Automated Drying For Pipe, Tube, and Extruded Shapes

Published on by Tyler DanielLeave a comment

The challenge with drying or cleaning a continuous pipe or tube is that air has to reach the entire circumference simultaneously. Standard nozzles or simple air rings often leave “dead spots” where moisture or debris can hide, leading to quality failures in downstream processes like ink jet coding or packaging. The Super Air Wipe solves this by generating a high-velocity, 360-degree laminar air curtain. As the pipe or tube passes through the center of the wipe, the air strips the surface clean without any gaps in coverage.

In many pipe and hose operations, the biggest bottleneck is the inability to break the line for maintenance or setup. Because the Super Air Wipe features a split design, it can be unlatched and clamped around the pipe at any point. You do not have to feed the material through the center, which means no downtime when a new roll is started or a different section of the line needs a blow off station.

For tubes ranging from 3/8 inch up to 11 inches, the Super Air Wipe provides a concentrated blast that moves with the material. On a PVC line, for example, the air wipe can be positioned immediately after the cooling tank. By stripping the water off the pipe at high speed, you ensure the surface is bone dry before it hits the printer or the saw. This level of consistency is impossible to achieve with manual wiping or haphazard nozzle arrangements.

Control is straightforward. By using a pressure regulator, you can dial the force up or down based on the line speed. If you are running a heavy gauge pipe at low speed, you can drop the pressure to save air. If the line speeds up, you increase the pressure to maintain the same drying efficiency. This flexibility ensures you are only using the compressed air required for that specific run.

For those working in high-temperature extrusion or corrosive environments, the 303 Stainless Steel models are the standard choice. They handle temperatures up to 800°F, allowing you to position the wipe closer to the die where the material is at its hottest. This prevents debris from baking onto the surface and ensures a cleaner finish. Whether you are dealing with cutting fluid on machined tubing or water on an extrusion line, the Super Air Wipe provides a repeatable, 360-degree solution that manual methods simply cannot match.

Tyler Daniel

Assistant Application Engineering Manager

E-mail: TylerDaniel@EXAIR.com

EXAIR Super Air Knives Help to Dry Labels In Bottling Factory

Published on by John BallLeave a comment

I spoke with a customer from a bottling facility that was using blower-type air knives.  They were trying to cool and remove condensation from the labels.  Their production rate was slow, and they were seeing issues in the labeling process.  Their operation consisted of an applicator that would place the label around the bottle prior to going into a steam oven to shrink the labels.  After this, a blow-off station was used to cool and set the label around the bottle and remove any condensation.  They determined that the bottles were not getting dry enough and the shrink rate was too long.  They were using a blower system, and they were having difficulty when they tried to reach the required bottle rate. 

With blower systems, they blow warm air which affects the cooling results.  Besides the maintenance and loud noises, the turbulent air causes erratic drying patterns.  EXAIR products use the power of the compressed air system to give a wide range of blowing forces for drying, cooling, or moving products.  With our Super Air Knives, we have a 40:1 amplification ratio, which means for every 1 part of compressed air, we bring in 40 parts of ambient air.  This adds mass to the airstream to make our Super Air Knives very efficient and effective.  With a laminar air flow, it creates a consistent force while moving the air in one direction.  This was important to push the condensation to the bottom of the bottles.  

Super Air Knife Kits include a Shim Set, Filter Separator, and Pressure Regulator.

So, I recommended two units of the model 110224SS Super Air Knife kits.  The kit includes the Super Air Knife, a filter, a regulator, and a shim set.  They mounted one knife on each side of the bottles to blow off and remove the liquid after the steam cycle.  Even at the increased bottle speeds, the EXAIR Super Air Knives had no issues with keeping the bottles dry and providing enough cooling to set the label.  With the regulator and shim set, it was easy for them to dial in the correct amount of force without using too much compressed air.  The labels remained attached, and the bottling process ran smoothly. 

In using compressed air, the EXAIR Super Air Knives are engineered to be very efficient and effective.  Now, they were able to dry the bottles to allow for a strong adhesion of the labels.  If you wish to speak to an Application Engineer about your cleaning, drying, blowing or cooling applications, we will be happy to hear from you. 

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

4 Mistakes Plants Might Be Making with Compressed Air (and How to Avoid Them)

Published on by Jordan T ShouseLeave a comment

Compressed air is one of the most versatile and expensive utilities in any plant. It powers tools, moves products, cools processes, and keeps production running smoothly. But it’s also one of the most commonly misused resources on the floor.

Small inefficiencies add up quickly, and many facilities are losing thousands of dollars a year without realizing it. The good news? Most of these issues are easy to fix once you know where to look, especially with engineered solutions from EXAIR.

Here are four of the most common mistakes plants make with compressed air, and how to avoid them.

1. Using Open Pipes Instead of Engineered Nozzles

The Mistake:
Blowing with open pipes or drilled tubes is still surprisingly common. It “kinda works,” but it’s incredibly inefficient, noisy, and unsafe.

Why It Matters:
Open pipes consume a massive amount of compressed air and can create dangerous dead-end pressure situations. They also produce high noise levels that can exceed OSHA limits.

How to Avoid It:
Switch to engineered air nozzles and knives like EXAIR’s Super Air Nozzles or the Super Air knife. These are designed to:

  • Reduce air consumption by up to 80%
  • Meet safety standards for dead-end pressure
  • Dramatically lower noise levels

The Result:
Immediate air savings, safer operation, and a quieter plant floor.

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

2. Running at Higher Pressure Than Necessary

The Mistake:
Many plants run their systems at higher pressure “just in case.” It feels safer—but it’s costing you.

Why It Matters:
Every 2 PSI increase in pressure can increase energy consumption by roughly 1%. Multiply that across your entire system, and the cost adds up fast.

How to Avoid It:
Use EXAIR’s pressure regulators to optimize pressure at the point of use instead of over-pressurizing the entire system.

The Result:
Lower energy bills and better control over your applications—without sacrificing performance.

EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

3. Ignoring Compressed Air Leaks

The Mistake:
Leaks are often treated as “minor” issues and left unresolved.

Why It Matters:
Leaks can waste 20–30% of your compressed air output. That’s essentially money leaking out of your system 24/7.

How to Avoid It:

  • Conduct routine leak audits using the Model 9207 Ultrasonic Leak Detector
  • Fix worn fittings, hoses, and connections
  • Use efficient components that minimize unnecessary air use

Pairing leak reduction with efficient products from EXAIR ensures you’re not just fixing losses, you’re preventing new ones.

The Result:
Reduced compressor load, lower maintenance costs, and immediate energy savings.

4. Not Optimizing Airflow for the Application

The Mistake:
Using too much air—or the wrong type of airflow—for blowing, drying, or conveying applications.

Why It Matters:
Inefficient airflow leads to higher consumption, inconsistent performance, and unnecessary wear on equipment.

How to Avoid It:
Adopt engineered air amplification products like EXAIR’s Air Knives, Air Amplifiers, and Air Wipes. These devices entrain the surrounding air to:

  • Maximize output while minimizing compressed air use
  • Provide uniform, high-performance airflow
  • Improve drying, cleaning, and conveying efficiency

The Result:
Better process performance with significantly lower air usage.

EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

Compressed air is too valuable to waste. The difference between an optimized system and an inefficient one often comes down to a few overlooked decisions.

By avoiding these common mistakes—and implementing engineered solutions from EXAIR—plants can:

  • Cut energy costs
  • Improve safety
  • Boost productivity
  • Extend equipment life

If your facility hasn’t evaluated its compressed air usage recently, now is the time. Even small changes can deliver fast, measurable results.

Jordan Shouse
Application Engineer
E: JordanShouse@exair.com
O: (513) 671‑3322
F: (513) 671‑3363
A: 11510 Goldcoast Dr Cincinnati OH 45249
www.exair.com

Find time on my calendar by scheduling a meeting here.

Should You Consider Rotary Screw Air Compressors For Your Process?

Published on by jasonkirbyLeave a comment
Rotary Screw

Rotary screw compressors are efficient, positive-displacement machines specifically engineered for continuous industrial air supply. Utilizing two interlocking helical rotors, these compressors provide a 100% duty cycle, operate quietly, and require less maintenance than traditional piston compressors. They are particularly well-suited for high-demand environments such as manufacturing and construction.

Rotary air compressors are positive displacement devices engineered for continuous, high-capacity industrial applications, employing rotational motion to capture and compress air. The primary types include rotary screw, sliding vane, scroll, root blower, and liquid ring compressors. These machines are categorized based on their cooling methods, which can be either air-cooled or water-cooled, as well as their efficiency control mechanisms.

Rotary screw compressors, characterized by their two interlocking helical rotors, are the most prevalent type used in various industrial settings. These compressors effectively trap and compress air, making them highly efficient for continuous operation. Their robust design ensures exceptional durability, which is essential for meeting the demands of industrial applications.

Sliding vane compressors operate by utilizing a rotor equipped with several sliding vanes that extend radially. This design facilitates the formation of air pockets between the rotor and the housing, which effectively reduces the volume of air and simultaneously increases its pressure.

Scroll compressors utilize two interleaved spiral scrolls—one stationary and the other orbiting—to compress air without any rotational movement. This design is particularly suited for smaller applications where quiet operation and energy efficiency are essential.

Lobe compressors operate by utilizing two precisely matched lobes to move air from the intake to the discharge port. This mechanism ensures a steady and continuous flow of low-pressure air (4.4 to 14.5 psig).

Liquid ring compressors are a specialized rotary compressor that utilizes a liquid, typically water, as the sealing medium to compress gas. This design is particularly advantageous in applications where it is essential to avoid oil contamination in the process.

Advantages: Rotary compressors, especially screw models, are known for their exceptional energy efficiency, achieving savings of up to 60%. They are designed for continuous operation around the clock, which makes them suitable for demanding industrial, HVAC, and refrigeration applications. With fewer moving parts, these compressors require minimal maintenance and operate quietly with low vibration levels. This combination ensures a consistent and reliable airflow while minimizing oil carryover, making them an excellent choice for environments that prioritize efficiency and performance.

Disadvantages: Rotary compressors, especially the rotary screw variety, entail significant upfront costs and require specialized maintenance. Their efficiency tends to decrease during periods of low air demand, which can result in condensation if the units do not operate at sufficiently high temperatures. Although these compressors are engineered for continuous use, they can incur substantial repair expenses in the event of a failure, particularly due to the high costs associated with air end replacements.

If you have questions about the rotary compressors, or anything regarding EXAIR and our products, please do not hesitate to reach out.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk