Super Air Knife Cools Laminated Packaging Material

I recently worked with one of our distributors on a Super Air Knife application for a manufacturer of flexible packaging material. They create the plastic material that is commonly wrapped around the outside of a wide variety of different containers. The material exits the laminating machine at about 129°F (54°C) and must be cooled to close to room temperature before it is able to be rolled without the material sticking together.

Model 110012, positioned to maximize counter-flow

They performed a test with a Model 110012, recording the temperature after the knife and determined that it would be suitable for them. Prior to using the Super Air Knife, they had been using a series of fans to cool down the material. This worked to some degree, but they had been experiencing quality issues as a result of inadequate levels of cooling and were forced to slow down the laminating machine in order to compensate. By implementing the Super Air Knife, they were able to cool the material down to ambient temperatures without having to slow production. As an added measure, they ordered a second knife to install on the underside to further decrease the temperature of the material.

Graph showing the effectiveness of a Super Air Knife vs. fans or no cooling method.

The laminar airflow of the Super Air Knife is critical to the success of any cooling application. A fan “slaps” the air which provides random spikes of air at moderate velocities. The uniform, high velocity, laminar sheet of air from the Super Air Knife, in addition to the low compressed air consumption, makes it a much more effective cooling method than fans. The design of the Super Air Knife allows it to entrain ambient air at a rate of 40:1, maximizing the force and flow from the knife while keeping compressed air usage to a minimum.

The design of the Super Air Knife allows it to entrain air from the top and bottom, creating a 40:1 air amplification ratio.

Super Air Knives are available in a range of different materials and sizes. From stock EXAIR carries knives from 3”-108” in Aluminum, 303 Stainless Steel, 316 Stainless Steel, and 3”-54” in PVDF (Polyvinylidene Fluoride) for superior resistance to highly corrosive materials. In addition to being an excellent tool for cooling, the Super Air Knife can solve a wide range of drying and blowoff applications. If you have an application that would be better served with one of EXAIR’s Super Air Knives, reach out to us today and get yours on order! We ship same day from stock with orders received by 3:00 pm EST, stop wasting time with ineffective cooling or blowoff methods!

Tyler Daniel
Application Engineer
Twitter: @EXAIR_TD

Super Air Amplifiers vs. Fans – Why are Amplifiers More Effective at Cooling & Drying?

Super Air Amplifier
Super Air Amplifiers entrain ambient air at a rate of 25:1!!

When seeking a suitable solution for cooling or drying your parts, you may be tempted to try out a low-cost fan to get the job done. While fans do a great job of keeping you cool during the warmer months, they’re not the best choice for cooling or drying parts. Have you ever noticed that when standing in front of a fan the flow pattern is not consistent? This is due to the nature in which the fan blades create that air flow by “slapping” the air as they spin rapidly. The air flow that exits from the fan is turbulent and is not as effective as the laminar air flow pattern that is produced by EXAIR’s Super Air Amplifier. The Super Air Amplifier utilizes a patented shim design that maintains a critical position of the air gap and creates a laminar air flow pattern that will exit the outlet of the unit.

fan data2

In addition to providing laminar air flow more conducive for cooling and drying, the Super Air Amplifier provides much more air that can be directed at the target. A standard 2.36” x 2.36” DC operated fan provides anywhere from 12-27 CFM at the outlet, depending on the model. For comparison, a Model 120022 2” Super Air Amplifier will provide 341 SCFM at the outlet when operated at 80 psig. At just 6” away from the outlet, this value increases to 1,023 SCFM!! When compared to the fan outlet air flow, the Super Air Amplifier produces more than an 1,100% increase in air volume!

When replacing a fan with a Super Air Amplifier, the process time can be dramatically reduced. The increase in air volume significantly reduces the contact time that your part will need to be exposed to the air flow, allowing you to increase your line speed and decrease the overall production cost of the part. This is achieved due to the nature in which a Super Air Amplifier draws in air from the ambient environment. At amplification ratios as great as 25:1, the Super Air Amplifier is the best way to move a lot of air volume across the part with very little compressed air supplied to it. Check out the video below for a good representation of the air entrainment of a Super Air Amplifier.

In addition to providing laminar airflow and increasing the volume of air, the Super Air Amplifier is also infinitely adjustable through one of two ways. Each size Super Air Amplifier has a shim set that can be purchased. Swapping out the stock shim for a thinner shim will reduce the compressed air consumption, force, and flow. Installing a thicker shim will increase it. Additionally, the force and flow can also be adjusted by regulating the input supply pressure through the use of a pressure regulator. With sizes ranges from ¾” up to 8”, there’s a Super Air Amplifier for all applications. Give us a call today to see how you can optimize your process by replacing your fans with one or more Super Air Amplifiers.

Tyler Daniel
Application Engineer
Twitter: @EXAIR_TD

Cabinet Cooler Keeps Large Panel Cool Near Steam Exhaust

Stainless cabinet near steam vent

The photo above shows a stainless steel Cabinet at left which has been installed near to a steam exhaust (within 1 meter) in a beverage manufacturing plant.

150 mm diameter fan, lower right side


Inside the panel is a 150 mm diameter fan which is pulling in an air and steam mixture which is causing the temperature inside the cabinet to climb to unacceptable levels. The result is that the motor drives located inside the panel are failing, causing a tremendous cost for replacement and downtime.

Our local distributor worked with the customer to acquire the necessary data for us to calculate heat load within the panel. We determined the customer needed our model HT4880SS-240 Cabinet Cooler System to keep their internal panel temperature at a more reasonable level, year round, even in their worst case scenario with constant steam exhaust in the area.

One key component to success in this application will be removal of the fan and covering of the vent that it once occupied in order to keep the steam from being drawn into the inside of the panel. Historically, fans have been the go to strategy for keeping panels like this cool. However, in this situation, as in many others, the fans pull in un-wanted contamination. There isn’t any filter that can keep steam from getting inside and causing all sorts of problems with condensate forming on internal components, thus promoting corrosion and heat related failures.

The Cabinet Cooler System will provide a filtered, and dry source of cooling airflow which will produce a slight positive purge pressure on the panel to keep such harmful outside atmospheres from entering into the panel. This assures, long life for the panel components and much less hassle and problems associated with heat related failures.

Neal Raker, International Sales Manager

Air Amplifier Provides Cooling for HOT Parts

Hot Cylinders

The five C’s of EXAIR products are Cooling, Cleaning, Conserving, Conveying, and Coating.  All EXAIR products are suitable for applications in these areas, with varying degree of possibility.  When it comes to cooling, one of the most suitable EXAIR products is the Super Air Amplifier.

An Air Amplifier can increase the volume of ambient air directed over an specific area, effectively decreasing the cooling time needed in an application.  Air Amplifiers cool effectively due to the fundamental principles of convective heat transfer.  In convective heat transfer, cooling capacity can be increased by increasing the temperature differential between the cooling medium and the object to be cooled, or by increasing the flow of the cooling medium.

An Air Amplifier is the best cooling choice when the material to be cooled is at an extremely high temperature.  For example, in the application above, 903°C (1650°F) cylinders need to be cooled to ambient temperature as quickly as possible. Vortex Tubes are another product our customers consider for cooling applications. Vortex Tubes are the best choice when the area to be cooled is small and the temperature differential is not as large. A Vortex Tube based solution will provide very cold air, but at a lower air flow over a small area and they were not the best choice for the application in the image above.

In the same application, a Super Air Amplifier can provide large volumes of ambient air over a large area, effectively cooling the cylinders much more efficiently.  The cooling can be achieved in less time, and with maximum efficiency of compressed air implementation. Air Amplifiers also offer great benefits over electric fans in this rough environment: they can withstand higher temperatures and there are no moving parts to wear or break.

If you have an application in need of efficient cooling, contact an EXAIR Application Engineer to find out if an Air Amplifier will work for you.

Lee Evans
Application Engineer