As an Application Engineer here at EXAIR, we get calls from customers looking for an air knife, but shorter than our typical 3″ stocked size. We can make an air knife to any length needed, but we will look at the 1″ and 2″ Flat Super Air Nozzles as a possible solution.
Like an air knife, the Flat Nozzles provide a wedge shaped pattern of air that maintains the width of the nozzle, to create a concentrated, powerful air flow. Thus, a 1″ Flat Super Air Nozzle has air stream 1″ wide, and the 2″ Flat Super Air Nozzle has one 2″ wide.
The Flat Super Air Nozzles are available in zinc aluminum alloy or type 316 stainless steel construction, to meet environmental conditions of the process. Both the 1″ and 2″ nozzles contain a changeable, patented shim that maintains the critical air gap, which allows the release of a precise amount of air through the thin slot, across a flat surface. The result is a wide, forceful stream of high velocity, laminar airflow, with minimal air consumption and noise.
Shims are available in thicknesses of 0.005″, 0.010″, 0.015″, 0.020″, 0.025″, and 0.030″. Shim Sets with either 2 or 3 shims are available for both sizes to allow for adjustment of the performance to best meet the application need.
Table below shows the stock offerings of 1″ and 2″ Flat Super Air Nozzles, along with Air Consumption, Force and Sound Level data for your review.
If you have any questions about the Flat Super Air Nozzles, or any EXAIR nozzle or other compressed air product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
So, you’ve selected a quiet, efficient, and safe EXAIR Super Air Nozzle for your blow off application – good call! – and now you’re thinking about how to install it. Sometimes, it’s as simple as replacing whatever you’re using right now:
Or maybe you’re using an open end blow off…in which case, you’re just an adapter away:
Perhaps, though, it’s a new installation, or the existing supply lines aren’t suitable for one reason or another. In those cases, we’ve still got you covered…consider the EXAIR Stay Set Hose:
Available in a variety of lengths from 6″ to 36″, they’re positionable, and re-positionable with a simple bending action. They won’t kink or easily fatigue like copper tubing. The supply end is 1/4 MNPT, and you have your choice of 1/4 MNPT or 1/8 FNPT on the other end, depending on which Super Air Nozzle, Air Jet you need to use it with.
We also offer Blow Off Systems, which are a combination of a specific Air Nozzle (or Air Jet,) fitted to a Stay Set Hose:
For added convenience and ease of installation, these products can also come with a Magnetic Base:
From the beginning in 1983, EXAIR’s focus has been on being easy to do business with, and that goes from our friendly customer service to our expert technical support to our 99.9% on-time shipments (22 years and running) to designing our engineered products and value-added accessories with efficiency, safety, and ease of installation in mind. If you want to find out more, give me a call.
I was recently contacted by a manufacturer of custom measurement systems. They were working on a design for a system that could measure (2) different sizes of gears with a high degree of accuracy. A robotic arm would pick up the gear off of a conveyor and deposit it onto a gauge for inspection.
During the initial quoting phase of the project they had been a little misled. They were told that the gears would be completely clean and free of debris before being deposited on the conveyor and picked up for inspection. It turns out this would not be the case. Chips, oil, or debris remaining on the gear would result in false part rejection. With the required completion date looming, they reached out to EXAIR for some help in implementing a solution to clean the gear before inspection.
While blowing off the oil or chips from the gear was the primary concern, having this debris flying around inside the machine could have been problematic as well. We needed to find a way to contain the chips and remove them. In the process, there was a brief moment that the robot arm held the gauge in place just prior to depositing it onto the gauge. It was there that we identified an opportunity to both clean and remove the chips that were blown off the gear. Using a Model 1105 3/8 NPT Super Air Nozzle and Model 9068 Swivel, they were able to precisely position the blowoff to hit across the bottom of the gear where the chips were located. They then 3D printed a shroud to contain the area where the gauge was held and the blowoff would be performed. They designed the shroud with a 1-1/4” outlet to connect directly to our Model 6082 Line Vac. The intake of the Line Vac was installed right at this point and was set to activate as soon as the air nozzles began their cleaning cycle. The chips were blown off of the gears, contained by the shroud, and taken away to a bin underneath the machine by the Line Vac. The crisis was averted!!
This was the first time they had implemented some type of method to clean the part before measuring. In the past, they had lost potential projects due to the inability for them to provide a clean part for measurement. With this newfound method of part cleaning, they’re now able to be a more complete solutions provider to their customers. They’re able to design the part cleaning feature into the process from the start, rather than retroactively as they had to do here.
