EXAIR’s Super Air Amplifier Amplification Ratio’s, Explained

Much like the popular song from decades ago that was about “money for nothing”,  EXAIR can provide you with “air for free”.  What we mean by this is that when you choose to use our Super Air Amplifiers, you will produce a large volume of air while only requiring a small amount of compressed air. This is because Air Amplifiers amplify total output flow up to 25 times by entraining (pulling in) ambient air.

So just how does the EXAIR’s Super Air Amplifier do this?   By utilizing our patented design (Patent # 5402938) that incorporates a special shim to maintain the air slots precisely.  The compressed air is released toward the center of the Super Air Amplifier  which creates a constant, high velocity outlet flow across the entire cross sectional area.  This

SAA How It Works

The amplification occurs by entraining most of the ambient air from the back of the Super Air Amplifier. Another small volume of air is added again as the air exits the Super Air Amplifier further increasing the amplification.

SAA Blog 1Super Air Amplifiers that have outlet diameter’s of 3/4″ (19mm), 1 1/4″ (32mm), 2” (51mm) and 4” (102mm) are supplied with a .003” (0.08mm) shim which is ideal for most applications, however there is the optional .006” (.15mm) and .009” (.23mm) if more air volume and force is needed. The 8” (203mm) Super Air Amplifier comes standard with a .009” (.23mm) shim and for increased performance we offer an optional .015” (.39mm).  The chart below explains how to determine the total output flow and air consumption at different operating pressures for each Super Air Amplifier model.

SAA Blog 2

When you need “air for free” or more accurately stated, to get all you can from every SCFM of compressed air you produce, put the EXAIR Super Air Amplifier to work in your facility!

If you would like to discuss the EXAIR Super Air Amplifier or any of EXAIR’s Intelligent Compressed Air® products, give us a call as we would enjoy hearing from you.

Erik Kuhnash
Application Engineer
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Customizing Air Amplifiers

EXAIR’s line of Air Amplifiers can be found in a multitude of different applications across the world. They solve problems as simple as blowing debris off parts to exhausting fumes or circulating air. The Air Amplifier comes in two different styles either the Super Air Amplifier or the Adjustable Air Amplifier. Super Air Amplifiers come in a stock Aluminum Body with a diameter that ranges from ¾” to 8”. This differs from the Adjustable Air Amplifier which comes in either type 303 Stainless Steel or Aluminum and are Sized from ¾” to 4”.

The main difference between the Super Air Amplifier and the Adjustable Air Amplifier is the fact the Super Air Amplifier has a shim inside of it that sets the gap for the air flow. The standard shim thickness for the Super Air Amplifier in sizes of 3/4″ to the 4″ is 0.003” which is suitable for most applications. These shims can be exchanged for a thicker shim of thickness of either 0.006″ or 0.009″. The 8″ Super Air Amplifier is the only air amplifier that comes with a standard stock shim of 0.009″ and can be exchanged for a 0.015″ shim if needed.

Flanged Stainless Steel Adjustable Air Amplifier
Sanitary Flanged Adjustable Air Amplifier

Even though there is a wide variety of sizes and materials for the Stock Air Amplifiers they may not meet a customer’s specific application or need. Over the years EXAIR has produced many different custom Air Amplifiers for a customer’s specific need and the images throughout this blog are just a few of what we have done.

High Temp Air Amplifier

• Depending on the environment certain specific materials may be required like the food industry which requires specific Stainless Steel for various applications. One customer had a special PTFE plug made for the Adjustable Air Amplifier to help pull a sticky material through the process. The PTFE helped prevent the material form depositing on the Amplifier.
• For applications were mounting may be an issue, special attachments have been made to assist. For instances were an Amplifier may need to be mounted to a pipe a custom Stainless-Steel Adjustable Air Amplifier with a class 150 raised face flanges.
• Applications that are in a hot environment may require a special high temperature version which has be developed to operate in areas up to 700°F. The High Temperature Air Amplifier was so widely sought after that we turned it into a stock item. It is commonly used in large roto-molds and ovens to circulate air in order to maintain consistent temperatures.

Adjustable Air Amplifier with PTFE Plug Installed

No matter what your application needs are EXAIR will to work with you to create any custom Air Amplifier that fits your specific application needs.

If you have any questions about compressed air systems or want more information on any of EXAIR’s products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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Cooling Parts? Super Air Amplifiers May Be For You

Super Air Amplifier Family

When working with a cooling application, many customers will immediately look to the Vortex Tube and Spot Cooling product lines. While this may be the best solution for some applications, cold air is not always the best method that we have available for cooling. EXAIR’s Super Air Amplifiers are very effective at reducing the temperature of a part without requiring cold air, when the temperature differential between the Super Air Amplifier’s airflow and the temperature of the part is significant. Due to their ability to entrain large amounts of ambient air, we can move a lot of volume of air across the surface of the part and quickly lower the temperature.

I like to compare this to blowing on a hot cup of coffee just as it’s been brewed. The temperature of the air coming from your mouth is around 98.6°F, the same as your body temperature. Coffee can be as hot as 185°F when fresh. Due to the temperature differential between your breath and the hot coffee, we’re able to achieve a reasonable amount of cooling just by simply blowing across the surface. Typically, when the target temperature of the hot part or material needs to be around ambient temperature or higher, a Super Air Amplifier can be a good choice. 

While many applications utilize the outlet flow of the Super Air Amplifier to blow off, clean or cool a part or material, the ability of the Super Air Amplifier to entrain large amounts of ambient air can also be utilized to convey light materials or to draw in dust, smoke, or fumes from the surrounding environment. As the plugs on the exhaust side of the Super Air Amplifiers come in sizes of ¾”, 1-1/4”, 2”, 4”, and 8” the exhaust flow can be ducted with standard size hose.

EXAIR’s Super Air Amplifiers utilize a patented shim design to maintain critical positioning of component parts. This allows a precise amount of compressed air to be released at exact intervals toward the center of the Super Air Amplifier. This creates a constant, high velocity outlet flow across the entire cross-sectional area. Free, ambient air is entrained through the unit, resulting in high amplification ratios. The balanced outlet airflow minimizes wind shear to produce sound levels far lower than other similar air movers.

Patented Super Air Amplifier Shims

Super Air Amplifiers are supplied with a .003” thick shim that is ideal for most applications. Flow and force can be increased by replacing the shim with a thicker .006” or .009” shim. The flow of air is also controlled by adjusting the input pressure supplied to the amplifier. Higher pressures increase both the force and flow, while lower pressures decrease both force and flow. All Super Air Amplifiers are available in kits that come with a shim set as well as a suitably sized pressure regulator and auto-drain filter.

EXAIR has a solution for you if you need to move A LOT of air. Reach out to an Application Engineer today if you have an application that you believe could be served with a low-cost, simple solution!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Rotational molding: EXAIR Super Air Amplifiers compared to fans

Super Air Amplifier Family

A customer contacted EXAIR to find a better way to cool a die in a rotational molding facility.  Rotational molding, or Rotomolding, involves a heated hollow mold which is filled with plastic material. It is then slowly rotated (usually around two perpendicular axes), causing the softened material to disperse and cling to the walls of the mold. In order to maintain an even thickness throughout the part, the mold has to continue to rotate during the heating phase. After the desired timing sequence, the heating is turned off to allow the material to harden. 

This particular company was making plastic containers.  To try and improve the cycle rate between each container, they were using two fans (reference photo below) for cooling.  Time is money in this industry, and they wanted to target the fans to improve cooling.  They mentioned that water jackets for cooling would affect the life of the molds due to thermal shock.  So, they needed to cool with air; and EXAIR had a solution for them; the Super Air Amplifiers.

The Super Air Amplifiers as compared to fans are compact, easy to use, and very effective in cooling.  The capacity to cool is determined by the mass of air and the temperature difference. Since the mold is heated to 650oF (343oC) and the ambient air is 80oF (27oC), we have a good temperature difference for cooling.  For this application, I recommended to replace their fans with our model 120024 4” Super Air Amplifiers.  Each one can move 2,190 SCFM (6,1977 SLPM) of air while only needing 29.2 SCFM (826 SLPM) of compressed air at 80 PSIG (5.5 Bar). 

I also recommended to add one piece of a model 120022 2” Super Air Amplifier for cooling the inside of the mold.  Because the opening in the center of the mold is relatively small, a fan would take up most of the area.  Thus, not allowing the hot air to escape.  Since the 2” Super Air Amplifier is much smaller, they were able to place the air stream in the center allowing the hot air to escape around the edge of the hole.  With this combination, we were able to cool the mold 25% faster than the fans.  EXAIR did a comparison video between a Super Air Amplifier and a fan for cooling.  Watch it here.  

To expand on the comparison, EXAIR Super Air Amplifiers and electrical fans are designed to move air.  Fans use motors and blades to push the air toward the target.  There are mainly two types, centrifugal fans and axial fans.  The customer above was using axial fans.  The air enters from directly behind the fan, and the blades “slap” the air forward to the target. This creates a turbulent and loud air noise.  The EXAIR Super Air Amplifiers does not use any blades or motors to push the air.  They use a Coanda profile with a patented shim to create a low pressure to draw the air.   (You can read more about it here: Intelligent Compressed Air: Utilization of the Coanda Effect.)  So, they create laminar air flow which is much quieter. 

Super Air Amplifier – flow region

In physics, it is easier to pull than it is to push.  The same goes for moving air.  Fans are designed to “push” the air and the Super Air Amplifiers are designed to “pull” the air.  This method of pulling makes it simple to create a laminar flow in a small package which is more efficient, effective, and quiet.  With the patented shims inside the Super Air Amplifiers, they maximize the amplification by “pulling” in large amounts of ambient air while using less compressed air.  More air means better cooling.  If you want to move away from blower systems or axial fan systems to get better cooling, drying, cleaning, and conveying; you can contact an Application Engineer for more details about our Super Air Amplifiers. 

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb