EXAIR Super Air Knives Increase Production of Jar Labeling Process

When a customer has a problem with a labeling process within their operation, many times they call EXAIR to provide a solution. The company in this example manufactures honey and dispenses it into jars and squeeze bottles. Due to an increase in demand, they were looking to increase their output. To do this, they simply increased the speed of their conveyor to accommodate approximately 70 jars per minute instead of their typical 50 jars per minute. This began to present a problem and they reached out to EXAIR for a solution.

honey SAKs

Honey jars traveling along conveyor and the recommended position of Super Air Knives.

After dispensing the honey, the jars and bottles travel through a washing station. The containers pass through a heated chamber that dries the excess water from the jar. At the higher speed, they were experiencing some residual water left on the containers. This began to pose an issue when they reached the labeling process. With water remaining on the jars, the labels adhesive would not adhere properly. This led to an increased amount of rejections and additional rework time to remove the rest of the label and re-run the defective containers.

They had a point in the conveyor just prior to labeling that the sides of the jar would be exposed. My recommendation was to install (2) 110009 9” Super Air Knives on each side of the conveyor to remove the water that was left after exiting the drying chamber. This worked like a charm and the customer was able to maintain an increased level of output without experiencing any further complications. Their previous rate of production without the Super Air Knives was approximately 50 jars per minute.  By installing the Super Air Knives, they were able fully realize their 70 jars per minute goal and increase their production by 40%!

The laminar flow that exits the Super Air Knife wraps itself around the outside of the jar, stripping away any leftover moisture. Supplied at 80 PSIG, each knife will consume only 26.1 SCFM of compressed air at a sound level of just 69 dBA. The flow and force from the knife are infinitely adjustable by dialing in the operating pressure with a pressure regulator or swapping out the shims with a Super Air Knife Shim Set. If you’re experiencing an issue with residual water or liquid on your product that is causing a problem during production, give us a call. An Application Engineer will be happy to take a look and recommend the most suitable blowoff solution!

Tyler Daniel
Application Engineer

E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

Non Hazardous Purge Cabinet Cooler System Keeps Enclosure Dust Free

A mining company has processing machinery operating in a poorly ventilated, dusty environment (actually, it’s a mine…as you might have guessed.) This machine’s control panel was supplied with filtered vents and fans to cool the electronic components inside. The filters clog regularly, and even though they checked them frequently, it’s not always frequently enough to prevent the drive from overheating.

Based on a referral they got from another one of their facilities, they called to get more information on a Cabinet Cooler System. For total dust exclusion, our Non-Hazardous Purge systems are ideal…they’re thermostatically controlled, so compressed air consumption is responsible and efficient, but they also provide a small, continuous flow, even when the thermostat set point temperature is attained, and the solenoid valve is shut. This keeps a low positive purge volume of clean, dry air in the enclosure.

EXAIR Non Hazardous Purge Cabinet Cooler Systems provide reliable and efficient cooling in the most aggressive environments.

The caller already had the data from our Cabinet Cooler Sizing Guide, so specification was quick & easy. A Model NHP4340 NEMA 12 Non-Hazardous Purge Cabinet Cooler System – 2,800 Btu/hr – w/Thermostat Control was ordered and installed the next day. We keep them in stock for situations just like this.

If you have heat issues with electrical & electronic equipment enclosures, give me a call.

Russ Bowman
Application Engineer
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Video Blog: Which EXAIR Air Knife Is Right For You?

The following short video explains the differences between the 3 styles of Air Knives offered by EXAIR – The Super, Standard and Full-Flow. All of these Models are IN STOCK, ready to ship, with orders received by 3:00 PM Eastern.

If you need additional assistance choosing your EXAIR Air Knife, please contact an application engineer at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

Social Media Finds Lost Dogs, Helps Save Compressed Air

Lost Dog – Her name is Molly

 

The versatility of  social media is one of its greatest assets. If you have an interest in something you can most likely discover others with the same interests on one of the social media platforms. From Facebook, Twitter, blog posts, LinkedIn, Google+ and YouTube to Pinterest, Flickr, Instagram and Reddit – you will be hard pressed to NOT find something you are looking for.

The other day, we lost our dog, and it was a traumatic experience for us.  She saw some deer in the backyard; and in her crazed state, she knocked down the pet gate.  Molly went after the deer into the woods behind our place.  Being that it was raining and approaching the evening hour, I mentioned that when she gets done hunting, she will come back home.  We placed her bed and food onto the porch for when she returned.

The next day, Molly was not on the porch.  We were disheartened.  Being that I am a bit “old” school, we decided to print some flyers with Molly’s picture.  After I returned from work, we started in my neighborhood and worked our way out.  We drove to all the neighbors to see if they had seen her, and we stapled the flyers to telephone poles and community boards.  We were going at it for hours, and it seemed to be getting hopeless.  (Now, I would not have written this blog if it had a sad ending.)

As we continued to make our journey, I went up to a house and knocked on their door.  A gentleman answered, and I gave him the story of how our dog got out of her pen.  As I was still speaking, my significant other rolled down her window and shouted to me that she found Molly.  I was a little confused as I headed back to the vehicle.  She told me that a picture of Molly was on her Facebook.  (Of course Molly was making herself right at home as the picture showed her laying on a couch).  We were extremely happy that we had finally found her.  Apparently, a lady that found Molly posted her picture, and tagged her friends.  Her friends then sent it out to their friends, and before you knew it, we had her picture on Facebook.  With a friend request, we were able to receive her location and start our way to pick her up.  Believe it or not, Molly was over 2 miles away from our house.

Being curious, I looked at the timeline of the post.  I noticed that she posted the picture at 6:44 p.m., and we were looking at Molly at 7:28 p.m. that same day.  This was definitely much quicker and easier than hanging flyers and knocking on doors.  I was amazed at how fast and simple that this social networking reunited us with Molly.

This got me thinking about social media.  Facebook is the largest social network with almost 2 billion users throughout the world.  In looking at the nature of Facebook, it is more than reuniting with friends or finding lost dogs.  It also unites companies.  EXAIR has a Facebook page in which we post videos, photos, and blogs of compressed air solutions.  We can show you how to save money by using less compressed air with our products and how to solve every day problems with your compressed air system.  We would love to have you as a friend at www.facebook.com/exair.  We may not be able to find your dog, but we sure can share some stories, solve compressed air problems, and become good friends.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

 

Replacing Unsafe Open Pipes with High Pressure Air Nozzles

Open pipes present unsafe working conditions and continuous pressure drops in compressed air systems

Let’s talk for a minute about pressure drops. Normally when the topic of pressure drops is raised, it comes in a context related to proper plumbing and volume supply.  (If there are significant pressure drops within a compressed air system, especially those which reduce volume flow, problems will arise with compressed air driven devices.)

But, there is another important aspect of pressure drops which relates to open pipe blow-off, a common homemade remedy for blow-off applications. This aspect has to do with the available compressed air pressure at the exhausting point from the pipe or nozzle.  In the case of an open pipe, it requires so much compressed air volume that, there can be a continuous pressure drop from the compressor to the open pipe.  However, when a nozzle is installed onto a compressed air pipe, there is a restriction to the flow and the entire pressure drop takes place across the nozzle.

What this means for the blow-off solution is a higher velocity blow-off and a more powerful force from the airflow, with less compressed air consumption.

To think of it another way, imagine the flow of water from your garden hose. If the hose is open-ended and the water is fully on, the flow will be high and the force will be low.  But, when you install a nozzle onto the end of the hose the flow reduces and the force increases.  This is because the pressure drop in the system is taking place across the nozzle rather than the entire system.

This type of a scenario was taking place in the image shown at the top of this blog. The plastic lines connected to the aluminum manifold were fully open on the end, providing a continuous pressure drop and poor blow-off performance.  This, coupled with the maximum operating pressure of similar types of hose being 35 PSI, led to a poor performance in this application.

The solution for this customer was to replace these open pipe blow-offs with EXAIR model 1126 Flat Super Air Nozzles and 12″ Stay Set Hoses, model 9262. The flat airflow of the 1126 Super Air Nozzles provide a highly efficient and forceful blow-off, and the Stay Set Hoses allow for articulation of the nozzles into any position needed.

