Eliminate Static from Many Applications Using Super Ion Air Knives

By combining an Ionizing Bar with a Super Air Knife, the Super Ion Air Knife provides rapid static elimination AND blow off of any dust, chips, or debris that was being held to a surface by static electricity.  The laminar curtain of ionized air not only maximizes the rate of static removal, but is also ideal for stripping/sweeping away any debris which leaves a clean, static-free surface.  No more jamming, tearing, nuisance shocks to operators, dust attraction, or any of the many problems associated with static electricity.

The ionized air flow can be precisely regulated to whatever level it takes to get the job done.  At 100psig, the powerful, high velocity blast will dissipate 5,000 volts of static charge in 0.18 seconds!  If the material is fragile, or if that kind of air flow might disrupt the process, it’s not a big deal…even at 5psig supply pressure, that same 5,000 volts is dissipated in 0.40 seconds.  That’s how it works on the plastic roll above – with just a whisper of ionized air flow from a Super Ion Air Knife, they consistently reduce the resultant static charge to less than 400 volts…far below the threshold for the nuisance shocks they wanted to avoid.

Gen4 Super Ion Air Knife Performance

They’re on the shelf in lengths from 3 inches to 9 feet long, and we can make custom lengths in three days after receipt of an order.  The 115/230VAC Power Supplies are available with 2 or 4 outlets, to energize from 1 to 4 EXAIR GEN4 Static Eliminators.

Versatile. Efficient. Effective. Quiet. Safe.  And, readily available.  If you’d like to discuss a static problem, give us a call.

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS

EXAIR’s Static Eliminator Variety Provides Solutions for Any Industry

As the weather starts to change and the colder dryer months are upon us, static electricity can become a real nuisance.  Machines will start jamming, alignments will be difficult, dirt will collect to surfaces, and hazardous sparks can shock personnel.  EXAIR manufactures a line of Gen4 Static Eliminators, also called ionizers, to remove these nuisances.

Static is generated from non-conductive surfaces being “rubbed”.  This could be caused from going over rollers on a conveyor, stacking product onto each other, sheet feeding, and even peeling away a backing material.  When a non-conductive surface, or insulator, is moved or separated, electrons are “stripped” and redistribute into different areas on the surface.  Static charges are typically measured in kilovolts (KV), or 1,000 volts, and they can be either positive or negative in nature.

The higher the charge, the stronger the static force.  At a 10 KV static charge, a spark can jump one inch (25 mm) from the surface.   You probably felt that shock when working with plastic or non-conductive materials.  EXAIR has a Digital Static Meter to measure the amount of static voltage on a surface.  It is a great tool for finding problem areas in your process as well as determining the effectiveness of the treatment.

Static is dynamic.  The more you rub or move the material, the higher the static charges can form.  Static can also regenerate itself after the charges have been removed.  With higher static charges, the attraction force to other materials is much stronger.  This attraction could be to other products, dust, lint, and even you.  An undesirable effect of static can be seen with dirty surfaces, tearing, alignment, jamming and shock to personnel.  The EXAIR Gen4 Static Eliminators are engineered to remove both negative and positive static charges in an assortment of designs to best fit the application.

EXAIR manufactures nine different products, including Static Eliminators with air assistance to reach farther distances or Static Eliminators without air when surfaces could be disrupted by air flow. The newest product, the Intellistat™ Ion Air Gun is engineered for clean processes, laboratory and test environments.

The Gen4 ionizers are powered by a 5,000 Vac power supply.  The alternating current, AC, will create both negative ions and positive ions.  No matter the kind of static charge is on the surface, the Gen4 Static Eliminators will be able to remove it.  The power supplies come in either a 2 port or 4 port design; so, you can power multiple Gen4 Static Eliminators with one power supply.  The input power is selectable from either 115Vac or 230Vac in both 50/60 hz. An armored and electromagnetic shielded cable connects the power supply to the ionizer in a single wire design. This will help to protect the cable from abrasions, cuts and splits in industrial areas.

The Intellistat Ion Air Gun is powered with a 24Vdc power supply. The Gen4 Static Eliminators and the Intellistat Ion Air Gun have a shockless design, and they are UL Component Recognized and CE compliant.  I will give a brief description of each product that utilizes this rugged design for optimal static neutralization.

Gen4 Static Eliminators with Air:

Super Ion Air Knife

  1. 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.  The laminar flow allows for a quick static discharge in fast conveyance speeds.  They can also remove static from surfaces up to 20 feet (6.1 meters) away.  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.
  2. Gen4 Standard Ion Air Knife: Similar to the Gen4 Super Ion Air Knife, this product has a good compressed air efficiency.  It utilizes the Coanda effect to draw in ambient air at a 30:1 amplification ratio.  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
  3. 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 pipe, 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 static decay for speedy transfers.

    Gen4 Ion Air Cannon
  4. 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 from 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
  5. 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 from “shock” zones.  The Ion Air Guns work great for small batch processes used for quality checks or label applications.

    Ion Air Jet
  6. 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 surface.  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.
  7.  Intellistat™ Ion Air Gun: This is EXAIR’s newest product that is a lightweight solution for static and particle removal.  The patent-pending air gun comes complete with a 24Vdc power supply and a 6mm compressed air tubing.  There is a red and green LED lights to signify the production of ionized air for visual feedback.  The engineered air nozzles are quiet and OSHA safe.  The emitter point inside that creates the ions can be easily changed for replacement.  The applications range from circuit boards, electronic manufacturing, laboratories, clean rooms, and scientific testing.

The Gen4 Static Eliminators with air can be purchased with kits which will include the power supply (required for ionization), a filter (to clean contamination from the compressed air), and a regulator (to control the blowing force).  In the spirit of compressed air efficiency, EXAIR also offers the Electronic Flow Control, EFC, that uses a photoelectric sensor to turn on the air flow only when the product is under the Static Eliminator.

Gen4 Static Eliminators without Air:

Ionizing Bar
Low cost Ionizing Bars eliminate static cling.

  1. Gen4 Ionizing Bar: This rugged design is for industrial use to remove static cling from flat surfaces. They range from a length of 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 shockless and works well in applications where blowing air could be a detriment for the process.  This would include screen printing, labeling, and large printing process.

    Gen4 Ionizing Points
  2. Gen4 Ionizing Point: This single point design is manufactured to remove static on small targets in tight spots.  Utilizing the same rugged design of the Gen4 Static Eliminators, this product can remove static in spot areas and help to stop jams in slitting operations. They can also be panel mounted to neutralize duct air.

If you find that static is creating process problems, wasting time, and costing you money, EXAIR has a large line of Static Eliminators that can help you.  For our U.S. and Canadian customers, we are offering a promotion for online orders for a limited time.  You will receive an AC Sensor, a $59.00 value, for free as a Promotional item from now until the end of March 2021 with a qualified purchase.  How can you not give them a try?  If you have an application, you can contact an Application Engineer at EXAIR to help select the correct model and remove that static nuisance.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Happy Holidays from EXAIR!

It’s currently… the most wonderful time of the year.

Though 2020 has undoubtedly been a challenging year, it’s times like the holiday season that remind us why we persevere. Gifts, random acts of kindness, cherishing loved ones… the season brings a unmistakable air of hope and good will towards each other. Though this holiday season we may not be able to celebrate it the way we have in past years, we continue to make the best of our individual situations and remain grateful for the chance to spread cheer and put a smile on someone’s face.

The holidays are a joyous time here at EXAIR, in large part because the values of this season coincide seamlessly with EXAIR’s. Giving back, kindness, and gratitude… are just a few of the things we love to celebrate here at EXAIR. So as much as we know you love hearing about quality manufacturing solutions, we thought we’d give our readers a bit of what is bringing us that holiday cheer this season.

After much deliberation, countless hours of focus groups, and spirited debates laden with power point presentations and hired attorneys… we present a playlist of the tunes that our making us smile today. And if your favorite didn’t make the list, leave us a comment and tell us what songs are filling your heart this holiday.

EXAIR Holiday Playlist

  1. Mel Torme– Sleigh Ride
    https://youtu.be/tq9Ya3uD-e8
  2. Run DMC– Christmas in Hollis
    https://youtu.be/L4NKwiXGiUQ
  3. Johnny Mathis– Winter Wonderland
    https://youtu.be/DJTmadAABkI
  4. Brenda Lee– Rockin Around the Christmas Tree
    https://youtu.be/1qYz7rfgLWE
  5. Bobby Helms– Jingle Bell Rock
    https://youtu.be/itcMLwMEeMQ
  6. Chuck Berry– Run Run Rudolph
    https://youtu.be/YiadNVhaGwk
  7. Nat King Cole– The Christmas Song
    https://youtu.be/hwacxSnc4tI
  8. José Feliciano – Feliz Navidad
    https://www.youtube.com/watch?v=N8NcQzMQN_U
  9. Wham– Last Christmas
    https://youtu.be/-YUH8Xfz-jg
  10. Frank Sinatra– Have Yourself A Merry Little Christmas
    https://youtu.be/pvA7-EjaSPI
  11. The Jackson 5– Santa Claus Is Coming to Town
    https://youtu.be/nYmPZrvThW8
  12. The Drifters– White Christmas
    https://youtu.be/GfZPtkqXQIA

We hope you all enjoy the music, and continue celebrating season the best you can. Wishing everyone a very happy holidays from the team here at EXAIR.

Jason Fox
Marketing- Holiday Music Connoisseur
E-mail: JasonFox@EXAIR.com
Twitter: @EXAIR_JF

Better Understand Your Blowoff Process with EXAIR’s FREE Efficiency Lab

panoramic view
The EXAIR Efficiency Lab

Many customers may not have the means to test the air consumption of their blowoff solutions. With compressed air being the most expensive utility in a manufacturing facility, it’s important to identify places where you can save money on your overall operating costs. EXAIR manufacturers a wide variety of products intended to help you reduce your compressed air usage. If you’re not able to accurately measure the consumption in your own shop, we invite you to send the products into EXAIR for testing. With EXAIR’s Award Winning Efficiency Lab, just simply contact an Application Engineer, box them up and send them to our warehouse in Cincinnati, Ohio.

EXAIR Efficiency Lab

Once we receive it, our engineers will complete some in-depth testing to determine the compressed air consumption, sound level, and force that your current solution provides. With this information, we’ll be able to compare it to an EXAIR Engineered Solution. This way we ensure that you receive the best, safest solution possible also capable of saving money through reduced air consumption and improved efficiency.  We’ll send you back a comprehensive report that’ll help you to make the best decision for your company.

I’ve been recently working with a customer that sent in one of the nozzles they’re using across all their CNC machines. They wanted us to test it out and see if we’re able to offer them something that could reduce their overall compressed air usage. The nozzle was one of the cheap plastic varieties and was attached to a commonly used modular hose. This type of modular hose is not designed for operating under high pressures. These hoses are more suitable for liquid coolant or air that is at or below atmospheric pressure.

IMG_7486
Inefficient and unsafe plastic nozzle

After testing, we found that at 80 psig the nozzle consumed 3.85 SCFM and produced a force of 1.92 oz. We also noticed that after 60 psig, the nozzle began to leak due to a poor seal where the nozzle met the brass hex. The EXAIR nozzle most suitable to replace this was the 1108SS. At just 2.5 SCFM at 80 psig, replacing the plastic nozzle with an engineered solution saves them 35% of their overall consumption for this blowoff. With close to 1000 of these nozzles in operation, that adds up quickly!!

In addition to increasing efficiency, replacing these nozzles also greatly increases overall worker safety. The sound level is reduced from 73 dBA to just 58 dBA and EXAIR’s nozzles also adhere to OSHA 1910.242(b). The plastic nozzles could be dead-ended, posing a hazard that can result in costly fines. These fines are assessed per infraction, so having multiple non-compliant nozzles can easily get very expensive if you’re subject to an unannounced visit by an OSHA inspector.

If you think you may have an opportunity to improve upon your existing blowoff methods, give us a call. We’ll be happy to take a closer look and have you send the product back to EXAIR for a quick trial in our Efficiency Lab. You’ll be glad you did!

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