Step by Step Guide – Choosing Atomizing Spray Nozzles

EB1040SS

Atomizing spray nozzles atomize fluids to create a fine spray in a variety of patterns for a variety of uses. They are commonly used to mark products, paint or coat, cool, reduce dust, lubricate and clean parts.

With the numerous types of Atomizing Nozzles sold by EXAIR, it can be challenging to shift through all the information. We can help you to narrow down the field to quickly find the correct Atomizing Nozzle for your application.  In a summary, here are the basic questions that need to be answered:

1.) Are you using a pressurized liquid feed?

2.) What is the viscosity of the fluid?

3.) What is the liquid feed rate in gallons per hour (gph) or liters per hour (lph).

4.)  Should I use the No-Drip option?

EXAIR’s flow chart with easy-to-follow steps will walk you through the decision tree and land you at the best Atomizing Spray Nozzle for your application. In answering these simple questions, this chart will guide you to the correct page in our current catalog to get additional information and specifications.    Click on Link below to determine the best nozzle for you.

Step_by_Step-Atomizing_Spray_Nozzle_Picker

When it comes to spraying a fine mist, EXAIR has a great range of Atomizing Nozzles. If you follow the flow chart, you will get the best product to spray your liquid and reduce waste.   If you have any problems or questions, you can contact one of our Application Engineers at EXAIR.

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

Video Blog: Air Entrainment Of An Air Amplifier

The following is a short video explaining how EXAIR’s Super Air Amplifiers work. It also shows the high volume of surrounding air that is pulled into the outlet flow with a very small amount of compressed air required. As yo will see, this high volume of ambient air produces a dramatic effect on the Air Amplifier’s  outlet flow. Super Air Amplifiers are very efficient, quiet and safe and can be used to vent fumes, circulate air, cool, clean and blow off surfaces.

 

 

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

What If Your Cabinet Is In An Extremely Hot Area?

As the weather starts to warm up we have already started getting calls about customers that are preparing for Summer time by installing Cabinet Cooler Systems on their enclosures.   This is not a lengthy process, in fact, we can hold races in the office to see who can do the calculations the fastest.  If we have a few simple pieces of information, we can even do the calculations and have a recommendation for the correct Cabinet Cooler System for your cabinet while you are on the phone with us.  What kind of information might we need you ask, just take a look at the Cabinet Cooler Sizing Guide below.  The only tools you will need are a tape measure and a thermometer.

EXAIR's Cabinet Cooler Sizing Guide

EXAIR’s Cabinet Cooler Sizing Guide

So what happens if your ambient external air temperature is above 125°F?  For EXAIR, that is not a problem.  We offer a full line of High Temperature Cabinet Cooler Systems.  These are ideal for those really hot environments that may be near a furnace, boiler, or other hot process.  The best part is, we will know whether this is needed without you even having to ask for it.  All we need is the information on the Sizing Guide.

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EXAIR’s Dual High Temp Cabinet Cooler System Stands Up To Extreme Conditions

 

Whether your enclosure is in an everyday machine shop, out building with pumps and sensors, or right next to a steel mill, EXAIR will provide the best possible solution to keep the internals safe. Don’t let the summertime heat sneak up on you and cause you problems all you have to do is contact myself, or any one of my team members and we will help as quickly as possible.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Air Knives – What Are They Good For?

It is rare that a week goes by without a unique application of an EXAIR product…

This week I was speaking with a DJ who wished to use an air knife to create a blast of air that would add emphasis to the musical experience had by his fans. He wanted a small burst of air that would last less than a second, but would add an additional element to an already very complicated setup. My initial reaction was that no DJ I have ever seen would possibly be able to supply an air compressor big enough to feed the air knives, but over the course of our conversation, I found out that the DJ travels with 2 semi trucks of equipment, so he had some space.

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An Aluminum EXAIR Super Air Knife

Another topic that came up in our conversation was how air knives were generally used. I have been asked this in a number of ways: What are they designed to do? Where do they work best? or What are they for?

I never have a succinct answer… The air knives create a flat laminar sheet of air in various sizes from 3″ up to 108″. This laminar sheet of air can be used to move, open, float, or separate. It can be used to clean, dry, or cool. I try to categorize these applications as best I can when speaking to customers, but then you talk to a DJ, and he wants an air knife to make a crowd cheer. I never thought that would be an application for an air knife. Knowing this, how do you convey all the air knife can do in a succinct answer?

Well, I can’t, so please be patient when you ask me the same question and I run through applications from cleaning surfaces to entertaining DJ crowds.

Here is a rundown of air knife applications. In case you don’t believe me.

Move: Air Knives are used around to world to move product from a conveyor to another location.

Open: Air Knives uniform air flow is perfect for opening bags or other packaging on a packaging machine.

Float: If you need to bridge a gap between two conveyors, the air knife has done this for products from pizza dough to sheets of veneer.

Clean: Blowing products off after removing them from a CNC machine is an easy air knife application.

Dry: One of my tastiest applications was to use an air knife to blow water from a potato chip after washing, but before frying.

Cool: Extrusion, molds, and baked goods have all been cooled with an air knife.

Just because it isn’t on this list though, doesn’t mean it is not possible.  This is why we will stand behind our stock product with our 30 day guarantee.   So if you want to try an EXAIR Air Knife in your application, give us a call.

30 Day Guarantee

30 Day Guarantee

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com

How To Choose An Air Knife

The EXAIR Super Air Knife has a prominent place near the front of our catalog, and THIRTEEN pages of photos, application details, performance data & specifications. It’s the most efficient and quietest product of its kind on the market, and our most diverse product offering in terms of size range, operational adjustability, materials of construction, and accessories available. For almost any general industrial air blow off application, the EXAIR Super Air Knife is the superior choice in terms of air usage, sound level, and capability.

EXAIR Super Air Knives come in a wide range of lengths, for a wide range of possibilities.

EXAIR Super Air Knives come in a wide range of lengths, for a wide range of possibilities.

As tireless champions of the causes of reducing air consumption and noise, we’re always going to promote these benefits of the Super Air Knife. Still, a caller asked me the other day, “Well, why do you still make the others?”…meaning, of course, our Standard and Full Flow Air Knives. Why, indeed:

*Given the same air supply pressure, the Standard Air Knife generates the highest force of our three styles. The amount of force applied isn’t always a prime consideration…if you think about one of the more “textbook” applications for an Air Knife, it doesn’t take a great amount of force to blow off dust and light debris from a conveyor belt…certainly this is a case where efficiency factors in: the lower air consumption of a Super Air Knife can pay for the cost difference between it and a Standard Air Knife in as little as three months of operation.

The Standard Air Knife has the highest force, for when it's needed.

The Standard Air Knife has the highest force, for when it’s needed.

Of course, if you’re blowing stubborn debris out of tight spaces, like gummy, greasy dirt that’s accumulating in the recesses of a finned tube heat exchanger, that extra force can make all the difference. No; the Standard Air Knife isn’t as efficient or quiet as the Super Air Knife, but it’s still a far cry better than a drilled pipe.

*While the Super Air Knife is pretty compact – you only need a few square inches of profile area to successfully mount it – the Full Flow Air Knife is even smaller, requiring not much more than one square inch of profile for mounting. With ports on the rear face (instead of the ends & bottom for the Super Air Knife,) they can fit in very tight quarters.

Low profile and lightweight, the Full Flow Air Knives are a great fit for tight quarters.

Low profile and lightweight, the Full Flow Air Knives are a great fit for tight quarters.

The Full Flow Air Knife is also the lightest weight for a given length. A 36” Aluminum Super Air Knife, for instance, weighs about 8lbs. The 36” Aluminum Full Flow Air Knife weighs less than 4lbs. Most of the time, 8lbs is a very manageable amount of mass to support, but there are situations where every ounce matters, and if yours is one of them, you’re looking at the Full Flow Air Knife all the way.

*The biggest (in the most literal sense) factor in Air Knife selection is, well…size. We make the Standard Air Knives in lengths to 48”, and the Full Flow Air Knives come as long as 36”. The Super Air Knives, however, are stocked in lengths from 3” to 108”, and can be coupled together for as long of an uninterrupted, steady, laminar air flow as you need.

At the end of the day, a majority of blow off applications can be handled just fine with any of our Air Knives. If you’d like to discuss your application and see which one is best for you, give us a call.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
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Cooling Efficiently

Last week, I had the opportunity to work with a customer who was trying to cool a thermoformed film from 85° C (185° F)  down to room temperature, 21° C (69.8° F) or low enough for the package to be handled by an operator. This container was 270 mm X 170 mm X 100 mm (10.63″ x 6.69″ x 3.94″)

 

In applications like this, the customer often calls in with the idea of using a Vortex Tube to produce the cold air.  There are two reasons to use a different product than a vortex tube in this application. First, a vortex tube is only going to cool a small area, so to cool anything this size would take several vortex tubes.  Second, the cold air is going to mix with the ambient air very quickly. When the ambient air mixes with the cold air from the vortex tube, the air will lose the cold temperature generated by the vortex tube. To counter act this mixing, we have had customers create an insulated container to hold cold air from a vortex tube close to a product, similar to a cooling tunnel. This works in some applications, but my customer had a continuously moving line. He did not have time to stop the line and install insulation around each product.  He also didn’t have the length of conveyor needed to put a cooling tunnel over the line.

Super Air Knife Promo

Instead of using the vortex tube, I suggested that he use a 12” (305 mm) Super Air Knife to cool the thermoformed container. The 12” Super Air Knife moves significantly more air than a vortex tube over the surface of the part. Thanks to the 40:1 amplification ration of the Super Air Knife, it creates more cooling to the product and use less compressed air than a series of Vortex Tubes.  By mixing a large volume of free ambient air, that is the same temperature he needs to cool the part to, and a small amount of compressed air over the product they can easily cool their part to close to ambient so the operator can handle the part. The best benefit for this customer was they would not need change their manufacturing line.  The air knife is the best choice when cooling a very hot, fairly flat, large surface part to a temperature close to ambient. If you need to cool a product to a temperature lower than room temperature, then a vortex tube would be a great product to do the job.

Dave Woerner
Application Engineer
DaveWoerner@EXAIR.com
@EXAIR_DW

New Atomizing Spray Nozzle Can Spray the Inside of a Duct

The second atomizing air nozzle that EXAIR introduced in Catalog 27 is the Internal Mix 360 Degree Hollow Circular Pattern Spray Nozzle, part number AT1010SS. This nozzle produces circular air pattern perpendicular to the flow of most atomizing air nozzles.  The AT1010SS can create a mist across 53 inch diameter circle.  The nozzle is constructed of 303 Stainless Steel for use in corrosive environments. It operates on a continuous stream of compressed air and pressurized liquid.  The AT1010SS features a compact design that is 3.20 inches long, 1.69 inches wide, and 0.88 inches thick to fit into small ducts or hard to reach corners.

360 degree Internal Mix Hollow Circular Pattern

The 360 degree nozzle, AT1010SS, can generate liquid flows up to 14.7 GPH.  The typical liquid pressure is from 10 PSI to 60 PSI, but can handle pressure much higher.  Contact an application engineer for more details on flow rates at higher or lower pressures. EXAIR has an extensive listing of the flow rates of various pressure on our website and in catalog 27.

This spray pattern is perfect for coating the inside of a pipe with rust preventative, paint, or protective coating. The flow pattern would also be able to coat a variety of duct shapes.  Mounted over a process, the nozzle pattern is also great for dust suppression, humidification and cooling over a wide area.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW

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