316 Stainless Steel Line Vac Conveys Cookies in Creamery

Cookies in need of pneumatic conveyance at creamery

An overseas ice cream manufacturer reached out to me recently with a request for assistance.  They were in search of a better means to transfer “inclusions” from a storage bin into the blending tanks of their creamery.  The “inclusions” in question, shown above, looked familiar.  I’ve found identical cookies stashed in my sons’ favorite places around the house, so I’m somewhat familiar with their transfer from one place to another.  Fortunately, in this application the cookie transfer is deliberate whereas it is always “magic” or “no one knows how it got there” when it happens at home.

Both solid cookies and crumbs (shown above) are conveyed.

Seeing as how this application involves the transfer of foodstuffs, we immediately explored a 316 grade stainless steel solution, and gathered the necessary data for determining the proper pneumatic conveyor (an EXAIR Line Vac).  Our Line Vacs utilize a high velocity airstream which travels along the ID of a conveyance tube to move material.  Because of this, application specifics like material/material size, bulk density, conveyance height and distance, and required conveyance rate play a key role in proper sizing.  Here’s how the specifics looked for this application:

 

Material:  Dry cookies and cookie crumbs, 8mm-50mm in diameter (5/16” – 2” in diameter)

Bulk density:  0.69 g/cm³ (43 lb./ft.³)

Conveyance height:  None

Conveyance distance:  5m (16.5 feet)

Required conveyance rate:  As high as possible, preferably in the range of 500kg/hr. (1100 lb./hr.)

Available compressed air supply:  170m³/hr. @ 5.5 BARG (100 SCFM @ 80 PSIG)

Material constraints:  316SS mandatory

 

With these details well defined, I used our empirical test data to appropriately size a suitable Line Vac.  In this case, we had a viable solution in our Heavy Duty Line Vac with regards to conveyance rate, but this solution is not the proper material.  So, we matched performance of a Heavy Duty Line Vac in our 316SS Line Vac using model HP6064-316.  Model HP6064-316 is not a stock option and not shown on the website, so having a proper dialogue with an Application Engineer was critical to dialing in on the right solution for this application.

Once the solution was confirmed, this customer was all set.  We worked with them on every aspect of the application solution and ended up shipping them (3) specialized Line Vacs in 316 stainless steel.  The Line Vacs are up and running, helping to make delicious ice cream for expecting customers.

If you have a similar application or are interested in exploring a Line Vac solution, now is the time to act.  We have a Line Vac promotion running through the end of October that includes a free 2” Flat Super Air Nozzle with the purchase of any Line Vac.  Application Engineers are available for any questions you may have via phone (1-800-903-9247), email (techelp@exair.com), and online chat.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

The Old One-Two: Super Air Knives And Super Air Nozzles

The EXAIR Super Air Knife is THE ideal, efficient, and quiet solution for most any blow off application. We know this for a fact; we’ve been making them for years, folks all around the world have been buying them for years, and they keep coming back for more. They’re popular enough that over the years, we’ve introduced Mounting Systems and Plumbing Kits for ease of installation, and when Coupling Kits (to join multiple Super Air Knives together for greater lengths) became big sellers, we “upped our game” and started making Super Air Knives up to nine feet (108″) long. And certain applications (I’m looking at YOU, lumber and paper industries) order multiples of THOSE, and our Coupling Kits. Quite literally, there’s no job too big for EXAIR Super Air Knives.

EXAIR Super Air Knifes come in a wide variety of lengths to suit a wide range of applications.

No matter how long they are, though, the laminar, high velocity curtain of air they generate only moves in one direction. So, if there are significant geometric features (holes, bosses, recesses, “nooks & crannies,” etc.) to be blown off, we’ll have to look at something supplemental.

Enter the EXAIR Blowoff Systems…it doesn’t get any easier than this: an EXAIR engineered Super Air Nozzle, attached to a flexible, repositionable Stay Set Hose, mounted to a Magnetic Base.  Put a hard hitting, high velocity, pointed flow of air right where you want it.  If the next piece is different, that’s no problem – just bend the hose to re-aim the air flow.

Mag Bases come with one or two outlets. Stay Set Hoses come in lengths from 6″ to 36″.

No matter what the requirements of your blow off application are, we have an efficient, quiet, and safe solution.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
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Custom Air Amplifiers To Meet Most Any Requirement

When I think of “special” in regard to Air Amplifiers, I’m more inclined to think of the applications they can be used in. I mean, the Air Amplifier itself is about as straight-forward as an engineered compressed air product can be:

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

Considering the simplicity of the product itself, they can be used for a large variety of “typical” applications:

  • Cooling
  • Drying
  • Cleaning
  • Ventilation
  • Fume Exhausting
  • Dust Collection

There are no shortage of “special” applications either.  They’re used successfully in Air Operated Conveyance applications (when the stronger vacuum head of a Line Vac isn’t required) and we’ve even got a customer who uses one instead of an E-Vac Vacuum Generator for a “pick & place” operation…they’re picking up small, porous fiber discs (sort of like a coffee filter) one at a time, and the E-Vac wanted to pick up a good part of the whole stack, no matter how low they turned the pressure.  And of course, I can’t think of anything more special about Air Amplifiers than this:

You have to read it to believe it.  Follow the link and click on “Case Study: Roaring Banana Breath”

With fifteen distinct models to choose from in a range of sizes (3/4″ to 8″,) materials (aluminum or Stainless Steel) and even a High Temperature model that’s rated to 700°F (374°C), we’ve still made a fair number of Custom Air Amplifiers too…thirty-four, to be exact, as of this writing.

I won’t bore you with all the details – I can’t, actually, because some of them are proprietary* – but here are some “regular” examples of “special” accommodations:

  • Connections: EXAIR Air Amplifiers have smooth bores on the inlet & outlet plenums that you can hose clamp a hose (or round duct) to if you need to get air flow from, or to, one place or another.  Sometimes, though, they’re going in to an existing system, so we’ve made them with flanges (150#RF and Sanitary Tri-Clamp, for example) or threads (NPT or BSPP.)  If you want to use something other than a standard hose or duct line, we can help.
  • Material of construction: Our durable, lightweight aluminum Super & Adjustable Air Amplifiers are just fine an awful lot of the time.  Our type 303 Stainless Steel Adjustable Air Amplifiers will hold up to heat and corrosives.  We’ve also in PTFE (Teflon™) as well as a range of metal alloys to meet specific corrosion or wear conditions.  If your environment calls for a little something extra, we can help.
  • Assembly: Super Air Amplifiers are fitted with a stock shim that gives you published performance.  We’ve got other thicknesses, though, if you need more (or less) flow, though.  Adjustable Air Amplifiers are, well, adjustable…you just thread the plug in/out of the body until you get the results you want.  Sometimes the user knows what shim they want in a Super Air Amplifier, or what gap their Adjustable Air Amplifier needs to be set to, and we can assemble it accordingly.  If you have a ‘tried-and-true’ performance setting and want it met right out of the box, we can help.
  • Assembly, part 2: Good engineering practices call for lubrication on O-rings and threaded connections, and we use high quality, general purpose compounds when assembling our Air Amplifiers.  These are detrimental, however, in certain situations (silicone exclusion areas, I’m looking at you.) If certain chemicals or compounds are prohibited by your application, we can help.

*Let’s say you’ve done the “heavy lifting” to call out one (or more) of these special design features.  If we make a custom product (and that’s not just Air Amplifiers, by the way) using directions based on your time and labor, we’ll treat that product as proprietary to you, and you alone.

EXAIR has 208 catalog pages worth of Intelligent Compressed Air Products on the shelf…8 of those pages are our Air Amplifiers.  If you want to talk about customizing one to meet your needs, give me a call.

Russ Bowman
Application Engineer
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Super Air Amplifiers – Adjustability for Blowoff, Drying, Cooling, Circulation and Ventilation

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.AirAmplifiers

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.

Capture

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.

Super Air Amplifier Shims

Patented* Shim Design for Super Air Amplifiers

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.

Brian Bergmann
Application Engineer

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*Patent #5402938

About Double Acting Reciprocating Air Compressors

My colleague, Lee Evans, wrote a blog “About Single Acting Reciprocating Compressors”, and I wanted to extend that conversation to a more efficient relative, the double acting reciprocating compressor.   As you see in the chart below, this type of compressor falls within the same family under the category of positive displacement compressors.

Compressor Types

Positive displacement compressors increase air pressure by reducing air volume within a confined space.  The reciprocating type of air compressor uses a motor that turns a crank which pushes a piston inside a cylinder; like the engine in your car.  In a basic cycle, an intake valve opens to allow the ambient air into the cylinder, the gas gets trapped, and once it is compressed by the piston, the exhaust valve opens to discharge the compressed volume into a tank.  This method of compression happens for both the single and double acting reciprocating compressors.  With a single acting compressor, the air is compressed only on the up-stroke of the piston inside the cylinder.  The double acting compressor compresses the air on both the up-stroke and the down-stroke of the piston, doubling the capacity of a given cylinder size.  This “double” compression cycle is what makes this type of air compressor very efficient.  A single acting compressor will have an operating efficiency between 22 – 24 kW/100 cfm of air while the double acting compressor has an operating efficiency between 15 – 16 kW/100 cfm.  Therefore, electricity cost is less with a double-acting reciprocating air compressor to make the same amount of compressed air.

To explore the internals a bit closer, the mechanical linkage used to move the piston is slightly different as well as the additional intake and exhaust valves.   Instead of the connecting rod being attached directly to the piston as seen inside a single acting compressor, a crosshead is added between the compression piston and the connecting rod (view picture below).  The rod that connects the crosshead to the compression piston can be sealed to keep the cylinder completely encapsulated.  For every rotation of the electric motor, the air is being compressed twice.  With the added heat of compression, the double acting compressors are generally water-cooled.  Also, with the added mechanism between the crank and the piston, the rotational speeds are typically less.  Because of the larger size, water jackets, and added parts, the initial cost is more expensive than the single acting compressor, but the efficiency is much higher.

Double Acting Reciprocating Air Compressor

Double acting compressors are generally designed for rugged 100% continuous operations.  Dubbed the work horse of the compressor family, they are also known for their long service life.  They are commonly used in high pressure services in multistage styles and can come in lubricated and non-lubricated configurations.   With the dual compression, slow speed and inter-cooling, it makes this type of air compressor very proficient in making compressed air.

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

 

Photos:  used from Compressed Air Challenge Handbook

EXAIR Line Vac Promotion Thru October 2017!

EXAIR will be giving away a free 2” Super Air Nozzle with the purchase of any EXAIR Line Vac from September 1st through October 31st, 2017.  This special promotion will apply to all versions of Line Vac orders, whether aluminum, stainless steel, heavy duty, threaded/non-threaded, or 316SS sanitary flanged.  Order within the promotional period and receive the free model 1122, a value of $65.00! The 2″ Flat Super Air Nozzle is more durable than plastic flat nozzles, operates at lower noise levels and produces a powerful blast of compressed air in a laminar sheet.

EXAIR’s Line Vac family

Line Vacs provide a fast, easy way to pneumatically transfer dry materials from one location to another.  They eliminate the need to have personnel manually transferring materials via bag, super sac, or bucket-and-ladder setups.  Doing so reduces worker fatigue and allows conveyance to occur simultaneously with other process operations.

Line Vac removing trimmed scrap from label making application

What kind of an impact can this have?  Here’s a link to a recent blog post where an EXAIR Line Vac saved the end user from having to shut down their conveyor to allow cleaning of spilled material underneath.  And here’s a link to an application using Line Vacs to empty and refill a large tank full of desiccant.  And here’s a link to an application where we customized a Line Vac for conveyance of dog bedding material.  You get the idea…

Depending on application parameters such as bulk density of the material (lbs/ft³ or kg/m³), conveyance height/distance, and required conveyance rate, we can size a Line Vac properly through the support of our Application Engineers who have years of experience working with these products and their implementation into industrial solutions.

The EXAIR Line Vac Promotion – now through October 31st

We’re here to help you find a pneumatic conveyance solution for your application, and earn a free nozzle in the process.  Contact our Application Engineers for assistance today.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Proper Supply Lines are Key to Air Knife Performance

A few weeks back I chatted with a customer on an Air Knife application where they were using our 48″ aluminum Super Air Knife to remove leftover dough from a baking pan. The knife was working somewhat, but they were seeing some residual dough being left in certain areas on the pans due to what they perceived as “weak” airflow. After reading through our catalog and installation guide, they noticed that there were available shim sets that would allow them to increase the gap setting to get more force and flow out of the knife.

Available in lengths from 3″ to 108″ in aluminum, 303ss or 316ss construction

Our aluminum Super Air Knives are shipped from stock with a .002″ shim installed. The optional shim set includes a .001″, .003″ and .004″ shim that would allow you to decrease or increase the performance. By operating the Super Air Knife with the .003″ shim installed, this would increase the force and flow by 1.5 times and using the .004″ shim would double the performance. Sometimes achieving greater force and flow may be required but with the customer saying they were seeing weak airflow, it seemed there may be a restriction on the supply side.

Super Air Knife with Shim Set

I asked the customer how the knife was plumbed and what size supply lines he was using. He advised that they were plumbing air to all 3 inlets on the bottom of the knife but they were using 3/4″ hose with a run of about 30′. I advised the customer that plumbing air to all 3 inlets is required for a 48″ Super Air Knife but we actually recommend 3/4″ Schedule 40 Pipe up to 10′ or 1″ pipe up to 50′. If using hose, he would need to go up a size to maintain a large enough ID to carry the volume required for the unit. In his case, since the length of the supply is close to 30′, he would need to use 1-1/4″ ID hose.

Improper plumbing line size is a common issue we deal with here at EXAIR. Using undersized supply lines can cause excessive pressure drops because they aren’t able to carry the volume of air necessary to properly supply the compressed air device. In this particular application, if the customer were to install either the .003″ or .004″ shim, while keeping his current plumbing size, the performance would actually be worse as now the lines are even more undersized due to the increased air volume requirement from the larger Super Air Knife gap.

If you are looking to change the performance with one of our Air Knives or if you would like to discuss a particular application or product, please contact one of our application engineers for assistance at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

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