EXAIR’s Super Air Knife Replaces Blower-Driven Slotted Pipe

EXAIR’s Super Air Knives are the ideal fit for any application requiring a laminar “curtain” of air for blowoff purposes. The high-velocity airflow does an excellent job of cleaning off surfaces, cooling, and drying in a wide variety of applications throughout industry. These products are engineered to provide a consistent and reliable force across the full length of the knife, ensuring repeatable performance in any application.

I recently worked with a customer who manufactures a variety of bread products. In one application, they were using slotted pipes connected to a blower to clean sesame seeds off of trays after baking. The cut pipes seemed like a simple and economical solution since they had the materials there in the facility already, but the homemade blower-knives were lacking in force necessary to clean the trays.

Slotted pipes operating off of a blower didn’t quite pack the “punch” necessary to clean the trays.

When the tray wasn’t fully cleaned, residual seeds would stick to the bottom of the next loaves and burn leaving an unacceptable product for their customers. The solution was to implement a manual step of scraping off the trays which required a dedicated operator to perform this single operation. The plant runs 24/7, leading the customer to hire 3 new personnel strictly for cleaning the trays all day long.

Recent staffing difficulties due to COVID-19 led management to seek out areas where they could enhance their production efficiency and identified an opportunity in this application. EXAIR’s compressed air operated Super Air Knives provide a hard-hitting curtain of air that is very effective at cleaning. The (2) slotted pipes were replaced with (2) Model 110024SS stainless steel Super Air Knives and plumbed into their existing compressed air system.

Immediately, the higher force provided by the Super Air Knives displayed the ability to completely clean the trays and eliminate the need for dedicated operators for this part of the process. This allowed them to shift personnel to areas in the facility in desperate need of help, while still solving the problem of rejected bread loaves due to residual seeds.

If you have an application in your facility that is in need of an efficiency makeover, give us a call. Our team of experienced Application Engineers is ready to help evaluate your process and make any necessary recommendations.

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

Save Compressed Air with the EXAIR Electronic Flow Control

The best way to save compressed air is to simply turn it off when it’s not being used. This might seem pretty simple, but there may be processes in your facility where this couldn’t be achieved by just turning a valve. In applications where product is traveling along a conveyor, and must be dried, cooled, or blown off, there is likely some spacing in between the parts. It isn’t necessary to keep the blowoff running constantly if there’s periods of intermittent spacing. To help reduce the overall load on the air compressor, implementing a solution to shut the air off in between each part can have a dramatic impact. EXAIR’s Electronic Flow Control, or EFC, is designed to improve efficiency by reducing overall compressed air usage. It utilizes a photoelectric sensor that detects when the part is present. When it’s not, it triggers a solenoid valve to close and shut off the compressed air supply.

efcapp
EXAIR EFC

One way to use the Electronic Flow Control would be for Turning a Atomizing Spray nozzle on to coat your product.  For example see the photo below where you could use the EFC to sense the pants coming down the line. Then turn the air supply on to spray a bleach solution to get the weathered look you are after. Once the pants pass the EFC will turn the nozzle off, replacing a manual operation awhile saving compressed air and your liquid solution!

Another use would be to tell when a hopper that is being filled by a Line Vac is empty or over filled.  You can adjust the sensor and the control module to sense that the hopper is empty and it will turn the compressed air on to the Line Vac to then feed the hopper.  Then set the timer module so it will run for the length of time it takes to fill the hopper.  The other way would be to place the sensor at the top of the hopper and have it sense when the pile of media has reached the full level.

The EFC models available from stock can accommodate flows up to 350 SCFM. For applications requiring more compressed air, EFCs with dual solenoids are also available. If you have an application in one or more of your processes where intermittent compressed air use could help save you money, give us a call. We’d be happy to take a look at the application and help determine just how quickly the EFC could start paying YOU

Jordan Shouse
Application Engineer

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What Is A Coanda Profile?

The big thing that sets engineered products like EXAIR Intelligent Compressed Air Products apart from other devices is the engineering that goes into their design.  Several principles of fluidics are key to those designs:

The one I wanted to discuss today, though, is the Coanda Effect, what it means for our engineered compressed air products, and what they can do for you:

The Coanda effect is named after Henri Coandă, who was the first to use the phenomenon in a practical application…in his case, aircraft design.  He described it as “the tendency of a jet of fluid emerging from an orifice to follow an adjacent flat or curved surface and to entrain fluid from the surroundings so that a region of lower pressure develops.”  Put simply, if fluid flows past a solid object, it keeps flowing along that surface (even through curves or bends) and pulls surrounding fluid into its flow.  Here’s a demonstration, using an EXAIR Super Air Amplifier and a plastic ball:

What’s interesting here is that the Super Air Amplifier is not only DEMONSTRATING the Coanda effect, it’s also USING it:

Air Amplifiers use the Coanda Effect to generate high flow with low consumption.

EXAIR Standard and Full Flow Air Knives also have Coanda profiles that the primary (compressed air) flow follows, and uses, to entrain “free” air from the surrounding environment:

Compressed air flows through the inlet (1) to the Standard Air Knife, into the internal plenum. It then discharges through a thin gap (2), adhering to the Coanda profile (3) which directs it down the face of the Air Knife. The precision engineered & finished surfaces optimize entrainment of air (4) from the surrounding environment.

EXAIR Air Wipes can be thought of as “circular Air Knives” – instead of a Coanda profile along the length of an Air Knife, an Air Wipe’s Coanda profile is on the ring of the Air Wipe, which entrains surrounding air into a 360° ring of converging air flow:

Air Wipe – How it works

So that’s the science incorporated in the design of our products.  But what does it mean to the user?

  • Efficiency.  Pulling in a tremendous amount of “free” air from the surrounding environment means minimal consumption of compressed air, while still getting a hard hitting, high velocity air flow.
  • Sound reduction.  This air entrainment also creates a boundary layer in the air flow, resulting in a much quieter air flow than you get from a simple open-end blow off.

EXAIR Corporation is committed to helping you get the most out of your compressed air system, and thanks to Mr. Coandă, that includes reducing your compressed air consumption and noise levels.  If you’d like to find out more, give me a call.

Russ Bowman, CCASS

 

 

 

Application Engineer
EXAIR Corporation
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Customer Saves Nearly $7000 by Installing Super Air Knives on Converting Machine

EXAIR proves often that we’re able to work with you to create a customized solution that best serves your application. Recently I had the pleasure of working with a customer who wanted a better solution on their tissue paper converting machine. What they currently had was too loud, too inefficient, and they knew there was a better way.

The machine was an old rewinder used to convert webs of tissue paper ranging from 99-115” in width. Installed on the old machine was a 115” drilled pipe with 1/16” drilled holes spaced out every ½” along the length of the pipe. This was using a substantial amount of compressed air and was significantly louder than they would’ve liked. They purchased a new machine that had an EXAIR Super Air Knife already installed and working great, so they reached out to us for some help.

The customer conducted some time studies to determine exactly how much air this application required. The air blast ran for 500 seconds per hour, equating to 8.3min/hr of air usage. The operation runs 24/7, but with time spent doing changeovers the actual run time is closer to 20hrs.

20hrs x 8.2min = 166 min/day of air usage

166min x 365 = 60,590 min per year

A 1/16” unpolished, drilled hole will consume 2.58 SCFM at a pressure of 60 PSIG. With a total of 228 holes across the full pipe, this is quite a bit of compressed air.

2.58 SCFM x 228 = 588 SCFM of compressed air

588 x 60,590 min = 35,626,920 SCF

Considering the lightweight nature of the material, we recommended that the customer use our .001” shim to cut the flow from our stock Super Air Knives to their minimum. We recommended our Model 110054-.001 and Model 110060-.001. At 60 PSIG, a Super Air Knife with .001 shim installed will consume 1.15 SCFM/inch of knife length.

114 x 1.15 SCFM = 131 SCFM of compressed air

131 x 60,590 min = 7,937,290 SCF

Installing the Super Air Knives with .001” shim reduced their air consumption by 77% for a total air savings of 27,689,630 SCF each year. But, what does this mean in terms of money? To determine the cost of compressed air, we use the approximate value of $0.25/1000 SCF.

27,689,630 SCF x $0.25/1000 = $6,922.41

In just one year, on this one single machine, this customer was able to save almost $7k per year. These knives quickly pay for themselves, then begin to contribute to your bottom line. All of this in addition to lowering the sound level and providing a safer working environment for their operators.

If you have areas in your facility that are using air inefficiently, contact an EXAIR Application Engineer today.

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