Proper Filtration Eliminates the Need for Maintenance of Super Air Amplifier in Brewing Application

EXAIR’s Super Air Amplifiers utilize a patented shim design to maintain critical positioning of component parts. This allows a precise amount of compressed air to be released at exact intervals toward the center of the Super Air Amplifier. This creates a constant, high velocity outlet flow across the entire cross-sectional area. Free, ambient air is entrained through the unit, resulting in high amplification ratios. The balanced outlet airflow minimizes wind shear to produce sound levels far lower than other similar air movers.

As with any EXAIR Product, we always recommend the installation of a particulate filter. If there is any oil present in your air supply, an oil filter is also recommended after the particulate filter. Nearly all of our products have no moving parts to wear out and will never require maintenance so long as they’re supplied with clean, condensate free, oil-free air. If the air is not filtered prior, anything contained within the air is going to be passed through into your process. Debris could  also eventually clog up the tight orifices in the product itself. Eventually the debris/oil will end up clogging it up and stop performing as it should. This leads to downtime while the root cause of the issue is sorted out, and subsequent maintenance of the product that has been clogged.

I recently worked with a brewing company that had a machine with one of our ¾” Model 120020 Super Air Amplifiers installed. It was used on a canning line and would dry off the cans after a washing operation before being marked with a date code. Up until recently it had worked just fine without any issues. Now they were noticing residual moisture leftover on the cans that was preventing a legible date code from being marked on the outside. Further investigation led them to determine that the outlet flow from the amplifier had been reduced to almost nothing. Since their compressor delivers oil-free air and they used stainless steel piping, they didn’t think it was necessary to install a filter.

The Super Air Amplifier is a maintenance-free product, when supplied with clean, condensate free air of course. After removing the plug from the body, they noticed a significant amount of oil present inside the plenum chamber and around the shim. This was clogging up the nozzle and restricting airflow through the unit. The photo below shows the inside of the amplifier prior to cleaning. The fine-toothed shim at the bottom is hardly even noticeable. In looking upstream, they noticed an oiler that was necessary for many of the other pneumatic components of the machine. This same air supply was being used to supply the compressed air to our Super Air Amplifier.

At our instruction, they installed an oil-filter on a new line dedicated just to this amplifier. And after cleaning the Super Air Amplifier the problem drying off the cans immediately stopped and they were back up in running in no time. Now that they had removed the oil from their air supply, this issue won’t return and they can begin operating the way we intend it to, maintenance free!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Many Air Knife Materials and Shim Options to Suit Your Application

The EXAIR Super Air Knives are used in many applications ranging from part drying, to web cleaning, to conveyor blowoff, and many other uses. For most processes, the aluminum models provide the performance required and withstand the environmental conditions present.

Ambient temperature limits for the aluminum models is 180°F (82°C). EXAIR also offers the air knives in types 303 and 316 Stainless Steel, which increase the temperature limit to 800°F (427°C) and provides a great degree of corrosion resistance. For the harshest, most corrosive environments, an air knife constructed of Polyvinylidene Fluoride (PVDF) with a temperature limit to 275°F (135°C) is available.

Super Air Knives
Aluminum, Stainless Steel and PVDF Super Air Knives

But what can we do about those applications where the increased corrosion resistance isn’t needed and the temperatures do not approach anywhere near to 800°F (427°C)?

The solution to this situation is an aluminum air knife with a custom stainless steel shim. The aluminum material is rated to 400°F (204°C) and the shim is good to 800°F (427°C) so this knife can be used in those hotter environments up to 400°F (204°C). This option helps to keep the cost of the knife low, by utilizing the lower cost aluminum for the body and cap.

The table below details the materials of construction options for the Super Air Knife – a wide array of material offerings to suit even the hottest, harshest conditions.

Air Knife Temperature Table

We recommend consulting with an Application Engineer to review the application, process, and environmental conditions, and we can present best options.

And don’t forget, the shims can be further customized for special blowoff requirements. See the blog that my colleague, Russ Bowman, posted here.

If you have questions about Super Air Knives or any of the 15 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer
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Universal Air Knife Mounting System Saves You Time & Money

Using EXAIRS Universal Air Knife Mounting System greatly ease’s the installation of all Air Knives (Except PVDF).  It will save you the time and expense of designing and fabricating your own mounting system which will maximize your uptime and keep your staff focused on key plant tasks!

Please note the table below that highlights the recommended number of the Universal Air Knife Mounting System to use for the various length of Air Knives.

Length Of Air Knife Number of UAKMS
3″ – 18″ 1
24″ – 54″ 2
60″ 3
72″ – 95″ 4
96″ – 108″ 5

If you would like to discuss Universal Air Knife Mounting System, Air Knives or any EXAIR compressed air product, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer

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Video Blog: Material Selection Guide for EXAIR Air Wipes

The below video covers the Super Air Wipe and Standard Air Wipe and details the materials of construction of all options to help in the selection process.

 

EXAIR offers the Air Wipes in diameters from 3/8″ (10mm) to 11″ (279mm), all in stock!  (Note – 3/8″ (10mm) size available in aluminum only)

All Offerings and Sizes 2-1

 

As a final review, consult the table below for a comprehensive summary of the materials of construction for the EXAIR Stainless Steel and Aluminum Super Air Wipes and the Standard Air Wipe.

Summary Table3

If you have questions about the Air Wipes, or would like to talk about any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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