Well the dog days of summer have come to an end, and the cold dry air of winter is on the horizon! There’s one other thing that comes along with the cold dry air of winter, and that’s SANTA! (Sorry that was the child in me).
Actually, it’s STATIC! During the warmer months the moisture in the air does a good job at eliminating a good amount of excess static charge. But as that cold dry air comes into play you need another way to rid your production of static or things will start to go wrong.
In many painting or finishing applications dust and debris from the ambient environment can settle on the part prior to painting or coating. Just blowing them off with a standard air gun won’t remove all of the particles if they’re statically charged. The static must be neutralized in order to remove it or it’ll cause imperfections in the paint or coating. This often results in a high amount of rejected parts that must be scrapped out.
Other processes that benefit from static removal include printing, slitting, molding, sheeting/trimming, shrink wrapping and packaging.
Break out your fall / winter gear and enjoy the cooler weather and activities that accompany the coming of Fall, but don’t let static wreak havoc in your processes. EXAIR has a wide range of solutions available that are designed to solve these problems. Give an Application Engineer a call and we’ll be happy to help recommend the best solution.
In the winter, as the temperature gets colder and colder and the air is getting drier and drier, static becomes a larger problem. In the summer, water in the air can help dissipate the electrons that we pick up as we move around, but when the air is drier, the static charge collects and clings to surfaces, building up until… zap! This can be a huge problem for companies as static can cause products to bunch up and not process correctly. Or even worse static can build so much it can shock electrical devices causing costly repairs and downtime. That’s whyEXAIR has a full catalog of static eliminating products, and we will talk about them and what each product is best suited for!
The most popular Static Eliminator we sell is our Gen4 Super Ion Air Knife! By combining a Gen4 Ionizing Barwith a Super Air Knife, The Gen4 Super Ion Air Knifeprovides rapid static elimination AND blows off any dust, chips, or debris that was being statically held to the surface. The laminar curtain of ionized air not only maximizes the rate of static dissipation, but is also ideal for stripping/sweeping away any debris, leaving a clean, static-free surface. No more jamming, tearing, nuisance shocks to operators, dust attraction, or any of the other host of problems associated with static electricity.
EXAIR’sGen4 Super Ion Air Wipe provides a uniform 360° ionized airstream that is simple to clamp around a part for reducing static electricity and cleaning contaminants. It is great for use on pipe, cable, extruded shapes, hose, wire and much more. We offer the Gen4 Super Ion Air Wipe in either 2” or 4” inner diameter, it is powered by compressed air and an external power supply. The Gen4 Super Ion Air Wipe generates both positive and negative ions that are transmitted the emitter points located on the i.d. of the wipe. Since static charges can be either negative or positive it is easy to eliminate both states of charge due to the mixed polarity of ions being generated.
To put it simple the Gen4 Ion Air Cannon is based on the mechanics of the 2″ diameter Super Air Amplifier with added static reduction capabilities and as its name implies it amplifies the supply air up to 25 times! This highly engineered product is very effective at cleaning product and reducing static at distances of up to 15′ away.
EXAIR’s Gen4 Ion Air Jet is a compact ionizer that is capable of delivering a concentrated ionized airflow that will cover a precise spot without disturbing the rest of the process. The quiet, focused air stream can quickly eliminate the static charge on surfaces. At a pressure of 80 psig the Gen4 Ion Air Jet is capable of dissipating a 5kV charge in .18 seconds!
In addition to providing rapid static decay, the Gen4 Ion Air Jet also helps to minimize compressed air use while maximizing the ionizing airflow. Utilizing a specially designed shim, the Gen4 Ion Air Jet entrains ambient air at a rate of 5:1. The airflow can easily be adjusted from a forceful blast to a gentle breeze simply by increasing or decreasing the inlet pressure to the ionizer.
Ion Air Jet on a Stay set hose.
Ion Air Jet
You can also get the Gen4 Ion Air Jetin a handheld gun option, this is called our Gen4 Ion Air Gun. This is great for applications where your operator is doing the static elimination and blow several times a shift by hand.
If you have an application that you believe would be better served by the use of an EXAIR Gen4 Static Elimination product, give us a call.
It’s “plug and play,” all the way. Connect the cable to the Power Supply, and hook it up to your compressed air system, and you’re ready to go.
It’s efficient and quiet. The high velocity jet entrains an enormous amount of air from the surrounding environment, where it’s ionized and ready to eliminate static charge quickly and effectively.
Instant static dissipation, at your fingertips (literally) – squeeze the trigger to blow ionized air, anywhere you want (well, within the reach of the 10 foot cable, anyway.)
Again, the Gen4 Ion Air Gun is just one of our Static Eliminator products. How do you know if it’s the right one? The selection of many EXAIR Intelligent Compressed Air Products comes down to the size & shape of the air flow that will solve the application. Static Eliminators are no different.
If you need to treat a large surface, you might be looking for a Gen4 Super Ion Air Knife. They come in lengths from 3 inches to 9 feet long, and blow a laminar, even curtain of ionized air that’s extremely effective and fast at static elimination, even at very low supply pressures.