At EXAIR, we understand how problems can crop up during design and cause potential delays in the completion of a project. For this reason, we keep all of our catalog products in stock and ship same day with an order placed by 3:00 pm EST. This customer was local and was able to call in with a problem, determine a solution, and come pick up their order the same day. If you are having difficulty cleaning or drying machined parts, give us a call. EXAIR has the solution, in stock, ready to ship to you immediately.
Air Wipes, which provide 360 degree blowoff, are typically used to remove heat, liquid, debris or static from wire, cable, pipe, tube, or extrusions.
We had a customer that was using a block type Air Wipe from a competitor to remove water from an extrusion. These air wipes are built using a plastic material, typically with some additional ceramic insert to resist abrasion of the wire, the halves are hinged with air holes drilled into each half which carries air through the block and on to the wire. They were using these block air wipes on several lines. The interesting point of this blog is that it required 5 block type air wipes to equal the results of 1 EXAIRSuper Air Wipe.
Since EXAIR’sSuper Air Wipe equaled the performance of 5 of the competitors it consumed less air was less expensive and produced less noise. Also in space sensitive applications the EXAIR Super Air Wipe is much thinner than the block type. To highlight this the Super Air Wipe is 1.13″ thick on all 11 models that range from 3/8″ to 11″ throat diameter. The performance of the block air wipe can only be changed by altering the inlet air pressure while the EXAIRSuper Air Wipe can also be changed by adusting the inlet air pressure OR by adding an additional shim the force can be nearly doubled!
Many of these block type air wipes use a series of holes to direct the compressed air supply at an angle over the material that needs to be cleaned off. EXAIR’sSuper Air Wipe being an engineered compressed air product use’s fluid dynamic’s to create more force as demonstrated below. The air from EXAIR’s Super Air Wipes is a continuous 360 degrees, without the gaps a series of holes creates.
Compressed air flows through the inlet (1) of the Air Wipe into the annular chamber (2). It is then throttled through a small ring nozzle (3) at high velocity. This primary airstream adheres to the Coanda profile (4), which directs down the angled surface of the Air Wipe. A low pressure is created at the center (5) inducing a high volume flow of surrounding air into the primary airstream. As the airflow leaves the wipe, it creates a conical 360° ring of air that attaches itself to the surface of the material running through it (6) uniformly wiping the entire surface with the high velocity airflow.
Block type air wipes are generally available in standard sizes up to 7″ in diameter while EXAIR’sSuper Air Wipes are available in stock diameters up to 11″ and we also offer custom sizes to suit many other applications.
If you have any items that need to have a 360 degree blowing pattern, I would enjoy hearing from you…give me a call.
This week in Cincinnati we hit a record high 79°F. Since less than a week earlier it snowed all afternoon, let’s just say many people around here began to get excited. While I don’t mind a little snow here and there, once February begins to draw to a close I’m ready to bust out the shorts, tank tops and flip flops and bring on some warmer temperatures. It also means I’m right around the corner from opening up the pool. Let’s hope that goes much smoother than last year….
Another benefit to the warmer temperatures, especially here in Cincinnati, is the coming of the baseball season. With the Reds Spring Training also starting this week, optimism is in the air (albeit reserved after the last few years performance).
Unlike baseball where it’s 3 strikes and youuuu’rrrreeee out! EXAIR’s unconditional 30 day guarantee for all stock products allows you the opportunity to test out several different solutions to ensure you get the right product for your application.
I recently worked with a customer that was interested in switching their current blowoff process with something that would reduce their sound levels but still allow them to complete the job in a similar time frame. The company makes aluminum castings and was using the air gun to remove residual sand leftover in the die after each cycle. Their current air gun was producing sound levels at 107 dBA, well above OSHA’s safe operating range for a full 8 hour shift of work according to OSHA 29 CFR 1910.95(a).
They didn’t want to commit to just one style of air gun, so he purchased a 1210SS-18 (Safety Air Gun w/ ¼ NPT Stainless Steel Nozzle and 18” extension) and a few different additional ¼ NPT nozzles to see which style his operators preferred. After some testing, they concluded that the air gun with an 1122SS 2” Flat Nozzle installed provided them with the best results. Having the added feature of changing out the shim to increase/decrease the force and flow was also welcomed. They’ll be returning the extra nozzles and applying the credit to the purchase of some new 1230SS-18 guns to outfit their other work stations.
