Category: Compressed Air

Taming Harsh Environments: The Power of EXAIR’s PVDF Super Air Knives

Published on by Al WooffittLeave a comment

Industrial blow off, drying, and cooling applications are tough. When your processes involve extreme chemicals, aggressive rinses, or highly corrosive atmospheres, standard aluminum or stainless steel hardware can discolor, degrade, or fail entirely.

EXAIR‘s PVDF Super Air Knives provide the ultimate solution for severe environments, combining Intelligent Compressed Air efficiency with the extreme chemical resistance of Polyvinylidene Fluoride (PVDF). These engineered tools deliver a high-velocity, uniform sheet of laminar airflow to eliminate moisture and debris while easily handling both low and high pH exposures.

The PVDF Advantage: Built for Aggressive Chemistry

PVDF is an advanced fluoropolymer engineered for environments where other metals degrade. EXAIR constructs these specialized knives using PVDF bodies paired with Hastelloy bolts to maximize corrosion defense.

  • Extreme Chemical Defense: Highly resistant to aggressive acids, halogenated solvents, and severe caustics.
  • pH Spectrum Versatility: Excellent performance on both ends of the pH spectrum, including direct exposure to brutal compounds like Sodium Hydroxide.
  • Zero Discoloration: Unlike metal alternatives that suffer surface rust or pitting, PVDF maintains its structural integrity and finish over time.

Unmatched Super Air Knife Performance

The PVDF version inherits all the award-winning performance benefits that make the EXAIR Super Air Knife line an industry benchmark:

  • 40:1 Air Amplification: For every 1 part of expensive compressed air used, the knife draws in 40 parts of “free” ambient room air using the Coanda effect.
  • Drastic Energy Savings: Reduces compressed air consumption by up to 80% to 90% when compared to inefficient open pipes or drilled tubes.
  • Whisper-Quiet Operation: Operates at a quiet 69 dBA even at 80 PSIG, protecting workers and ensuring OSHA noise compliance.
  • Laminar Uniformity: Produces a perfectly balanced, hard-hitting line of air across the entire length, eliminating the dead spots common with drilled pipe manifolds.

Size Options and Customization

While metal EXAIR Super Air Knives span up to 108 inches, the stock PVDF Super Air Knives are available in lengths ranging from 3 to 54 inches. Because industrial footprints vary, EXAIR engineers can also machine Custom Super Air Knives at specific metric or imperial lengths tailored to unique application spaces.

Tuning and Fine-Adjustments

Every unit ships with a standard 0.002-inch shim installed to set the initial airflow gap. To scale your force up or down, you can use specialized Super Air Knife Shim Sets.

PVDF Super Air Knife Kits include the Air Knife itself (PVDF body, Hastelloy C-276 hardware, and PTFE Shims,) a PTFE Shim Set, an Automatic Drain Filter Separator, and Pressure Regulator.

Tech Tip: Because PVDF is a softer polymer material than aluminum or steel, it requires a unique, careful tuning approach during installation to achieve the exact airflow pattern required. You can view step-by-step guidance on the EXAIR Blog video guide for changing PVDF shims.

For complete system installations, pairing the knife with EXAIR Super Air Knife Kits—which include an automatic drain filter separator and a pressure regulator—enables easy input pressure dialing to achieve the exact blowoff impact needed.

If you are ready to swap out loud, corrosive-damaged open pipes for a quiet, highly efficient, and chemical-resistant alternative, contact an EXAIR application engineer to configure the perfect PVDF setup.

Al Wooffitt
Application Engineer

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Double-Acting Reciprocating Air Compressors: What They Are, Where They Fit, and Why Industry Still Chooses Them

Published on by Neal RakerLeave a comment

A plain-English look at a tough, “old-school” compressor design that still earns its place in modern plants.