If you’ve got large areas, multiple surfaces, or complex geometries to contend with, one (or an array) of these products might be the solution. For a simple, straightforward, hand held static elimination solution, though, it just doesn’t get any easier than the EXAIR Gen4 Ion Air Gun. Call me to find out how you can get one today.
***Order any qualifying EXAIR Static Eliminator by February 28, 2019, and we will include a FREE AC Sensor. Click here for details.***
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The Gen4 Super Ion Air Knife is a powerful static eliminator that prevents jamming, tearing, shocks and dust build up by neutralizing static and blowing away the debris.
The Gen4 Super Ion Air Knife combines the quiet and efficient Super Air Knife with the compact design of the rugged Gen4 Ionizing Bar resulting in a total solution to remove static electricity from plastics, webs, sheet stock and other product surfaces. Removing the static helps reduce or eliminate the process issues that the static electric causes, allowing for greater production speeds, improved product quality and a cleaner product.
The Gen4 Super Ion Air Knife floods an area or surface with static eliminating ions. With a uniform airflow across its length, misalignment to critical surfaces like webs is avoided. The force can be adjusted from a light breeze, to a full out blast of air. The Gen4 Super Ion Air Knife is electrically powered, is shockless and has no moving parts.
How It Works
In the diagram above, compressed air flows through an inlet (1) into the plenum chamber of the Gen4 Super Ion Air Knife. The flow is directed to a precise, slotted orifice. As the primary airflow exits, it creates a uniform sheet of air across the entire length, pulling in in surrounding air (2). An electrically powered Gen4 Ionizing Bar (3) fills the curtain of air with positive and negative charges. The air stream delivers the static eliminating ions to the product surface (4) where it instantly neutralizes static and cleans off dust and other particulates.
The Gen4 Super Ion Air Knives are powerful tools, and very quickly dissipates 5kV of static even at low compressed air supply pressures. At 5 PSIG, only 3.7 SCFM (0.3 BAR, only 105 SLPM) of compressed air per foot of length is required!! Sound levels are also very low, resulting in quiet operation.
Added Features –
Compressed Air Inlets are provided on each end and the bottom of the Super Air Knife
Thicker shims can be installed easily if a harder air flow is needed
Emitter points are sharp, durable stainless steel
The high voltage cable is armored to resist cuts and abrasion, and has integral grounding. Threaded bayonet connector is fully assembled and ready to use
Gen4 Ionizing Bars and Power Supplies are UL Component Recognized to U.S and Canadian safety standards and are CE and RoHS compliant
Power Supplies are 115/230 VAC selectable and come with 2 or 4 outlets
Standard lengths from 3″ to 108″ (76mm to 2743mm) are offered, and custom lengths are available to meet your process needs
Successful applications include web cleaning, pre-paint dust removal, shrink wrapper machinery, printing equipment, package cleaning,and bag opening/filling operations.
If you have questions about Gen4 Super Ion Air Knives, other types of Static Elimination products, or any of the 16 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.
As the weather gets colder and the air gets dryer, static electricity can become a real nuisance in a production plant. Machines will start jamming, alignments will be difficult, debris will collect on surfaces, and hazardous sparks can shock personnel. EXAIR manufactures a large line of Gen4 Static Eliminators to remove this static nuisance. And beginning January 1st, 2019; EXAIR will be giving away a free AC Sensor, a $57.00 value, with a purchase of any of the Gen4 Static Eliminators.
EXAIR stocks eight different product lines in two different styles, Gen4 Static Eliminators with Air and Gen4 Static Eliminators without Air. In conjunction with a power supply, these ionizers can create both negative ions and positive ions to remove any type of static charge that is on the surface. The Gen4 Power Supplies come in either a 2 port or 4 port configuration; so that, you can power multiple Gen4 Static Eliminators at once. From the power supply to the ionizer, an armored and electromagnetic shielded cable is used in a single wire design. This helps to protect the cable from abrasions, cuts and splits in industrial areas. The Gen4 Static Eliminators have a shockless design, and are UL Component Recognized and CE compliant. I will give a brief description of each product that utilizes this rugged industrial design for optimal static neutralization.
Gen4 Static Eliminators with Air:
Gen4 Super Ion Air Knife: This product has the best compressed air efficiency in removing static by combining the Super Air Knife with an Ionizing Bar. The Gen4 Super Ion Air Knife has a 40:1 amplification ratio and uses the laminar air flow to carry the positive and negative ions to the surface up to 20 feet (6.1 meters) away. The laminar air flow also allows for a quick static discharge in applications with fast conveyance speeds. EXAIR manufactures stock lengths from 3” (76mm) to 108” (2.74 meters). Some typical applications for the Gen4 Super Ion Air Knife are found in web cleaning, sheeters, pre-paint dust removal, and shrink wrappers.
Gen4 Standard Ion Air Knife: Similar to the Gen4 Super Ion Air Knife, the Gen4 Standard Air Knife has a good efficiency at 30:1 amplification ratio. It utilizes the Coanda effect to draw in ambient air, and they come in stocked lengths from 3” (76mm) to 48” (1.22 meters). The Gen4 Standard Ion Air Knife are used in similar applications as well as mold releasing, package cleaning, label applications and plastic bag opening.
Gen4 Super Ion Air Wipe: This product blows ionized air in a 360-degree pattern. They are engineered to remove static and debris from the outside of hoses, plastic pipes, extrusions, and coated wires. With the split design, the Gen4 Super Ion Air Wipe can easily mount around the product without having to rethread. They come in two different sizes with a 2” (51mm) and 4” (102mm) inner diameter. The ionized air has a fast decay in removing static for speedy transfers.
Gen4 Ion Air Cannon: Just like the name, this product will shower an area with ions to remove static. It can reach distances up to 15 feet (4.6 meters). They are used in multiple areas including pre-paint car bodies, containers, shrink packaging, lenses, etc. As an Air Amplifier, a small amount of compressed air will draw in a large amount of ambient air. The ions are carried to the surface by the Gen4 Ion Air Cannon in a laminar air steam. Once the ions coat the surface area, the air flow can gently remove any debris held by static forces.
Gen4 Ion Air Gun: For manual static removal to target specific areas, the Gen4 Ion Air Gun will work great. This product comes standard with 10 feet (3 meters) of shielded cable for maximum reach. An ergonomic air gun is attached to a Gen4 Ion Air Jet to manually remove static in difficult areas and to pre-treat within “shock” zones. The Ion Air Guns work great for small batch processes used for quality checks or label applications.
Gen4 Ion Air Jet: Similar to the Ion Air Gun, this product is used for “hands-free” operations. They use a small amount of compressed air to “shoot” the ions onto a target area. They can be operated with a solenoid valve or foot pedal to blow ions during specific times and situations. They can easily be attached to a Stay Set Hose and Magnetic Base for best “hands-free” positioning for optimal cleaning. They work well on small targets for automated systems or inspections areas prior to packaging.
Gen4 Static Eliminators without Air:
Gen4 Ionizing Bar: This rugged design is for industrial use to remove static cling from flat surfaces. They range in length from 3” (76mm) to 108” (2.74 meters). Without the assistance of air, the product has to be within 2 inches (51 mm) from the surface to remove static charges. The Gen4 Ionizing Bar is compact, shockless and works well in applications where blowing air could be a detriment. The applications would include screen printing, labeling, and large printing processes.
Gen4 Ionizing Point: This single point design is manufactured to remove static on small targets in tight spots. Utilizing the same rugged design, this product can remove static in spot areas and help to stop jams from slitting operations. They can also be panel mounted to neutralize areas using ducted air.
Now how about that free promotional item, the AC Sensor, with a purchase of any of the Gen4 Static Eliminators above? This device, as mentioned above, has a $57.00 value which you can get for free. This sensor provides a non-contact way to verify if voltage is present. A red light at the tip will glow, and an audible tone is sounded when voltage is detected. The model 7929 AC Sensor is an ideal tool to quickly verify that power is going to your ionizer. This instrument will also work for finding power in receptacles, junction boxes, switches and breaks in power cords. Batteries will be included, so you can start using it right after receiving the robust Gen4 Static Eliminators.
If you are an end-user and located within the United States or Canada, you can take advantage of this offer until March 31st, 2019. An Application Engineer at EXAIR will be happy to assist you with your application and a solution with the Static Eliminators. And if you qualify, a free AC Sensor.
Recently I had the pleasure of working on an application with one of our South American distributors, AYRFUL. Their customer is an OEM manufacturer of packaging machines that deals with a variety of different industries in the region. They had a machine in the field operating in Argentina that was posing some issues for a company that processes flour.
Static was building up on the packaging material and was causing flour particles to stick to the outside of the package. If there was any residual flour stuck at the top of the bag after filling, it wouldn’t allow the package to seal properly. This would result in bags of flour that would be improperly sealed, this caused housekeeping issues as some would spill out, but also some of these bags have to be thrown out due to potential contamination.
They reached out to our distributor who was able to go see the application and confirmed that the static was causing the problem with a Model 7905 Static Meter. The web was 27” wide, making our Model 112030 30” Gen4 Super Ion Air Knife a near perfect fit. By placing the Super Ion Air Knife just prior to the filling operation, we were able to remove the static charge on the material and blow off any residual flour that was still stuck to the outside of the packaging. This immediately mitigated the static on the material and allowed for the packages to seal properly, resulting in a production improvement of almost 20%!!
We’re smack in the middle of winter here in the US with drier air causing an uptick in static problems across a wide variety of industrial processes. With a wide range of Static Eliminator solutions available from stock, EXAIR has the ability to solve your problem QUICKLY!
Get in touch with us via phone, chat, or e-mail and an Application Engineer will be happy to assist you in selecting the most suitable Static Eliminator based on the application.
The video below provides details on the simple conversion to the new Gen4 style Super Ion Air Knife from the previous style or the addition of a Gen4 Ionizing Bar to an existing Super Air Knife to add static elimination to an existing blow off.
If you have questions about the Gen4 Super Ion Air Knife or any of the 16 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.