While we do have a highly trained team of Application Engineers ready and available to help you determine the most suitable product, sometimes testing it out at your facility is the best way to ensure a positive result. That is EXACTLY why we give you 30 days to test out any stock product. If for any reason at all you’re unsatisfied with the performance, give us a call and we’ll arrange for a return. Don’t be afraid to swing and miss!
ROI or Return On Investment is a way to gauge the productivity or profit/loss from money spent on an investment. In business, companies will use this information to determine if a project or investment is worth the risk, ultimately leading to a net profit gain as the end result.
In my own personal experience, my wife and I were considering buying into a timeshare vacation property a few years ago. To enter into the agreement, the company required a $ 22,000 “buy-in” (financed of course) and a recurring cost of approximately $60/month for the next 22 years. This would have afforded us 124 “points” for nightly stays on our planned vacation. Their timeshare rentals are tiered into different room types – Studio, 1 bedroom, 2 bedroom or a 3 bedroom villas – with each room type costing a certain amount of points. For us to maximize the length of our stay, we would have to select the studio room which would have given 6 nights at a total of the 124 points.
We have visited this popular vacation destination several times so we know what the average cost is to spend a week on property and purchase theme park tickets for our stay. When we booked on our own, we spent on average a little less than $ 3,000 for 7 days which included our room each night and 6 day park passes per person.
The timeshare rental cost was just for the nightly stay, it didn’t include any park tickets, food or other recreations. On average, the cost for 6 days worth of park passes per adult is close to $ 450.00 and per child it was around $ 400.00. Considering there are 2 adults and 1 child (at the time) we had to pay an additional cost of $ 1,300.00.
So if we joined the timeshare and stayed for 1 week once a year, it was going to cost us approximately $ 3,020.00 ($ 1,720.00 (timeshare cost) + $ 1,300.00 in tickets). In this case, it was actually going to cost us MORE in the long run than if we booked a yearly vacation on our own (< $3,000), leading to a negative ROI. (not to mention, I really didn’t want to commit to the same vacation for the next 22 years!).
When discussing replacement compressed air blowoff solutions with a customer, many times they look at the purchase price of the device and question if it’s worth it for them to make a change. If you follow along with our blog, you will notice that over the last few months we have submitted several different entries relating to this topic, like replacing drilled pipe with our 12″ Super Air Knife resulting in a 47 day ROI or where a customer replaced 4 open copper tubes with our 1110SS Nano Super Air Nozzle and recurring their expenses in just 38 days. In these instances, we show the calculations in regards to the true cost of ownership and how quickly you can recover capital funds when considering the whole scope of the project.
At EXAIR, we are committed to providing Intelligent Compressed Air® Products that reduce compressed air consumption leading to a more efficient process, as well as increasing operator safety. If you are considering an EXAIR solution for your current process but have questions about price or performance, contact one of our application engineers for assistance.
The 2″ Flat Super Air Nozzle is a very powerful yet quiet engineered nozzle. Operation at 80 PSIG of compressed air pressure yields a strong 1.38 lb. of force, at only 77 dBA of sound level. Compare this with many of the plastic flat nozzles that blow air through a series of holes, with sound levels ranging form 78-83 dBA, not to mention some might violate the OSHA dead ended pressure standard and results in fines being levied.
The patented technology utilizes a changeable shim to generate the high flow of air in a smooth and laminar flow, to keep noise down and power and strength up. With (6) stainless steel shim thicknesses available, the 2″ Flat Super Air Nozzle offers a very flexible package that can be set and tuned to meet exacting performance criteria, while using the minimum amount of compressed air, and at the quietest possible sound levels.
The model 1122 is offered in a zinc aluminum alloy body and cap, and the 1122SS is constructed from type 316 stainless steel. All shims are stainless steel. The shim thickness for the 1122/1122SS is 0.015″ thick.
Also available, for extra blowing force, are the HP1125 and HP1125SS. The nozzles utilize the same zinc aluminum alloy or stainless steel body and cap and have the 0.025″ shim installed – and deliver 2.2 lbs of force, while only increasing sound levels to 83 dBA.
Shim sets for any of the 2″ Flat Super Air Nozzles are available. The 1132SS shim set includes shims of thickness of 0.005″, 0.10″, and 0.020″. For higher force levels, the HP1132SS shim set includes the 0.020″ and 0.030″ shims.
As you can see- for a versatile, forceful and quiet engineered air nozzle, it is hard to beat the EXAIR 2″ Flat Super Air Nozzle. If a 1″ wide nozzle better suits your needs, the same flexibility and power can be found in the 1″ Flat Super Air Nozzle as well. Check it out as well.
If you would like to talk about Flat Super Air Nozzles or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.