Super Air Wipe Vs. Block Type Air Wipe

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 EXAIR Super Air Wipe.

Since EXAIR’s Super 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 EXAIR Super 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’s Super 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.

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How The Air Wipe Works

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’s Super 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.

Steve Harrison
Application Engineer
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The Case For The EXAIR Super Air Wipe

If you’ve ever used an air gun to blow something off, you’re familiar with the cleaning ability of compressed air.  If you can get the whole object blown off from where you’re standing, there really is no substitute…but what if you need to get to the other side…or sides?

Even if your product is not on fire, you probably wouldn’t want to “limbo” under it with an air gun…

This is where the EXAIR Super Air Wipe comes in…they allow you to blow a continuous, uniform 360° air stream, all around your product.  Consider their benefits:

*Sizes: the Super Air Wipe’s compact ring design means it won’t take up a lot of room; you just need a few inches, in any direction, to install one.  We stock them in eleven sizes, from 11″, all the way down to our brand-new 3/8″ diameter.

*Durability:  All EXAIR Super Air Wipes are assembled with stainless steel shims and hardware.  Models up to 4″ come with a rugged, stainless steel wire braided hose, connecting the two halves for compressed air supply.

The aluminum Super Air Wipe is available in 11 sizes; the stainless steel Super Air Wipe comes in 5 sizes…all from stock.

*Ease of installation:  Smaller sizes can be supported by the compressed air supply line, if a pipe is used and threaded into the connector hose’s 1/4 NPT port.  Larger sizes can likewise be adequately supported with pipe to both halves. All models have a bolt circle of 1/4″-20 tapped holes for more permanent and rigid mounting.  The split ring design is another key feature:

Simply open the two halves, and clamp them around your product…no threading!

*Corrosion resistance: Depending on the environment in which the Super Air Wipe will be installed, we offer them with aluminum (3/8″ – 11″ sizes) or stainless steel (3/8″ – 4″ sizes) bodies.

*Temperature rating: Aluminum Super Air Wipes are good to 400°F (204°C) and stainless steel models are good to 800°F (427°C.)

*Range of operation: We install a 0.002″ thick shim in all stock Super Air Wipes; this is suitable for a wide range of typical industrial/commercial blow off applications…a Pressure Regulator can then be used to “dial in” the air flow precisely to meet specific needs.  If a job calls for higher force & flow, additional 0.002″ shims can be installed.  Shim Sets come with the Super Air Wipe Kits, or individual shims can be ordered separately.

*Performance: Before the Super Air Wipe, a ring of nozzles was commonly used.  In fact, they still are, but we’re trying to fix that, at every opportunity we come across.  Problem with those is, it’s hard to get an even air flow all around, which leads to inconsistent blow off.  They can also be loud & inefficient, as we’ve found in numerous Efficiency Lab tests and Case Studies, like this one…

These wasteful and loud modular plastic tube blow offs…
…were replaced with EXAIR Super Air Wipes. 24 such replacements netted the customer an annual compressed air cost savings of over $13,000.00.

…and this one…

Implementing a Super Air Wipe salvaged a $30,000 job for this customer. Click on the picture to read all about it in our Case Study Library (registration required.)

Do you have a challenging blow off application that you need help with?  Call us to find out how an EXAIR Super Air Wipe (or another one of our Intelligent Compressed Air Products) can be a simple, quick & easy solution.

Super Air Wipe Cools, Cleans and Dries Extruded Shapes

We have many customers that use the manufacturing process of extrusion to make their various type of products.  EXAIR has an Intelligent Compressed Air Product that works very well with these processes to provide a drying, blowoff and cooling function.

Many types of products are produced via the process of extrusion, which is to shape (as metal or plastic) by forcing through a die.  There are many advantages to the extrusion process, including it being a continuous operation, it runs at high speeds, is good for high volume and low production costs, as well as many other factors.