Compressed air is one of those behind-the-scenes utilities that keeps a lot of everyday industry moving. It powers tools, helps run automated equipment, and supports processes that need clean, controlled air. There are lots of ways to make compressed air, but one of the most common “workhorse” designs is the reciprocating compressor—think of it like a mechanical bicycle pump that runs on a motor. In this post, we will focus on a specific version: the double-acting reciprocating air compressor.

What is a double-acting reciprocating air compressor?

A reciprocating air compressor uses a piston moving back and forth inside a cylinder to squeeze air into a smaller space (that is what makes the pressure go up). The “double-acting” part means it squeezes air on both sides of the piston—so it does useful work on the forward stroke and on the return stroke.

Why it matters: you can usually get more compressed air from the same basic machine size, and the output tends to be steadier than a single-acting design.

How it works (in plain language)

  1. It pulls air in. As the piston moves, a valve opens and outside air fills the cylinder.
  2. It squeezes the air. The piston comes back, shrinking the space and raising the pressure.
  3. It pushes the air out. Once the air is at a higher pressure than the system, another valve opens and the compressed air flows out.
  4. It repeats on both sides of the piston. In a double-acting design, one side is working while the other side is also taking a turn—so more of the motion becomes useful compression.

When a site needs higher pressure, reciprocating compressors are often built in stages—basically, the air gets squeezed a little, cooled down, then squeezed again. Cooling matters because air heats up when you compress it. In real installations, the compressor is usually part of a whole “compressed air system” that can include storage (an air receiver tank), cooling, drying, and filtration depending on how clean and dry the air needs to be.

How double-acting reciprocating compressors are used

You will find double-acting reciprocating compressors in places that need dependable air, especially when pressure needs are higher, or when demand goes up and down a lot during the day. Common examples include:

  • General plant air for tools, equipment, and production support—especially when the facility wants higher pressure.
  • Controls and automation (after proper drying/filtration) where steady, reliable air helps equipment behave predictably.
  • Work that comes in bursts, for example, operations that run hard for a while, then slow down—where a reciprocating machine can be a good match.
  • Job sites and temporary setups (often smaller reciprocating units), like maintenance work or seasonal blowouts.
  • Backup duty when a facility wants a second, dependable air source ready to step in.

Why industry chooses them: the “unique factors”

  • They can manage higher pressures. If the job calls for “more push,” this design is often on the shortlist.
  • Double acting = more done per stroke. Because both sides of the piston compress air, you get more output from the same basic motion.
  • They are a good fit when demand is not steady. Many sites do not use the same amount of air every minute of the day. Reciprocating machines can be controlled to respond to those changes.
  • They are built to be maintained. These compressors are known for being serviceable; parts that wear can be replaced, and the machine can keep going for a long time with proper care.
  • They match well with a “complete system.” Pairing the compressor with storage tanks, dryers, and filters can make the whole air system smoother and more dependable.

Where it fits vs. rotary screw compressors

If you have ever investigated industrial compressors, you have probably seen rotary screw compressors mentioned a lot—and for good reason. They are popular for steady, all-day air demand. Double-acting reciprocating compressors tend to shine when you need higher pressure, when air demand swings up and down, or when you want a machine that is very “mechanical” and service-friendly.

Quick selection checklist (rules of thumb):

  • Pick double-acting reciprocating when you need higher pressure, your air use changes a lot, and you value a design that can be maintained and rebuilt over time.
  • Pick rotary screw when you need lots of air, continuously, and you expect long run hours at a steady load.
  • Either way, remember: the compressor is only part of the story. Storage tanks, piping leaks, dryers, and filters can make a substantial difference in performance and cost.

Bottom line

A double-acting reciprocating air compressor is a classic workhorse: it uses a piston to compress air, and it does that work on both strokes. That simple idea—getting useful compression on the way out and the way back—helps explain why this design is still common in demanding industrial settings.

Neal Raker, Application Engineering Manager

nealraker@exair.com

Priorities of Work

Published on by Brian FarnoLeave a comment

Triage, priorities of work, MoSCoW Method, ABCdE, the list could go on and on. These are all methods to help you prioritize your day. I have blogged about my first career as a field service/training on CNC machines. This was something that I was baptized into. During the day-to-day here at EXAIR, and during GORUCK events, it became solidified in the way I approach almost any project and most of the days.

