Tag: Air Knife

Laminar Flow vs. Turbulent Flow: The Science Behind More Efficient Compressed Air Systems

Published on by Jordan T ShouseLeave a comment

Why Understanding Airflow Matters

Every compressed air system moves air—but how that air moves determines whether you’re maximizing performance or wasting energy.

In industrial applications, airflow generally falls into one of two categories: laminar flow and turbulent flow. While turbulence has its place in applications like mixing or combustion, it is often the enemy of efficiency when it comes to compressed air blow off, cooling, and drying.

That’s why EXAIR engineers products designed to produce laminar, controlled, high-velocity airflow rather than chaotic turbulent air streams. The result is lower compressed air consumption, quieter operation, and improved process performance.

What Is Laminar Flow?

Laminar flow occurs when air travels in smooth, organized layers with very little mixing between them.

Imagine cars traveling down a highway where everyone stays in their lane at the same speed. Traffic flows efficiently with minimal disruption.

Characteristics of laminar airflow include:

  • Smooth, predictable air movement
  • Minimal energy loss
  • Lower noise levels
  • Greater directional control
  • More efficient momentum transfer

In industrial compressed air applications, laminar flow allows the air to reach the target with much more of its original energy intact.

What Is Turbulent Flow?

Turbulent flow is exactly the opposite.

Instead of orderly layers, the air is filled with constantly changing eddies and vortices. These swirling motions cause the airflow to scatter in multiple directions.

Think of rush-hour traffic with vehicles constantly changing lanes, braking, and accelerating. Energy is wasted simply trying to keep moving.

In compressed air systems, turbulence results in:

  • Increased air consumption
  • Pressure losses
  • Higher operating noise
  • Less effective blow off
  • Reduced cooling efficiency
  • Inconsistent drying performance

Unfortunately, one of the biggest sources of turbulence in manufacturing plants is also one of the most common: the open pipe.

Why Open Pipes Waste Compressed Air

Many facilities still use open copper tubing or pipe as blow off devices.

At first glance, this seems simple and inexpensive.

However, as compressed air exits an open pipe, it expands rapidly into the surrounding atmosphere. The sharp pipe edge creates intense turbulence, causing the airflow to disperse almost immediately.

The result is:

  • High compressed air consumption
  • Loud noise levels
  • Poor force at the target
  • Significant energy waste

Simply increasing supply pressure rarely solves the problem—it usually makes the turbulence even worse.

How EXAIR Engineers Better Airflow

Rather than allowing compressed air to escape uncontrollably, EXAIR products are carefully engineered to optimize airflow.

Engineered Air Nozzles, Air Knives and other blow off devices

EXAIR Air Nozzles use specially designed internal geometries that entrain the surrounding ambient air.

Instead of relying solely on compressed air, they pull in additional free air from the environment, multiplying airflow while dramatically reducing compressed air consumption.

Benefits include:

  • More usable airflow
  • Reduced compressed air usage
  • Lower noise levels
  • OSHA-compliant dead-end pressure
  • Improved blow off performance

The exiting air stream remains much more organized than an open pipe, allowing more energy to reach the work surface.

Ready to make your compressed air system work smarter? Whether you’re replacing noisy open pipes, improving blow off performance, or looking to reduce compressed air consumption, the engineers at EXAIR are here to help. Our Application Engineers will evaluate your application, recommend the right solution, and help you optimize airflow for maximum efficiency and performance. Contact EXAIR today to discuss your application and discover how engineered compressed air products can reduce energy costs, improve productivity, and deliver more consistent 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.

Compressed Air Problems? Ask An Application Engineer If An EXAIR Super Air Nozzle Is Right For You.

Published on by Russ BowmanLeave a comment

A few years back, I had the pleasure of working with a machine shop manager who wanted to reduce the compressed air consumption in their facility. They had ten lathes, machining high-tech plastic products, and used crimped copper tubing to blow off chips and shavings as the parts were turned. They ran continuously — as did the air compressor — which occasionally caused header pressure to drop below the level required for operation of the pneumatic chucks & tool changers.

These cheap and easy blow offs were making things expensive and difficult for the company.

After some discussion and an Efficiency Lab test of one of their crimped tubes, I recommended our Model 1100 1/4 NPT Zinc Aluminum Super Air Nozzles. They’re our most popular engineered Air Nozzle for typical industrial blow-off applications. They generate a forceful, focused blast of air that’s ideal for chip removal on machine tools, and they’re ideally suited for a number of other uses as well. They bought ten (one for each machine) and installed them one afternoon, right before close of business, by cutting the crimps off the copper tubes and fitting them with simple compression fittings. The whole operation took about five minutes. When the machine shop manager arrived the next morning, he was at first alarmed because there was so little noise coming from the shop (he thought something was wrong with the machines) and then impressed when he found all the lathes were running, and the Super Air Nozzles were so much quieter than the crimped tubes.

The copper tube used to have a crimped end that was aimed at the part in the chuck. They simply cut it off and used a compression fitting to install the Super Air Nozzle.

While our Model 1100 Super Air Nozzle is our most popular one, EXAIR makes a wide range of engineered Air Nozzles to meet the needs of almost any blow-off application. If you’re replacing something else, we can test your current device(s) in our Efficiency Lab (like we did the crimped copper tubing here) and determine the Air Nozzle that most closely matches the performance required for your application.

If it’s a new application, we have tools at our disposal for proper product selection too:

  • The Catalog: Our Air Nozzles & Jets catalog section lists them all, from smallest to largest, with performance data, dimensions, and airflow patterns. I actually like to start with the airflow pattern: once we know the size & shape of the needed/desired flow, we can narrow down our selection.
  • Application Database: At last count, we had over 200 blow-off applications written up. Now, that includes Air Nozzles as well as Air Knives, Air Amplifiers, and Safety Air Guns (which have Air Nozzles on them), but keep in mind what I said about picking the size & shape of the airflow.
  • Engineering Assistance: If you’re short on time, find yourself completely stumped, or just want a 2nd opinion on the best product for your application, we’re here from 7am to 4pm Eastern Time to help you over the phone, in a Live Chat, or at an Engineering Consultation web meeting. You can also email techelp@exair.com, 24/7, with details about what you’re after.

At EXAIR, we want to help you get the most out of your compressed air use. If you want to find out more, give me a call.

Russ Bowman, CCASS

Application Engineer
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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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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