EXAIR Super Air Knives Blast Away the Competition

When a wide area is in need of cleaning, cooling, or drying there isn’t a better option available on the market than EXAIR’s Super Air Knife. It’s laminar and even airflow across the length has solved process problems and provided manufacturing solutions for thousands of customers. We’ve been manufacturing Air Knives for over 30 years now, with the Super Air Knife making its first appearance back in 1997. Since then, the Super Air Knife has undergone a few enhancements over the years as we’re constantly trying to not only introduce new products but also improve on the ones we have. We’ve added new materials, longer single piece knives, as well as additional accessories.

What sets EXAIR’s Super Air Knife above the competition is the ability to maintain a consistent laminar flow across the full length of the knife, particularly when compared against blower operated knives or even fans. A fan “slaps” the air, resulting in a turbulent airflow where the airflow particles are irregular and will interfere with each other. A laminar airflow, by contrast, will maintain smooth paths that will never interfere with one another.

Blower Style air knife

Blower knives are commonly seen in industry that also cannot provide a laminar airflow. Additionally, they are expensive to purchase, produce a high sound level, and require periodic maintenance. Costly maintenance that results to downtime, as well as the physical space the system takes on the shop floor are all eliminated when using the Super Air Knife.

One of the simplest alternatives to the Super Air Knife is a homemade drilled pipe. While it’s quite easy to put together with materials that are likely already available to you, the true hidden cost here is the operating cost. The high energy use related to the total compressed air consumption makes this “seemingly economic” solution into an expensive one quickly. Not to mention, these devices are not considered to be safe per OSHA 1910.242(b).

The effectiveness of a laminar airflow vs turbulent airflow is particularly evident in the case of a cooling application. The chart below shows the time to cool computers to ambient temperatures for an automotive electronics manufacturer. They used a total of (32) 6” axial fans, (16) across the top and (16) across the bottom as the computers traveled along a conveyor. The computers needed to be cooled down before they could begin the testing process. By replacing the fans with just (3) Model 110012 Super Air Knives at a pressure of just 40 psig, the fans were cooled from 194°F down to 81° in just 90 seconds. The fans, even after 300 seconds still couldn’t remove enough heat to allow them to test.

While the fans no doubt made for large volume air movement, the laminar flow of the Super Air Knife resulted in a much faster heat transfer rate.

Utilizing a laminar airflow is also critical when the airflow is being used to carry static eliminating ions further to the surface. Static charges can be both positive or negative. In order to eliminate them, we need to deliver an ion of the opposite charge to neutralize it. Since opposite charges attract, having a product that produces a laminar airflow to carry the ions makes the net effect much more effective. As you can see from the graphic above showing a turbulent airflow pattern vs a laminar one, a turbulent airflow is going to cause these ions to come into contact with one another. This neutralizes them before they’re even delivered to the surface needing to be treated. With a product such as the Super Ion Air Knife, we’re using a laminar airflow pattern to deliver the positive and negative ions. Since the flow is laminar, the total quantity of ions that we’re able to deliver to the surface of the material becomes greater. This allows the charge to be neutralized quickly, rather than having to sit and “dwell” under the ionized airflow.

With lengths from 3”-108” and (4) four different materials all available from stock, EXAIR has the right Super Air Knife for your application. In addition to shipping from stock, it’ll also come with our unconditional 30-day guarantee. Test one out for yourself to see just how effective the Super Air Knife is on a wide variety of cooling, cleaning, or drying applications.

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

EXAIR’s Return on Investment For One Engineered Air Nozzle is Amazing!

Return on Investment (ROI) is a measure of the gain (preferably) or loss generated relative to the amount of money that was invested.  ROI is typically expressed as a percentage and is generally used for financial decisions, examining the profitability of a company, or comparing different investments.  It can also be used to evaluate a project or process improvement to decide whether spending money on a project makes sense.  The formula is shown below-

ROI
ROI Calculation
  • A negative ROI says the project would result in an overall loss of money
  • An ROI at zero is neither a loss or gain scenario
  • A positive ROI is a beneficial result, and the larger the value the greater the gain
1100group
Our catalog publishes most products’ performance and specification data for a compressed air supply pressure of 80psig.

Example – installing a Super Air Nozzles (14 SCFM compressed air consumption) in place of 1/4″ open pipe (33 SCFM of air consumption consumption) .  Using the Cost Savings Calculator on the EXAIR website, model 1100 nozzle will save $1,710 in energy costs. The model 1100 nozzle costs $42, assuming a $5 compression fitting and $45 in labor to install, the result is a Cost of Investment of $92.00. The ROI calculation for Year one is-

ROI2

ROI = 1,759% – a very large and positive value.  Payback time is only 13 working days!

If you have questions regarding ROI and need help in determining the gain and cost from invest values for a project that includes an 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.

Jordan Shouse
Application Engineer

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Save Compressed Air Energy with Pressure Regulators

Why should you consider a Pressure Regulator when designing your compressed air system? As many know, our products and those of other  product manufacturers have a certain set of specifications regarding performance at stated input pressures. But what if your application doesn’t require that “full, rated performance”? Maybe instead of needing two pounds of force, you only need one pound? Sometimes more force does not produce the desired result for an application. By that, I mean you cause damage to the target or other surrounding items in the application. Or, perhaps blowing too hard (or vacuuming too hard in the case of a Line Vac or E-vac) might cause the vessel or the material you are picking up to collapse or deform (due to too much power).

Regulators catalog
EXAIR offers a range of Pressure Regulators capable of handling air flow of up to 700 SCFM.

There is also the concern about using more energy than one really needs to in order to achieve the desired effect in an application. In other words, if you can achieve your goals with only 40 PSIG, then why would you ever use 80 PSIG to accomplish the goal? By reducing your compressed air from 80 down to 40 PSIG, you can easily reduce the air consumption of the “engineered” solution by another 40% or more.  Once you have installed engineered air nozzles to reduce compressed air on blow off applications, a pressure regulator can fine tune the pressure to save even more energy.

Regulator Internal
Regulator Internals

Then there is the issue of taking advantage of the pressure differential (from 80 down to 40 PSIG) that creates a little bit more air volume capacity. At 80 PSIG, your compressed air to free air volume ratio is 6.4:1. At 40 PSIG, it is only 3.7:1. The net effect is you effectively have an overall larger volume of air you can use for other applications in your facility. By reducing compressed air pressure of your demand applications, you may be able to reduce over all compressor discharge pressure. Reducing compressor discharge pressure by 2 PSIG also reduces required input power by 1 percent – so keep your pressure as low as possible!

Regulating pressure is definitely warranted given the benefits that compliment the operation of the core EXAIR products.

If you need a deeper understanding about how EXAIR’s products can help your application, feel free to contact us and we will do our best to give you a clear understanding of all the benefits that can be had by our products’ use as well as proper implementation of accessory items such as compressed air filters and regulators.

Jordan Shouse
Application Engineer

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Super Air Amplifiers and Amplification Ratio

Super Air Amplifier Family

In the pneumatic industry, there are two types of Air Amplifiers.  One type will amplify the inlet air pressure to a higher compression.  The other type uses the inlet air pressure to amplify the air volume.  EXAIR manufactures the volume type called the Super Air Amplifiers™.

This change in air volume is called the amplification ratio.  So, what does this mean?  The definition of a ratio is the relation between two amounts showing the number of times one value is contained within the other.  For the Super Air Amplifier, it is the value that shows the amount of ambient air that is contained within the compressed air.  The higher the ratio, the more efficient the blowing device is.  With the EXAIR Super Air Amplifiers, we can reach amplification ratios up to 25 to 1.  This means that 25 parts of ambient “free” air is introduced for every 1 part of compressed air.

Air Amplifiers Are Great For blowing!

Why an EXAIR Super Air Amplifier?  Like a fan, they are designed to move air.  But fans use motors and blades to push the air toward the target.  The fan blades “slap” the air which creates turbulent air flows and loud noises. The Super Air Amplifiers do not use any blades or motors to move the air.  They just use a Coanda profile and a patented shim to create a low pressure to draw in the ambient air.  In physics, it is much easier to pull than it is to push.  The process of pulling air through the Super Air Amplifiers make them a more efficient, uniform, and quiet way to blow air.

Most people think that compressed air is free, but it is most certainly not.  Because of the amount of electricity required, compressed air is considered to be the fourth utility in manufacturing plants.  To save on utility costs, it is important to use compressed air as efficiently as possible.  In reference, the higher the amplification ratio, the more efficient the compressed air product.  Manufacturing plants that use open fittings, copper tubes, and drilled pipes for blowing are not properly using their compressed air system.  These types of products generally only have between a 2:1 to 5:1 amplification ratio.  The Super Air Amplifiers can reach a 25:1 ratio.

EXAIR manufactures and stocks five different sizes ranging from ¾” (19mm) up to 8” (203mm) in diameter.  Some of the benefits that the Super Air Amplifiers have is the inlet and outlet can be ducted for remote positioning.  They are very compact and can fit into tight places.  They do not have any moving parts to wear or need electricity to run.  They only need clean compressed air to operate; so, they are maintenance-free.

Another unique feature of the EXAIR Super Air Amplifier is the patented shim which optimizes the low-pressure to draw in more ambient air.   With extracting welding smoke, increasing cooling capacities, and moving material from point A to point B; the more air that can be moved, the better the performance.  And with the patented shim inside the EXAIR Super Air Amplifiers, it provides that.  As an added bonus, they are OSHA safe and meet the standards for noise level and dead-end pressure.

Super Air Amplifier Patented Shims

To explain things in every day terms; the amplification ratio can be represented by gas mileage.  Like your car, you want to get the most distance from a gallon of gasoline.  Similarly, with your compressed air system, you want to get the most for your pneumatic equipment.  An EXAIR Super Air Amplifier has a 25:1 amplification ratio.; so, in other words, you can get 25 mpg.  If you use drilled pipes, open fittings, copper tubes, etc. for blowing, then you are only getting 2 to 5 mpg.  If you want to get the most “distance” from your compressed air system, you should check the “gas mileage” of your blow-off components.  If you need assistance, an Application Engineer at EXAIR can help you to “tune up” your compressed air system.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb