Super Ion Air Knife Removes Debris In Vinyl Window And Door Manufacturing

I recently worked with a vinyl window and door manufacturer on a static issue they were experiencing during the manufacturing process. After the aluminum frames are cut to length they are placed into a holding fixture where the vinyl seals are placed in a channel inside the frame and clamped together. A machining tool then travels around the parts to trim and machine the excess material, creating dust and some small chips. They tried to vacuum the debris away but were still seeing some residual material cling to the surface due to static, which resulted in manual rework of the parts, slowing down the production cycle.

Vinyl window – similar to the window being produced by the customer

The customer was able to send a drawing of the holding fixture for reference and after reviewing the information, I recommended they use our 18″ Super Ion Air Knife Kit in this application. The Super Ion Air Knife provides a high velocity, laminar sheet of ionized air across the length of the knife. As the positive and negative ions neutralize the surface charge, the airflow is able to clean the part of the unwanted material so it can be more easily vacuumed away. Using the regulator included in the kit, they can reduce the supply pressure to control the outlet flow and velocity to an acceptable level that doesn’t disrupt the current process.

Super Ion Air Knives are available in standard lengths from 3″ up to 108″ and ship from stock.

If you have an application you would like to discuss or are considering an EXAIR product for your process, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Vinyl Slider Window with Grid image courtesy of Steve Anderson via Creative Commons License

 

Another Unique Solution in an Aluminum Processing Plant

Fine dust particles needed to be removed from this belt on the underside of a conveyor

A few months back I wrote about the impact of installing Super Air Knives in an aluminum processing plant.  Those Super Air Knives solved a recurring problem with cleaning alumina dust around conveyors and reduced costs for the end user by over $80k.

That same customer has also found a method to remove fine dust from the underside of the conveyor belt in an application area not suitable for an Air Knife.  In this application there was no dust collection system in place to carry away the fines as they are blown off of the belt, so a different type of solution was needed.

Model 150200 Heavy Duty Line Vac provides the vacuum needed to remove the dust fines.

That solution was to install a Heavy Duty Line Vac affixed to a vacuum hood to remove fines from the belt and convey them back to the head chute.  The only problem with this setup was that the 2” Heavy Duty Line Vac produced a bit too much vacuum flow than what was really needed in the application.  So, a pressure regulator was installed to allow for adjustment and fine tuning of the vacuum solution.  The customer was able to adjust the operating conditions for the Line Vac and minimize compressed air use while maximizing the vacuuming effect on the fines stuck to the conveyor.

The Line Vac used in this application quickly and easily solved a chronic problem plaguing this manufacturer.  By installing this vacuum solution they were able to prevent build-up of dust and debris underneath the conveyor which originally required shutting down the line to clean.  This improved process uptime, reduced cleaning costs, and increased throughput in the application.

If you have an application in need of a vacuum solution, consider an EXAIR Line Vac.  And, if you have any questions, contact an EXAIR Application Engineer.  We’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Removing Debris from Jars Prior To Filling

pv-500-jar-image-without-sleeve
These PET jars needed a way to remove static dust prior to filling with product

Back in the spring of this year I had some interaction with a customer in India about a Vortex Tube application.  At the time, they were facing an overheating condition and needed some guidance as to which model would provide the best solution.

Fast forward to this week and this same customer reached out to me again, this time for a static problem.  The application in question was plagued with difficulty in removing small dust particles from the inside of PET jars (shown above).  The jars range from 220-260mm in height (8.6”-10.25”), 80-100mm (3.1”-4”) in diameter, and travel through the process at a speed of ~40 units per minute.

Due to static charge, the dust in this application would adhere to the inside of the jars, presenting a problem with filling during the next stage of the process.  What this customer needed was a way to remove the static, blow away the dust, and then pull a slight vacuum on the jars as a safeguard against any remaining dust.

The solution was to use the Stay Set Ion Air Jet to blow into the jars, removing the static and blowing away the dust, followed by a Super Air Amplifier to remove any dust particles which were not removed by the Ion Air Jet.

The customer was happy with this solution, but there was a bit of hesitation as to whether the Air Amplifier would be able to truly remove debris from the jars.  In an effort to visualize the effects of an Air Amplifier on this type of application I made the short video below.

This video shows paper pieces inside of a cylinder of comparable height to the jars in this application.  After the paper is placed in the cylinder the model 120021 Super Air Amplifier is used to pull the paper out of the cylinder, mimicking the effect it will have on residual dust in the customer’s application.  After seeing the video the customer was confident in the application solution.

Providing this type of assistance for our customers is nothing new for us at EXAIR.  We’re available via phone, online chat, or email for all of our customers, and commit to taking the time needed to really provide the assistance needed.  If you find yourself in need of solid engineering support for an application in your facility, contact an EXAIR Application Engineer.

 

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Super Air Knife Removes Dust In Furniture Application

One of the biggest disruptions to the home furniture business in the latter half of the 20th century was the introduction of self-assembled units.  Consumers found more attractive prices for items they put together themselves, and manufacturers found a way to expand their markets.

This change, coupled with the advances in CNC machining, has led to a booming industry.  And, EXAIR Super Air Knives provide a solution within this industry that allows the manufacturer of component based furniture to package their items with better quality and at higher production rates.

SAK at IKEA 2
Cutting and routing machine

The application involved cutting and routing components in the machine above.  The machining is precise, but the manufacturer found that the bottom of the pieces held an undesirable dust, and they needed a way to remove the dust before packaging.

SAK at IKEA 1
Super Air Knife installed to blow off dust from the bottom of finished pieces

The solution was to install a Super Air Knife onto the machine, below the track rollers used to guide the ejected parts.  When the wood pieces travel over the Super Air Knife, the dust is blown away and they are completely ready for packaging.

Installing the Super Air Knife improved product quality and increased production throughput by removing a wasteful and needless process of hand treating each piece.

If you have a similar application or problem, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Dust Removal With Super Ion Air Knife and Light Duty Line Vac

Cap De-duster

We always enjoy solving problems for the end users of our products.  Last fall I worked with a company in Lebanon needing to remove static dust from small caps as they travelled down a conveyor line.  We discussed the needs of the application, I made model number recommendations, and the system was installed.  Using a 3” Super Ion Air Knife and a Light Duty Line Vac, the end user was able to eliminate the static, remove the dust, and vacuum away the dust as needed.

Now, this same end user is aiming to repeat the application, only this time for a larger cap.  The setup is identical – the caps travel left-to-right on the conveyor track, they are blow off with ionized air from an EXAIR Super Ion Air Knife, and the dust is collected with a Light Duty Aluminum Line Vac.  The only revision to this system (and retroactively applied to the last) was to reposition the Super Ion Air Knife so that the caps spend more time in contact with ionized air.  This allows for increased throughput, should the application ever require increased production.

It’s great to solve problems for our customers.  It’s even better when the solution worked so well that it leads to repeat business.

If you have an application in need of an EXAIR device, but aren’t sure which one to use or where to start, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Audi Update:  The holiday break was slated as a perfect time to dive back into the engine concern on my latest project car, but, sadly, it didn’t happen.  Check my blog post next week for a full report.