A large manufacturing company called looking for a better solution to control the thickness of a curing agent being applied to the outside of tubing used in the automotive industry. The tubing is formed in an extruder and travels through a liquid cooling chamber and then air dried. After the tubing is dried, it is sent to a spray chamber where the curing agent is applied to the exterior. On the exit side of the spray chamber, the customer had installed several flexible air lines placed around the perimeter of the tubing to blow air across the surface to help control the coating thickness. This worked somewhat but they were seeing an increase in the amount of rejected material as the air pattern was sporadic and uneven, which caused streaking and dry spots in certain areas of the tubing. They reviewed our web site and familiarized themselves with our Air Wipes but were unsure of the best design and size to fit their need so they reached out for assistance.
After further discussing the process, their tube O.D. sizes range from 3/8″ – 1/2″, making our 1″ Air Wipe the ideal solution. As far as the design, the Standard or Super Air Wipe, I recommended they use our Model # 2451 Super Air Wipe kit due to the aluminum construction and stainless steel wired braided hoses being able to withstand the potential temperature in the area of 200°F. The kit includes a filter separator to remove any water or contaminants in the supply and a pressure regulator which would allow them to control the flow and force of the exiting air, to help “dial” it in to fit the demand of the application.
EXAIR Air Wipes features a split design, which can easily be clamped around the material, to provide a 360° uniform airflow, perfect for treating the surface of round shapes, like extruded tubing. If you have an application where you are needing to dry, cool or clean the outside of a pipe, hose or cable, contact an application engineer for help making the best product selection.
Recently, I was working with a customer that has purchased several of the EXAIR Atomizing Spray Nozzles, specifically the model Aw5020SS. The customer had another project coming up and needed two more nozzles. I inquired about the application and we discussed at length the way the nozzles are being used.
When a concrete road is being poured, several sample forms are poured during the process. The local Department of Transportation takes the samples and cures them in a wet room for 30 days, and then performs tensile testing, to confirm the concrete meets the strength requirements. The wet room must be kept at 23°C (73.4°F) and 100% Humidity during this time frame. The EXAIR model AW5020SS Atomizing Nozzles are used to provide the moisture that ensures the room humidity conditions are met and maintained. Because the droplets are very fine, the effect of a fog is achieved, with the water droplets suspended in the air, keeping the humidity at 100%.
Atomizing spray nozzles are capable of producing very fine droplet sizes. A typical rain drop is 6000 microns in diameter, standard liquid nozzles produce droplets ranging from 300-4000 microns. The EXAIR Atomizing Nozzles produce droplets from 20-100 microns!
Droplet sizes can be adjusted by varying either the liquid pressure or air pressure. Increasing the air or decreasing the liquid pressure will generally produce a smaller droplet size.
EXAIR manufactures (3) types of Atomizing Nozzles – Internal Mix, External Mix, and Siphon Fed, in both 1/4 NPT and 1/2 NPT sizes. Maximum liquid viscosity is 800 cP. Flow rates range from 0.6 GPH up to 303 GPH, so we’ll be able to find one that meets your flow requirements.
To discuss your application and how an EXAIR Atomizing Nozzle can benefit your process, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.