If you Google or use your favorite search engine for What are Priorities of Work, then you may get a list something like what is shown above. I’ve heard many of these over the years, but it wasn’t until one of the GORUCK events I was doing that it truly sank in that if I am not addressing the appropriate tasks first, then I wouldn’t have time for them later. When I was in machine tool, it meant evaluating all the issues preventing the customer’s machine from operating and making sure the longest lead time parts were ordered first, then the ancillary problems after. The goal was always to get the machine back up and running as fast as possible to get the customer back on schedule.

In endurance events, the priorities are to assess yourself, hydrate, if blister/skin care is needed, take care of those, and consume calories if needed. Then, take off your shoes and socks, lie down, elevate your feet, and sleep. Chatting and socializing can happen during, or it can wait until after.

Optimizing a compressed air blow off, reducing wasted compressed air, and maintaining the existing system can very often get knocked down on your priority list. The fact is, these priorities of keeping production moving and then ignoring subservient tasks can add up over time. This can then be the reason you are not able to keep production moving. That’s why here at EXAIR, we help you with a triaged list of priorities when it comes to maintaining your compressed air system.

The six steps to compressed air optimization are laid out to make it easy to check off the big-ticket items first and put the most back into your system. We can also help every step of the way with just a few clicks. Simply request a chat, reserve a video meeting with an Application Engineer, call, or email.

Brian Farno, MBA – CCASS
National Business Development Manager

BrianFarno@EXAIR.com
@EXAIR_BF

Laminate flooring – Step Up to Protect the Surface

Published on by John BallLeave a comment

A manufacturer of laminated floor planks was having issues with defects prior to packaging.  The planks were made from a high-density fiberboard as the core with a top layer of a picturesque image, then sealed together.  They were getting fine material that was stuck on the surface, making them defective.  The issue was caused after the cutting process.  The fine debris remained on the surface and when the image or the sealing material was applied, it could be seen.  They tried wiping, but the solution caused scratches.  They tried blowing the surface to clear the debris, but due to the static, it would not fall off easily.  They required a good solution to improve the cleaning without slowing the process.  EXAIR’s Static Eliminators are a great product for industrial processes like this. 

In looking at the process, I recommended two pieces of a model 112242 42” Gen4 Super Ion Air Knife Kit.  The planks could come out in two spots or four spots.  (Reference photo above) To reduce compressed air usage, they could turn on or off which side is needed.  The customer asked about the mounting and compressed air attachments.  I mentioned the proper setup for the most effective blowing.  As a benefit, I offered a plumbing kit to help with the compressed air connection.  The PKI option, or Plumbing Kit Installed, has the proper amount of connection to the Super Ion Air Knife to allow for an even force across the entire knife.  I upgraded the model number with the PKI option to a model 112242PKI. 

Gen4 Super Ion Air Knife Kit

This kit will include the Gen4 Super Ion Air Knife with a PKI, a power supply, a filter, a regulator and a shim set.  The Gen4 Power Supply creates both positive and negative ions to remove any type of static.  The filter will remove bulk liquids and debris from the compressed air to keep the product clean and to optimize performance.  The Regulator is used to control the force.  This helps to not overuse the amount of compressed air required for the job.  With a regulator, you can make fine adjustments to get the proper amount of air.  For coarse adjustments, you can change shims to increase or decrease the force.  The customer was happy with the properly sized components to operate a non-contact wiping with the Gen4 Super Ion Air Knives. 

Once installed, their defect rate almost dropped to zero.  They were very happy with the cleanliness of the planks; they decided to purchase six more units.  They could place them in different areas of the lamination line to ensure a clean surface.  EXAIR manufactures a variety of Static Eliminator products.  If you feel that static is an issue in your process, you can always contact an Application Engineer to help you.  For the company above, they were “stepping” high.   

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