The extrusion process typically requires heating of the metal billet or melting of the plastic to a high enough temperature to allow it to flow and be shaped as it it forced through the die. After the product has passed through the die and has been shaped it must be cooled and this is usually achieved by passing the it through a water bath.  Once the material has been cooled, it needs to be dried to remove the moisture, before the extrusion enters the next stage of processing, like getting cut to length or printed upon.

The EXAIR Super Air Wipe is ideal for blowoff, drying, cleaning and cooling of continuous materials such as extrusions, pipe, cable and more.

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The Super Air Wipe has a split design which offers easy clamping around the surface of the material, eliminating the need for threading. All Super Air Wipe models include stainless steel screws and shims.  Stainless Steel wire braided hose which is plumbed to each half, is included on sizes up to 4″ to simplify installation and plumbing. Aluminum models are rated to 400°F and the stainless steel models for temperatures up to 800°F.  Models are available in size from 1/2″ to 11″ Throat Diameters.

The Super Air Wipe provides a uniform, 360° air stream that is ideal for drying and cooling of extruded materials.

To discuss your application and how an EXAIR Super Air Wipe can benefit you extrusion process, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Excellent Customer Service Is The Only Way To Live

I have recently had a few dealings with other companies recently which has left me with two reactions: 1) How they are still in business? and 2) They really have their customer service running well.  The first company was, of course, a large conglomerate that provides our home internet service. The second company was a web-based company providing clothes dryer repair parts.

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So the first company, it is a local supplier of internet service.   I called to try and upgrade my service to higher speeds and see when I could get it changed.   I have had their service for over 8 years and haven’t had a whole lot of issues with them, everything has been pretty good.   That is until I tried to use their live chat feature on the website where I was told one price for the service, I then questioned why that price didn’t match the one on their site and was told in order to get that price I would need to call a certain number and speak with a representative.   I thanked the person and made the call.  It took me about 15 minutes or so to get to an actual human and then ended up the price still wasn’t the same and got a little run around on features, so I decided I would look at competitive service.

I spoke to their competitor in my area, which was very straightforward with pricing and answered every question I had directly and gave me a very speedy installation date of the next day, but were about 5 dollars more expensive.  So I called my current provider back and got yet another different price but did finally get some straight answers… and then we got to the installation date – 3 weeks out.   I asked if the fact I was a long-standing customer that was upgrading mattered and found out that is actually hurt my installation date.   Since I was merely an upgrade it was extremely low ranking, but if I signed up for additional services then I would get someone to install it within 3 days. When I expressed my concern for this practice I was greeted with silence and sorry that is just how it is followed by when would you like me to schedule this.

So, needless to say, I contacted their competitor, laid everything out and got the service installed the next day, today I call to cancel my existing service and will hopefully never have to look back.   The moral of the story here is, even though I was a long-standing customer the provider saw no merit in that and actually ranked me even lower than a new account.   They were very cumbersome in how they answered questions which left me feeling uncomfortable and I couldn’t get even the same bad answer from the three different people I spoke with.   Ultimately I left them as a customer and am glad to be with another provider.

As for the second instance, I needed to fix the clothes dryer because it was making some funny noises.   So I took a few pieces off, moved stuff around, didn’t see a whole lot wrong and put it back together.   It started making the noise again so I gave it “The Fonz” treatment (hit it hard) and all was good.   The next time I went to dry something my wife then accused me of not starting the dryer because everything was still wet.   I took a look into it yet again and this time I took the dryer all the way apart thanks to an informal video from the manufacturer. The problem seemed to be some bad preventative maintenance on my part and hair/lint wrapping around a roller guide which cause the  roller to stop and the drum to start going slower, as well as a lot of burnt crud around the heating element. So then the parts search began.   I found a company online whose site was easy to navigate, had lots of pictures, even used their live chat which I got quick responses from, and even found videos of how to fix the exact problem I was having.  So I ordered the parts late at night on Monday, their site showed in stock and shipping the next day.   Tuesday I end up getting a confirmation that the parts will be shipped.  Wednesday I received the parts as well as a follow-up e-mail confirming that the parts had been delivered.

