A large manufacturing shop recently purchased a high speed band saw to cut aluminum. It was equipped with a mechanical rotating brush system to clean the blade as it ran, but this was unable to keep up with the volume of coolant-soaked chips that were produced at higher speeds. They had two options:
*Run the saw at a slower speed (and actually, their production schedule would not allow this, so technically there was only one option…)
*Come up with a reliable method of cleaning the saw blade (this is where EXAIR comes in.)
This has made a “night-and-day” difference for this sawing operation:
*In the first week they had the saw, they went through four saw blades…when the teeth get clogged with chips, they don’t cut right; they get hot; and they fail.
*The inability of the brush system to remove the chips caused them to accumulate in the belt pulley housings…operators were spending 2-3 hours A DAY just to shut down the saw and clean them out.
*The excess of chips also caused the blade’s guide bearings to fail, which caused almost a day’s worth of down time to replace.
*The Maintenance Supervisor was called to the saw repeatedly during the work day to address these, and many other minor, malfunctions due to the inability to remove the chips.
This saw is now operating at the capacity they intended when they purchased it. All for about $400, and that includes the door hinge they used to install it and allow for precise positioning (how cool is that?)
The EXAIR Super Air Knife has a prominent place near the front of our catalog, and THIRTEEN pages of photos, application details, performance data & specifications. It’s the most efficient and quietest product of its kind on the market, and our most diverse product offering in terms of size range, operational adjustability, materials of construction, and accessories available. For almost any general industrial air blow off application, the EXAIR Super Air Knife is the superior choice in terms of air usage, sound level, and capability.
As tireless champions of the causes of reducing air consumption and noise, we’re always going to promote these benefits of the Super Air Knife. Still, a caller asked me the other day, “Well, why do you still make the others?”…meaning, of course, our Standard and Full Flow Air Knives. Why, indeed:
*Given the same air supply pressure, the Standard Air Knife generates the highest force of our three styles. The amount of force applied isn’t always a prime consideration…if you think about one of the more “textbook” applications for an Air Knife, it doesn’t take a great amount of force to blow off dust and light debris from a conveyor belt…certainly this is a case where efficiency factors in: the lower air consumption of a Super Air Knife can pay for the cost difference between it and a Standard Air Knife in as little as three months of operation.
Of course, if you’re blowing stubborn debris out of tight spaces, like gummy, greasy dirt that’s accumulating in the recesses of a finned tube heat exchanger, that extra force can make all the difference. No; the Standard Air Knife isn’t as efficient or quiet as the Super Air Knife, but it’s still a far cry better than a drilled pipe.
*While the Super Air Knife is pretty compact – you only need a few square inches of profile area to successfully mount it – the Full Flow Air Knife is even smaller, requiring not much more than one square inch of profile for mounting. With ports on the rear face (instead of the ends & bottom for the Super Air Knife,) they can fit in very tight quarters.
The Full Flow Air Knife is also the lightest weight for a given length. A 36” Aluminum Super Air Knife, for instance, weighs about 8lbs. The 36” Aluminum Full Flow Air Knife weighs less than 4lbs. Most of the time, 8lbs is a very manageable amount of mass to support, but there are situations where every ounce matters, and if yours is one of them, you’re looking at the Full Flow Air Knife all the way.
*The biggest (in the most literal sense) factor in Air Knife selection is, well…size. We make the Standard Air Knives in lengths to 48”, and the Full Flow Air Knives come as long as 36”. The Super Air Knives, however, are stocked in lengths from 3” to 108”, and can be coupled together for as long of an uninterrupted, steady, laminar air flow as you need.
At the end of the day, a majority of blow off applications can be handled just fine with any of our Air Knives. If you’d like to discuss your application and see which one is best for you, give us a call.
(800)923-9247 toll free
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