By replacing these open pipes this customer saved compressed air, added safety (open pipes present an operating hazard per OSHA Standard CFR 1910.242(b)), and improved the performance of their operation.

If you have a similar application or would like to speak with someone about increasing the efficiency of your compressed air applications, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

EXAIR Line Vac, Air Operated Conveyors, Expand to Include Sanitary Flange Models

EXAIR’s Air Operated Conveyor product line just expanded, making it easier than ever for a wide range of industries to solve an ever growing range of bulk conveyance applications. Before we get to that, let’s look at just how versatile the Line Vacs are:

The standard Line Vac has been making bulk conveyance as easy as it could get for years now. They come in sizes from 3/8″ to 5″, and all you need is a hose to move material from point A to point B.

Lightweight and durable aluminum is the most popular choice, but we make them in stainless steel (Types 303 and 316) for heat and corrosion resistance. For extreme heat, the High Temperature option affords protection to 900F (482C) in either 303SS or 316SS.

When rigid pipe is preferable to hose, our Threaded Line Vacs offer the same performance:

These come with male NPT threads from 3/8″ to 3″. They’re also available in aluminum, 303SS and 316SS, and High Temperature versions, same as the standard Line Vac.

If you need high power for higher conveyance rates, longer distances, or very dense material, the Heavy Duty Line Vacs are what you’re looking for.

They come in sizes from 3/4″ to 3″, with options for slip-on hose or threaded pipe. They’re also made of a hardened alloy for superior abrasion resistance.

Light Duty Line Vacs are aimed at applications implied by the name…when smaller volumes of low density material don’t require all the head & flow generated by the standard or Heavy Duty models, these are as quick & convenient as the rest, and come in sizes from 3/4″ to 6″.

They’re also ideal when fragile parts might be subject to damage in the high velocity, turbulent air flow produced by the other models.

The newest additions to the Line Vac family are the Type 316 Stainless Steel Sanitary Flange models:

Also known as Tri-Clamp or Tri Clover, these connectors have a variety of advantages beneficial to certain industries: Quick to make up & take apart. No nooks or crevices, so they’re easy to clean. Wide variety of fittings, pipe and tubing are readily available.

These are especially popular in pharmaceutical, food, and brewing applications.

If you’d like to find out more about how to move bulk product quickly, easily, safely, and cleanly, give me a call.

Russ Bowman
Application Engineer
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Another Label Problem, Another Super Air Knife Solution

Last week, I used this space to brag on our Super Air Knives, and how they solve a common problem in bottling applications: label adhesion. This week, I have another opportunity to brag on the Super Air Knife. AND it’s another solution to a labeling problem.

Self-adhesive labels are commonly applied to goods are they travel on high speed conveyors. If they’re going onto a flat, smooth surface (like a box,) it’s pretty easy…they come right off a timed roller with a wheel that presses them in place. This can even work with round containers (like drums, jars, or bottles) by putting an idler on the wheel to take up the slack as it rolls over the rounded surface.

Sometimes, the label needs to go around the corner of a box. This requires the roller to turn that corner. Or two rollers to pull the old “one-two” on the label. Either way, that’s going to slow down the speed at which the conveyor can be run. And time is money.

Enter the Super Air Knife…mount it so it’s blowing at the corner. The laminar, high velocity air flow will then press the label in place on each adjacent surface.

With a laminar curtain of air traveling as fast as 13,500 feet per minute, an EXAIR Super Air Knife is the ideal solution for corner labels.

Another benefit: when supplied with clean, dry air, the Super Air Knife will run darn near indefinitely, maintenance-free. Those rollers get dirty, and the bearings will fail eventually. Same with the idlers, and they’ll need adjusted from time to time.

Super Air Knife Kits include a Shim Set, Filter Separator, and Pressure Regulator…everything you need for long term operation & performance.

The Super Air Knives come in lengths from 3″ to 108″ – if you’d like to discuss how these, or any of our Intelligent Compressed Air Products, can make a difference in your processes, give us a call.

Russ Bowman
Application Engineer
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