a priority for the manufacturer.  The sand also offers a large surface area for efficient cooling and absorption of enormous amounts of energy.  In the event of an arc, the sand melts, forming a non-conductive body that prevents any further current flow.

Our customer in this application needed to remove the sand leftover at the top of the fuse after filling.  The existing setup provided no vacuum system, creating a mess of sand in, and around the filling station.

Line Vac Fuse 2
Semiconductor fuse filled with sand

The solution we came to was to install a 6078 or 6058 Line Vac, depending on the impact to the machine budget for each model.  (Note: The 6078 and 6058 Line Vac have identical performance, however, they are made of different materials – aluminum vs. 303 stainless steel – and thus have different costs.)  The Line Vac will vacuum the sand from the workspace, and convey it to a nearby container for reuse.

By recovering and reusing this sand, the machine area is cleaner, employees no longer have to sweep up and discard the spilled material, and the machine throughput can be increased.  Recovering the spilled material saves both time and money while increasing production capabilities.

With a Line Vac installed, we aim for a machine workspace that looks like this:

Line Vac Fuse 1
A nice, clean workspace

If you have an application that may benefit from an EXAIR product, or a discussion with an EXAIR Application Engineer, give us a call.

Lee Evans
Application Engineer


Dealing With The Unexpected

Last year about this time, I used the bully pulpit of my weekly blog to update you on the success of our ninth annual Father’s Day Weekend Campout. If you hadn’t guessed, I’m about to fill you in on how awesome the tenth was, but first:

A fellow Boy Scout leader is fond of saying that, when you camp, the weather is always perfect. It may be perfectly sunny or perfectly rainy. Perfectly warm or perfectly cold. Perfectly wet or perfectly frozen. Regardless, it’s always perfect. Yeah; we don’t always like him.

If we’ve learned one thing, it’s to expect the unexpected. This year, it rained. Well, not the whole time. Friday evening was beautiful…we got the campsite set up and dinner cooked well in advance of sundown. My friend & his son had recently waterproofed their tent, and me & my boys had recently purchased a new tent. Both were successfully, and extensively, leak tested Friday night. And all day Saturday. ALL DAY.

This, of course, put a damper on our plans to zipline, which didn’t exactly bother me. I’m sure it’s a temporary reprieve; I mean, I know darn well what I’m doing next year for Father’s Day Weekend, and it CAN’T rain forever. It also, however, put an unexpected damper on our plans to kayak on Sunday. The weather was gorgeous…and fitting for the first day of summer. It was hot enough to make some horseplay in the river sound downright inviting…but the constant rain over the past week had swelled the river banks, and none of the docks were accessible. So we broke camp and returned home to dry our gear. And to look forward to next year.

As Application Engineers, it’s a big part of our jobs to not just expect, but eliminate the unexpected. At EXAIR, we have an impressive arsenal of tools at hand to do just that. Our Efficiency Lab is fully stocked and outfitted to test any of our products…or yours…for performance and effectiveness. We’ve got a wealth of data in our constantly growing Case Study Library. Our Application Database has over 1,000 instances of what will work in certain situations, and our notes on product returns from our 30 Day Unconditional Guarantee give us information on what WON’T work.

If you’d like to find out how our products…and their capabilities…can work for you, give us a call. I look forward to seeing how we can help.

Russ Bowman
Application Engineer
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Small Threaded Line Vacs for Quick Transfers

EXAIR’s new small Line Vacs are perfect for small conveyance jobs. Years ago EXAIR discovered that our Line Vacs, which are designed to move small bulk products, are very versatile in a variety of application where compressed air is available. For instance view this video below.

In the video the Line Vac is seen shooting the string roughly 10 feet continuously.  This makes for a great demonstration of the Line Vacs power. In the video above, a customer need to be able to pull a tension on several spools (or cones) of thread. The Line Vac is able to easily accomplish this task, but the video also hints at other applications. Take for instance a web trimming operation were a 3/8″ or less strip of material is removed from the side of the web. A Line Vac can both convey the scrap trim and pull a tension on piece for easier cutting.

In the beginning of 2015 EXAIR introduced two new small threaded Line Vacs, the 140038 3/8″ aluminum threaded Line Vac and the 141050 1/2 aluminum threaded Line Vac. These Line Vacs will thread into a piping system to convey small parts,  scrap, trim and bulk materials that can pass through the inner diameter of the Line Vac.

Small Threaded Line Vacs
Small Threaded Line Vacs Convey Colored Plastic Pellets.

The Line Vacs use compressed air to create a small conveyance system.  The Line Vacs are perfect for moving any component, material, or trim that is smaller for its overall ID. The 3/8″ unit features a 0.19″ ID and the 1/2 unit features a 0.31″ ID. These ID’s are the smallest in the threaded Line Vac product line, other threaded model ID’s go up to 1.75″ (44mm). These small Line Vacs won’t work for every application, but they can be the right tool for the job.  Take the 1/2″ Stainless Steel Line Vac. It only uses 15% of the compressed air required by the 2″ Line Vac, but can still move a small amount of material 50 or 100 feet. Take a look at EXAIR’s site for information on how the Line Vacs may help you.

Dave Woerner
Application Engineer

NEMA 4 Cabinet Cooler Keeps Vision Inspection Camera Cool

Recently, I visited a packaging manufacturer who specialized in thin-wall, metal containers for such things as paint, oil, thinner, denatured alcohol, etc. On one application the process involved applying a small bead of rubber sealant to the underside of the top portion of a metal spray can to help in sealing the top of the can when assembled. After the sealant was applied, heated air was blown onto the bead to cure it prior to inspection.

The problem was that heat generated from the curing process was collecting in the housing for the inspection camera itself. The enclosure was mounted over top of the track on which the parts were moving by. This lead to overheating of the camera system and resulted in false rejections. The customer installed model 4708 (NEMA 4 Cabinet Cooler System) onto the enclosure to keep it cool for steady, effective operation of the camera. The photo below show the Cabinet Cooler System mounted to the top of the vision inspection system enclosure at the inspection stage.

Model 4708 Cabinet Cooler System

Neal Raker, International Sales Manager

Aircoolant System Cools Aluminum Laminate Cutting Process

A machine shop contacted me about a cutting/sawing application.  The customer had a new project to cut an aluminum laminate sheet.   The laminate sheet had a specialized material integrated within the aluminum.  The crux of this situation was that the material could not come in contact with any type of liquid coolant.  Most of his machines used liquid coolant to keep his tools sharp and long lasting.  In this operation, he could use a radial arm saw to cut the sheet, but the blade on this saw was expensive.  Without liquid coolant, he did not want to run the risk of damaging the blade.

My suggestion was to use the model 5330 High Power Cold Gun System.  It is designed to cool tools during milling, drilling, grinding, and sawing operations.  It can reduce the temperature of compressed air by 50 deg. F (28 deg. C).  It has a magnetic base for easy mounting and a dual point hose kit to cool both sides of the blade evenly.  In a short time, he could see the benefit in operating speeds and without using coolant, faster cleanup.  He was able to land the project, operate longer between blade changes, and open the possibility to get more business with new similar applications.

High Power Cold Air Gun

With the new types of materials being generated today, many applications cannot use liquid coolant.  Besides the example above, it would be the same for applications in electronics, food, and pharmaceutical. EXAIR has a range of Aircoolant Systems that may fit into your application.  If you would like more details, you can contact one of our Application Engineers.


John Ball
Application Engineer
Twitter: @EXAIR_jb

Super Ion Air Knife Assists With Lid Sealing

Last week I worked with a food packaging company who was experiencing a static issue when applying a film to seal their single-serve oatmeal cups. The cups move down a conveyor, 6 wide, where they are treated with a nitrogen purge. This causes a fine dust to become airborne. The sealing film travels through a series of rollers overhead and develops a static charge which attracts the dust to the film’s surface. As a result, when the film is applied to the top of the cup, it causes an improper seal which gets rejected at the inspection point.

The roll width is 33″ so I recommended the customer use our 36″ Super Ion Air Knife in the application. The Super Ion Air Knife consist of our Super Air Knife with an Ionizing Bar attached. Together they provide a high velocity, laminar sheet of ionized airflow that would be capable of not only eliminating the surface static to release the dust but also provide blow off to carry the dust away.

Super Ion Air Knife
Super Ion Air Knife ideal for eliminating static over a wide area.

With the dust being airborne once again, the customer was concerned that it could possibly fall back down into the cups after the nitrogen purge. Since they weren’t concerned with static in this particular area, I recommended they mount an additional 6″ Super Air Knife on one side of the conveyor, blowing the high velocity airflow across the top of the cups to create an air barrier to keep the dust from re-entering the cups.

Justin Nicholl
Application Engineer