Using EXAIRSUniversal 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!
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)
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.
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.
EXAIR will be giving away a free Soft Grip Safety Air Gun with the purchase of any EXAIR Super Air Knife from November 1st through December 31st, 2017. This special promotion will apply to all Super Air Knife orders, whether aluminum, stainless steel, or PVDF. Use the promotional model number during the promotional period and receive a free model 1210, a value of $81.00! The Soft Grip Safety Air Gun is a Top Pick, and provides the ideal combination of forceful flow, quiet noise level and low compressed air usage. To get the special promotional item, use the special part numbers as detailed in the link below.
The Super Air Knife is the latest generation of the EXAIR engineered air knives with dramatically reduced compressed air usage and noise compared to other types of blowoffs. The Super Air Knife is truly a more efficient tool for cleaning, drying or cooling parts, webs, or conveyors. The air flow is a uniform sheet of laminar air across the entire length with a hard-hitting force.
Replacing a noisy blowoff with a Super Air Knife results is a significant reduction in sound. Operation at a high pressure of 80 PSIG (5.5 Bar) leads to a sound level of just 69 dBA for most applications. Air amplification ratios (entrained air to compressed air) of 40:1 is produced. It also meets OSHA maximum dead-end pressure and noise requirements, for safe operation in the vicinity of plant personnel.
Typical applications for use include-
Post wash part drying
Sheet cleaning in strip mills
Part or component cooling
Web drying or cleaning
Environmental separation (air curtain)
Pre-paint blowoff and cleaning
Bag opening/filling operations
Scrap removal on converting operations
Take advantage of the Promotional Offering by clicking on the link at the top of the page. Qualified orders receive the free model 1210 Soft Grip Safety Air Guns as shown below.
If you have questions about Super Air Knives, Safety Air Guns, or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
We’ve seen in recent blogs that Compressed Air Dryers are an important part of a compressed air system, to remove water and moisture to prevent condensation further downstream in the system. Moisture laden compressed air can cause issues such as increased wear of moving parts due to lubrication removal, formation of rust in piping and equipment, quality defects in painting processes, and frozen pipes in colder climates. The three main types of dryers are – Refrigerant, Desiccant, and Membrane. For this blog, we will review the basics of the Refrigerant type of dryer.
All atmospheric air that a compressed air system takes in contains water vapor, which is naturally present in the air. At 75°F and 75% relative humidity, 20 gallons of water will enter a typical 25 hp compressor in a 24 hour period of operation. When the the air is compressed, the water becomes concentrated and because the air is heated due to the compression, the water remains in vapor form. Warmer air is able to hold more water vapor, and generally an increase in temperature of 20°F results in a doubling of amount of moisture the air can hold. The problem is that further downstream in the system, the air cools, and the vapor begins to condense into water droplets. To avoid this issue, a dryer is used.
Refrigerant Type dryers cool the air to remove the condensed moisture and then the air is reheated and discharged. When the air leaves the compressor aftercooler and moisture separator (which removes the initial condensed moisture) the air is typically saturated, meaning it cannot hold anymore water vapor. Any further cooling of the air will cause the moisture to condense and drop out. The Refrigerant drying process is to cool the air to 35-40°F and then remove the condensed moisture. The air is then reheated via an air to air heat exchanger (which utilizes the heat of the incoming compressed air) and then discharged. The dewpoint of the air is 35-40°F which is sufficient for most general industrial plant air applications. As long as the compressed air stays above the 35-40°F temperature, no further condensation will occur.
The typical advantages of Refrigerated Dryers are-
– Low initial capital cost
– Relatively low operating cost
– Low maintenance costs
If you have questions about getting the most from your compressed air system, or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
An overseas company contacted me about an issue with drying copper wires. Their production process utilized fourteen wire drawing machines in their facility. They could make very fine wire in the range of diameters from 0.2mm to 2.6mm. Some of their drawing machines were able to make a maximum of sixteen wires at the same time.
Each wire is made by a process of drawing and annealing. The machine will draw a thicker copper wire through dies that will get progressively smaller in diameter. Before the material goes through the dies, the copper is annealed to make it ductile and workable. Annealing is a process of heating to make the material softer.
In this application, once the wire was to the correct diameter, it would go through a coolant bath to cool and harden. To remove the coolant from the wires, it would travel over a set of drying cloths. From there, the wire would travel out of the drawing machine and into a spooler.
The spooler places the wire onto a spool for packaging and shipping. The reason that they contacted EXAIR was because the wires were not properly dried before it went to the spooler. If any coolant was left on the surface, it would corrode the wires in that area. They needed a better way to dry the wires because they started to receive complaints from their customers.
When the company first contacted me, they had an interest in the Super Air Wipes. The Air Wipes are designed to blow air in a 360 deg. pattern around the wire to dry the entire surface. But, after getting more details about their process, the sixteen wires were coming out of the drawing machine at 1.75cm apart.
With the gap between the wires being so small, the Super Air Wipes would not be able to fit around each wire. As another engineered solution, I recommended the Super Air Knives Kit, model 110212. The Super Air Knives are 12” long (30.5cm) to span across all sixteen wires. The kit includes a filter, regulator, and shim kit to accommodate different forces for different wire speeds.
The Super Air Knife can blow a laminar flow of air consistently across the entire width. Air, as a fluid, likes to “hug” the surface. Since the air stream isn’t turbulent, the contact time along the surface of the wire will be much longer; making it very effective at removing liquid.
I had the customer mount one Super Air Knife above and one Super Air Knife underneath, spanning across the entire row of wires. They were positioned at a 45 deg. angle to blow in the opposite direction the wires were traveling.
Being compact, the Air Knives could be placed at a close distance near the drawing machine to blow the excess coolant back into the machine. This would keep the floor clean and safe from coolant collecting on the ground. So, no matter the diameter of wires being drawn through the machine, the Super Air Knives would be a non-contact way of drying the surface without having to use the drying cloths which were inconsistent and had to be replaced often.
If you require a non-contact way of keeping your product clean and dry, EXAIR has many products to tackle this. No matter how large or small of a profile, we can efficiently and effectively accomplish this. You won’t have to replace items that wear or cause damage to your product by improper contact. EXAIR has the ability to use compressed air to create a strong force without scraping or scratching your material.
The Super Air Amplifier is a powerful, efficient, and quiet air mover. Applications currently in place include blowoff, drying, cooling, circulation and ventilation. Sizes from 3/4″ to 8″ are available to best match the air volume that is necessary to achieve the process goals. There are a couple of ways to change the performance of the Super Air Amplifier if either a small or large change to the output flow is required.
The chart below shows the Total Output Flow for each of the 6 models. As an example, the Model 120021 or 121021, when operated at 60 PSIG of compressed air supply, will have a total output flow of 120 SCFM. These same devices when operated at 80 PSIG will have a total flow of 146 SCFM. By simply using a pressure regulation device on the compressed air supply, the output performance can be tuned to match the desired outcome.
For those applications where much greater flow and/or force is needed, the option of installing a thicker shim is available. The Super Air Amplifiers are supplied with a 0.003″ shim installed (the 8″ model 120028, has a 0.009″ shim as standard) and can be fitted with shims of thicknesses of 0.006″ or 0.009″ (the 8″ model has an optional 0.015″ shim.) Installation of a thicker shim increases the slotted air gap, allowing for a greater amount of controlled air flow. As a general rule, doubling the shim thickness will double the air flow rates.
The Super Air Amplifier design provides for a constant, high velocity outlet flow across the entire cross sectional area,. The balanced outlet flow minimizes wind shear to produce sound levels that are typically three times quieter than other air movers. By regulating the compressed air supply pressure and use of the optional shims, adjustability and flexibility of the unit is wide ranging and sure to meet your process needs.
If you have questions regarding the Super Air Amplifier, or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
When seeking a suitable solution for cooling or drying your parts, you may be tempted to try out a low-cost fan to get the job done. While fans do a great job of keeping you cool during the warmer months, they’re not the best choice for cooling or drying parts. Have you ever noticed that when standing in front of a fan the flow pattern is not consistent? This is due to the nature in which the fan blades create that air flow by “slapping” the air as they spin rapidly. The air flow that exits from the fan is turbulent and is not as effective as the laminar air flow pattern that is produced by EXAIR’sSuper Air Amplifier. The Super Air Amplifier utilizes a patented shim design that maintains a critical position of the air gap and creates a laminar air flow pattern that will exit the outlet of the unit.
In addition to providing laminar air flow more conducive for cooling and drying, the Super Air Amplifier provides much more air that can be directed at the target. A standard 2.36” x 2.36” DC operated fan provides anywhere from 12-27 CFM at the outlet, depending on the model. For comparison, a Model 120022 2” Super Air Amplifier will provide 341 SCFM at the outlet when operated at 80 psig. At just 6” away from the outlet, this value increases to 1,023 SCFM!! When compared to the fan outlet air flow, the Super Air Amplifier produces more than an 1,100% increase in air volume!
When replacing a fan with a Super Air Amplifier, the process time can be dramatically reduced. The increase in air volume significantly reduces the contact time that your part will need to be exposed to the air flow, allowing you to increase your line speed and decrease the overall production cost of the part. This is achieved due to the nature in which a Super Air Amplifier draws in air from the ambient environment. At amplification ratios as great as 25:1, the Super Air Amplifier is the best way to move a lot of air volume across the part with very little compressed air supplied to it. Check out the video below for a good representation of the air entrainment of a Super Air Amplifier.
In addition to providing laminar airflow and increasing the volume of air, the Super Air Amplifier is also infinitely adjustable through one of two ways. Each size Super Air Amplifier has a shim set that can be purchased. Swapping out the stock shim for a thinner shim will reduce the compressed air consumption, force, and flow. Installing a thicker shim will increase it. Additionally, the force and flow can also be adjusted by regulating the input supply pressure through the use of a pressure regulator. With sizes ranges from ¾” up to 8”, there’s a Super Air Amplifier for all applications. Give us a call today to see how you can optimize your process by replacing your fans with one or more Super Air Amplifiers.