Super Air Wipe at Sea

I recently worked with a Chief Engineer on a large shipping boat who was having issues with water being brought in by the mooring cables. That salt water was getting into the maintenance room where the mooring cables were wound around a large spool. He wanted to remove the water from the cable before it went below deck so the extra water could just run off the deck back into the ocean.

After talking a bit we decided on a 4″ Super Air Wipe constructed of 303 stainless steel. This way the extra water would be removed and any debris the cable pulled in with it.

Mooring Cable going thru a EXAIR Super AirWipe

The Super Air Wipes provide a full 360° conical airflow that is used to blow-off, cool, clean and dry products. A Coanda profile is designed into the body of the unit to maximize entrainment of ambient air as well as give the precision angle for the air to exit from. This gives the air stream impacting the target zone a 30° angle to the surface in order to provide a substantial shear force for debris removal. This also ensures the large volume of ambient air entrained will all travel the correct direction and not become turbulent before impinging on the surface.

To meet all the tasks at hand, the Super Air Wipes are offered in two main materials of construction. Aluminum body with brass air fittings, connected with stainless steel hardware, shim and connecting hose for up to 4” (102mm). As well as 303 stainless steel body with stainless steel bolts, shim, the connecting hose for up to 4” (102mm) and fittings. The stainless-steel components give the units better corrosion resistance, higher temperature ratings, and more durability in harsh industrial environments.

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

EXAIR stocks the aluminum Super Air Wipes with inner diameters from 3/8” (10 mm) for wire and cables up to 11” (279mm) for large pipes and hoses. The aluminum models have a temperature rating up to 400oF (204oC). We also stock the stainless-steel models from ½” (13mm) to 4” (102mm) inner diameters, and they have a temperature range up to 800oF (427oC). If you require different diameters or materials, we can do that as well easily.

With the creation of the Super Air Wipe, uniform cleaning, cooling, and blowing around the outside of parts is a simple task. You don’t have to worry about a variety of nozzles to target the circumference or a fabricated blow-off device that will waste air and take much time out of your day. A simple purchase of the Super Air Wipe Kit will solve the problem and keep production going. If you need help in selecting the proper size or want to know what material we would recommend for your application, contact us.

Jordan Shouse
Application Engineer

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Compressor Maintenance: Steps to Minimize Wear

While I was still in college, I worked in a meat processing plant as a Project Engineer in the maintenance department. During my time in the maintenance department I learned the importance of proper maintenance on machines. A meat processing plant is one of the most taxing environments on machines as they will have to survive in extreme cold temperatures to extreme hot temperatures; they are also put through deep sanitation wash downs multiple times a day sometimes for periods of over an hour. The plant really put into perspective the importance of preventative maintenance of machines. This includes utilities such as a boiler and of course your air compressor.

Industrial Air Compressors
Neglected air compressors can cause a lot of issues ranging from expensive repairs to a decrease in efficiency. Wear and tear placed on the motor of an air compressor can cause the compressor to produce less compressed air (SCFM) at the same power consumption. This means you are paying the same amount of money for less compressed air.

A primary focus to prevent an increased amount of wear on your compressor motor is to seal up compressed air leaks. Leaks can cause the compressor to cycle more often and/or refill receiver tanks on a more frequent basis, causing the motor to run more often. With the motor having to run more often to keep the air present, it will wear down faster. Using EXAIR’s Ultra Sonic Leak detector, leaks can be found in the pipes so that they can be sealed up.

EXAIR Ultrasonic Leak Detector
Another important maintenance is to make sure that the compressor gets cleaned. As the motor runs excess heat is generated; the heat generated then needs to be dissipated which is done by exhausting air through vents. If these vents become dirty or blocked and the air cannot escape then the temperature of the motor and winding resistance will increase; this in turn will shorten the life of the motor and increase the energy consumption. Using one of EXAIR’s Super Air Nozzles is a sure way to keep your compressor vents clean and dust free in a quiet and efficient manner.
EXAIR Nozzles
There are many other items that require maintenance over time such as keeping belts in good condition and the drain traps clean. Good maintenance on any item whether it’s a production machine or  air compressor keeps it running a peak performance helping you save money and headaches in the long run. 

If you have any questions about compressed air systems or want more information on any EXAIR’s of our products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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EXAIR, Manufacturing Locally Equals Quick Customizations

Dryer with corn cob material

A manufacturing company contacted EXAIR about their metal tube processing. They made industrial precision tubes from start to finish. This would include turning, cutting, coating, washing and drying metal tubes to specific diameters and lengths.

For one specific problem area, they manufactured a tube with the dimensions of 1” (25.4mm) in diameter and 6” (152mm) in length. They would run a batch of 750 tubes through a wash cycle and then through a vibrating dryer with a drying material made from corn cobs. At the bottom of the vibrating dryer, the tubes would fall to an open mesh shaker table to transfer the tubes to Quality Control. The idea was to remove the excess cob material from the surface of the tubes before inspection and to recycle the drying material. But the problem was static.

When non-conductive materials slide, hit, peel, and vibrate; electrons from the surface can move from one atom to another; thus, creating static. The type of material and the amount of movement governs the positive and negative charges, and the amount of static forces.

The corn cob material is a non-conductive material, but what about the metal tubes? Since the metal tubes were coated for corrosion and abrasion protection, the surface is now a non-conductive area which will contain static. Since opposite charges attract each other, the cob material would cling to the outside surface of the metal tubes (reference photo below). Being a precision tube manufacturer, they did not want to send “dirty” tubes to their customers or allow the drying material to contaminate their measuring equipment. And, with the required quality control, the measurements had to be exact.

Tubes with cob material

The shaker table was 8 feet (2.4 meters) long and 2 feet (0.6 meter) wide with rigid walls. The top of the shaker table was covered with a canvas to allow for a vacuum system to collect the excess material and dust. About half way down, there was a 2” (51mm) drop to help jolt additional cob material off of the tubes as they landed. But the static forces were too strong to release the material. Thus, the static had to be removed from the surface, so they contacted EXAIR to see if we could find a solution.

They sent photos of their setup which always helps us to diagnose and find solutions. The target place that they suggested would be near the 2” (51mm) drop as the tubes would be suspended for just a moment. My recommendation was to use a Gen4 Super Ion Air Knife to blow ionized air around the tubes as they fell. By blowing air, we can use the non-contact force to remove the static and the cob material at the same time. But we had two issues to overcome. The width was fixed at 2 feet (0.6 meter), and the operation controls were 10 feet (3 meters) away from the mid-section of the shaker table.

Gen4 Super Ion Air Knives

EXAIR stocks many Gen4 Super Ion Air Knives ranging from 3” (76mm) to 108” (2.74meters) in incremental lengths for quick shipments. But our standard 24″ product was not able to fit inside that area nor was the five foot electrical cable long enough to reach the control panel. (As a note, it was important for the operator to be able to manually turn on and off the unit from the control panel.)

EXAIR uses an electromagnetically shielded cable to carry high voltage from our Gen4 Power Supply to our shockless, non-radioactive Gen4 Ionizing Bar. Our  stocked length for our armored cable is 5 feet (1.5 meter). After discussing the amount of movement with the table and the desired distance to the control panel, EXAIR could not use an item off the shelf. But not to worry… Since we are the manufacturer, we have the ability to make a special design for this customer.

Super Ion Air Knife Part Numbering System

I recommended a model 112220-10 special length Gen4 Super Ion Air Knife Kit. (Reference model numbering system above). Specials are non-returnable and non-cancelable, but for this customer, it was exactly what they needed. The Gen4 Super Ion Air Knives are engineered to efficiently blow ionized air to the target and remove static charge and debris.

For this special model, it was made to a specific width where the Super Air Knife was manufactured to a length of 20” (508mm), and the high voltage cable was lengthened to 10 feet (3 meters). The kit includes the Gen4 Power Supply to power the Ionizing Bar, a filter to clean the compressed air, a regulator to control the force, and a shim set to change force rates. This complete kit had everything required to begin operations to remove static and cob material from their precision tubes. The customer was able to mount the special length Gen4 Super Ion Air Knife within the shaker table and mount the power supply near the control panel.

Static can be an issue even with coated metal parts. For the customer above, EXAIR was able to make a special length Gen4 Super Ion Air Knife to work in their system. If you believe that static is causing issues, EXAIR has a great range of Gen4 Static Eliminators to remove that nuisance. You can discuss further with an Application Engineer as EXAIR for help; even if you need a custom product.

John Ball, Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

EXAIR Atomizing Spray Nozzles for Coating, Cleaning, Cooling

A recent customer in the automation / tool making industry had a need to spray a mold release agent onto some specialized tooling. Originally, the customer had planned to use some sort of pressurized sprayer. After some initial tests to prove the concept, the customer found that the moving mechanical parts of the sprayer became fouled by the release agent. And cleaning the internal parts was not easy to do.

No Drip Atomizing Nozzle
No Drip Atomizing Nozzle

In their search for a more permanent solution, the customer came across EXAIR Atomizing Nozzles. After going through some application type questions to narrow the focus down to one model, we determined that the customer would be best served by model AF1010SS (Internal Mix, Flat Fan Pattern Atomizing Nozzle). The customer had a couple of questions about the nozzle in order test the product.

  1. Is it possible to disassemble the nozzle and clean it completely? The answer is yes, the Atomizing Nozzles can be completely disassembled to allow for cleaning, maintenance or replacement of worn parts.
  2. Are the nozzles solvent resistant? The answer is also yes; the Atomizing Nozzles are made of AISI303 type stainless steel and can be cleaned with any normal solvent based cleaner.

Earlier in this article, I mentioned that we went through some application type questions. Here is a list of general questions that we normally ask a customer about their application in order to determine which in our selection would be best suited.

  1. What is the volume of liquid flow (G/Hr) needed for the application?
  2. What is the viscosity (cP) of the liquid being applied?
  3. What are the required spray pattern, size and shape required?
  4. Is the liquid under pressure (by pump or pressure pot)? If so, what is the liquid pressure?
    1. Side note: we have options for non-pressurized liquid by using our siphon fed nozzles.

If you have an application where you have a liquid that needs to be applied in atomized form to a target, or perhaps a humidification application, please give EXAIR Atomizing Nozzles your consideration.

Jordan Shouse
Application Engineer

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