A rubber cable manufacturer was looking for a better way to clean water from the surface of their product. Their process entailed extruding a rubber cable from the machine through a cooling water bath to harden the material. This machine was able to make eight lines at a time. After the water bath, the cables would pass through homemade blow-off devices to remove the liquid water from the outside surface. From here, the cables would move through an inkjet printing machine. They were having issues with the inkjet markings as they were not able to remove enough water. They decided to contact EXAIR to see if we could help.
The extruded rubber cables were close to ½” (13mm) in diameter. So, I recommended the model 2401 1” (25mm) Super Air Wipe. This would give enough clearance to remove the water in a non-contact way. I challenged them to compare their home-made devices with our engineered design. With our 30-day unconditional guarantee for U.S. and Canadian customers, they took me up on that challenge. They ran a test and videoed the results.
The test was a bit crude as the Super Air Wipe was not aligned correctly. But, with a short trial run, they were quite impressed. In the photo below, you can see the dryness of the conveyor belt after the Super Air Wipe as compared to the home-made devices. They were fascinated on how effective the Super Air Wipe was able to remove the water. They replaced all eight units and noticed an improvement right away in reducing their visual defects in the printing process.
Besides reducing defects, they noticed a few more things. The production process ran smoother; even at faster line speeds. They also observed that the Super Air Wipes were much quieter. With a decibel rating of 80 dBA at 80 PSIG (5.5 Bar), the nearby operators were very happy with this choice during operations. The biggest thing that they saw after a few weeks was the reduction in compressed air use as compared to their home-made devices. Because the design utilizes the Coanda effect, “free” ambient air is drawn into the air stream, reducing the compressed air requirement. They were using 30% less compressed air, which saved them a lot of money on their electric bill and operational costs.
EXAIR offers a line of Super Air Wipes available to ship the same day from stock. The Super Air Wipe is available in aluminum construction in sizes ranging from 3/8” to 11” (10 to 279mm) in inner diameters. All Super Air Wipes come with stainless steel hardware and stainless steel shims. Sizes up to 4” (102mm) include a cross-over stainless wire braided hose to supply the other half of the Super Air Wipe. In addition to the aluminum construction, the Super Air Wipe is also available in 303 stainless steel for corrosive or high temperature applications. The Stainless Steel Super Air Wipe can withstand temperatures up to 800°F and is available in sizes from ½”-4” (13mm – 102mm) from stock.
If you’re processing any type of hose, pipe, wire, or extruded shapes, the Super Air Wipe could benefit you in your process. The customer above was able to reduce defects, decrease the noise level, and save compressed air with a simple replacement. And if you wish to challenge your blow-off devices with an engineered EXAIR product, you can contact an Application Engineer for additional information.