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The moral of this interaction as a customer is that I experienced what I hope our customers at EXAIR experience everyday.   All the information I needed was in one place and easy to find,  all the parts were in stock, I got quick responses that were truthful, and in the end even after I ordered the part  I still got great customer service.  Needless to say I have bookmarked their site and will be returning.

Here at EXAIR, you don’t get greeted by a robot when you call during business hours, you get greeted by a human.  We do our best to ensure all information you need is accessible from our site, as well as back that support up with our Application Engineering staff being available by phone, e-mail, chat, fax, visits to EXAIR, and even mail if need be.   Then if you decide to order something from us, if it is standard stock, we ship it same day as long as we get the order by 3 PM EST and are shipping within the United States.  Then, we offer helpful videos, as well as support after you have made your purchase.  On top of all that, we stand behind our products with a 30 day guarantee and a 5 year built to last warranty.

30 Day Guarantee

So no matter how small a project you have, or if you are having any issues with your existing supplier for compressed air products, contact us and see if you notice a difference.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

 

Ready for an Upgrade? Me Too!

For the past year or so my wife and I have been contemplating getting rid of our satellite TV service.  The topic comes and goes as the months go on and finally when our bill increased by more than $20 because all of our “introductory” specials finally ran out.  You see we’ve been a paying customer for 7 years and every time our bill goes up I have to call and play the unhappy customer dance, threaten to cancel, and then eventually it whittle them down and they find all these incentives I am eligible for.

My argument with this is if I’m eligible for it in the first place why do I need to ask for it?  I’m pretty sure anyone that has ever paid for a cable or satellite service has done the same as I have.  Well this past week I called about the increase and they said there’s nothing we can do other than a $10 a month loyal customer discount.  Which again I had to ask for.

After seven years of playing this game I have completely had enough.  I have several friends that have went other routes and some still pay a monthly service just so they can record their over the air shows to a DVR.  Two of my other friends however have built what has been deemed as a “Home Theater PC” (HTPC).

This is essentially a computer that will act as a DVR for all over the air programming along with stream Netflix, or any other online service, play music, basically everything a computer can do but it will be hooked up to our TV instead.  This is basically the new tech savvy version of a VCR.

Now you can go out and buy one of these units off a website but you will pay a good chunk of money for it.  I on the other hand have some great friends that agreed to help me build one.   So after shopping around I acquired a stack of parts and was just waiting for a case.

Well, the case came in last night.  The case isn’t a normal PC case, it’s a case that will look just like another home theater receiver sitting on our TV stand and will have no display on it.  These cases are built just for being in a living room or media room and are quieter than a typical PC case.

Since the case was in I decided to do the smart thing and open it up to make sure there weren’t any defects.  Well this lead to putting the motherboard in, then the CPU, then the hard drive, and next thing you know it the whole thing is put together.  I wasn’t brave enough to hook it up to power yet as I was to have everything inspected by my computer tech friend first.  Once that’s done then I will begin installing all the software.

The best part of all is i am going to be able to surprise my wife who uses Skype quite frequently to see her family that live out-of-town.  Since this will be running Windows I can simply hook up a webcam and download Skype, next thing you know the TV is a life-size picture.

All in all this unit will have a pay back period of about 3-4 months.  You can build these units for considerably cheaper and on the other hand you can also go considerably higher in price.  I went with the middle of the road because I saw it was a good investment and it will be upgradeable and expandable to our needs.

If you have open pipes and are using non-engineered blowoffs in your compressed air company you too are paying too much for that application.  We offer a full line of Intelligent Compressed Air products that will help you to conserve compressed air and we can even help you to calculate the return on investment as long as we know how much air you are currently using.   So feel free to contact us and we’ll see what we can do to help you lower your monthly bills.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF