I recently worked with a beverage manufacturer in replacing some inefficient and cheap plastic nozzles on one of their processing lines. The customer manufactures a wide variety of various beverages for consumer use, packaging them into juice-box containers. After sealing, the boxes go through a washdown process to remove any residual that may have spilled onto the outside of the container during filling.
Upon exiting the washer, they travel along a 3” wide conveyor where they’re dried by (2) plastic flat nozzles. After drying, the boxes make their way to a printer that marks the manufacturing codes and expiration date on the top of the container. If any residual moisture is present, they do not receive a legible marking. Since the boxes were not always dead-center on the conveyor, they had to stagger two nozzles in order to ensure the top of the box was dried regardless of its orientation on the conveyor.
Their search for a more efficient solution led them to the EXAIR Super Air Knife. Not only was the knife significantly more efficient, but it was also able to dramatically reduce the sound level as well. The current nozzles consume 56.8 SCFM at a pressure of 80 PSIG. The two nozzles were replaced with (1) Model 110003 Super Air Knife and Universal Mounting System. The knife was positioned directly over top of the boxes, covering the full width of the conveyor. In comparison, the 3” Super Air Knife consumes just 8.7 SCFM of compressed air AND we only needed to use one of them. The customer runs two 8-hr shifts per day, 7 days per week. Exactly how much did they save (assuming $0.25/ 1000 SCF cost of compressed air)?
Before EXAIR: (2) nozzles consuming 56.8 SCFM
56.8 SCFM x 16hrs x 365 days/year = 331,712 SCF of compressed air per year
331,712 SCF x $0.25/1000 SCF = $82.93/ year
After EXAIR: (1) 3” Super Air Knife consuming 8.7 SCFM
8.7 SCFM x 16hrs x 365 days/year = 50,808 SCF of compressed air per year
50,808 SCF x $0.25/1000 SCF = $12.70/ year
This equates to a 75% reduction in compressed air usage per installation. The customer had a total of (4) lines running with the same setup and was able to replace each with a 3” Super Air Knife. In addition to the air savings, the sound level was reduced from 85 dBA to just 69 dBA with the Super Air Knife!
Stop wasting your time with cheap and ineffective plastic nozzles. They’re wasting you a ton of money on your bottom line, not to mention can’t stand up to the ruggedness of our Super Air Knife. Replacing any inefficient blowoff products with an engineered solution can really help during these difficult times, as well as improve the working environment for your operators.