Light Duty Line Vac For Paper Trim Removal

Today I worked with a customer that manufactures a wide variety of material handling equipment including coil unwinders.  The engineer was calling because there was a special project for a coil unwinder that could handle a waste piece of paper trim.  As the metal coil is being unwound for delivery to a metal processing machine, the protective paper is pulled off and was to be collected into a waste receptacle for easy handling and disposal/recycling.  The engineer was hoping to replicate an existing system that used a hybrid blower system, with an extra compressed air nozzle, but in a simpler form.

Coil Unwinder

We proposed the use of the 4″ Light Duty Line Vac– shown below.130400The Light Duty Line Vacs offer an effective way to convey small and light materials a short distance. Like the standard Line Vac, the Light Duty Line Vac converts an ordinary hose or tube into a  conveyor for scrap, trim, and bulk materials.

When the process involves moving low volumes of materials over short distances, the Light Duty Line Vac is a great choice. The simplified (2) piece design offers effective conveying at a lower cost. As an added plus, the compressed air consumption is lowered to levels commensurate with handling the lighter materials, at lower volumes and short distances.  Using a pressure regulator to control the supply air allows for tuning of the transfer rate, and keeps air usage to the minimum amount needed.

The Light Duty Line Vacs are available with inlet/outlet diameters from 3/4″ up to 6″.  With no moving parts, maintenance free operation is assured.

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Light Duty Line Vacs – Available in 3/4″, 1″, 1.25″, 1.5″, 2″, 3″, 4″ and 6″ Diameters. All in Stock!

For other larger materials, higher transfer rates, corrosive environments, or abrasive materials, take a look at the other EXAIR Line Vac offerings including the aluminum, 303 and 316 stainless standard Line Vacs, the aluminum, 303 and 316 stainless steel Threaded Line Vacs, high temperature models, standard and threaded Heavy Duty Line Vacs, and lastly the new Sanitary Flanged 316 stainless steel type.

If you would like to talk about Light Duty Line Vacs or any of the EXAIR Intelligent Compressed Air® Products, 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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When Efficiency And Practicality Collide

Even if you’re a casual reader of our blogs, you already know that EXAIR Application Engineers LOVE to preach efficiency in the use of compressed air…it’s our “bread and butter;” the very nature of our business. This year, we’re celebrating thirty-five years of leading the way in the development of efficient, safe, and quiet compressed air products. Our track record of success as a solutions provider across a diverse range of industrial and commercial applications is well documented in our blogs, as well as Knowledge Base and Case Study Libraries.  We devote considerable resources (engineering, research & development, product testing, etc.) to making certain that EXAIR Intelligent Compressed Air Products cost less to operate, and perform better, than whatever you’re using right now.

Strange as it may seem, though, sometimes our products are EXTREMELY popular in cases where they INCREASE a facility’s consumption of compressed air…by replacing something that DOESN’T use compressed air at all:

*I’ve written before about how our Large Maximum Cold Temperature Vortex Tubes have replaced liquid nitrogen rigs in freeze sealing operations.  Now, a Vortex Tube directs a portion of its air supply to (usually) unusable hot exhaust, in order to generate the usable flow of cold air.  When compared to the costs of liquid nitrogen and the resources involved to get it where it needs to be, though, the cost of the compressed air needed to operate the Vortex Tube is indeed the practical solution.

A 1/4 ton of refrigeration from a product that fits in the palm of your hand, and all you need is a supply or compressed air!

*Line Vacs are probably THE prime example of the value of using compressed air where it wasn’t used before…replacing a “bucket and ladder” operation:

Straight from our Catalog, a perfect example of using valuable compressed air to save even more valuable resources.

*Then there are the situations that just come down to time.  In large spaces, our Super Blast Safety Air Guns can be used to “sweep” the floor in a fraction of the time it takes an operator with a push broom.

Super Blast Safety Air Gun makes short work of large area cleanup.

To make a long story just a little bit longer…if you’re using compressed air, you can use it better with EXAIR’s engineered compressed air products.  And there are plenty of practical applications where you’re not using compressed air right now too.  If you’d like to find out more about either one, give me a call.

Russ Bowman
Application Engineer
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Line Vac – Air Operated Conveyors

Convey parts, materials, and waste – with no moving parts!

The Line Vac is a fast, low cost way to convey pellets, scrap trim, textiles, bulk solids, food products, chips, and much more.  Simply connect to a standard hose, tube, or pipe and a powerful in-line conveyor is created.

Available in (4) materials – aluminum, 303 and 316 stainless steels, and a special hardened alloy, and (3) end connection types – NPT threaded, smooth bore, and the new sanitary flanged. Sizes range from 3/8″ up to a 6″. It is certain that an available Line Vac option will meet your process criteria.

For lighter materials and short conveyance distances, the Light Duty model is ideal, and for the most abrasive and heaviest materials over longer distances, the Heavy Duty style is available.

The Line Vacs offer many safety benefits, including eliminating the dangers of lifting heavy sacks and climbing ladders to fill hoppers, and with the 316 stainless steel sanitary flanged Line Vacs, food materials are kept enclosed and and separated and provides ease of cleaning.

Check out the video by clicking the photo below

Capture

The Line Vac works by having a small amount of compressed air injected through directed nozzles to produce a vacuum on one end and high output air flow on the other, with instantaneous response.  By using a pressure regulator, available as part of a kit or separately, the flow of the material transfer can be easily controlled. No moving parts or electricity assures maintenance free operation!

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Trim Scrap Removal

Conveyance rates are determined by the material bulk density, typical particle size, total distance of conveyance, including vertical rise, and the targeted transfer rate.  An EXAIR Application Engineer can assist you, and with the above information, recommend the right size and type of Line Vac to meet the desired results.

All catalog models are in stock and we ship same day with an order received by 3 pm EDT in the US and 2 pm EDT for orders shipping to Canada.

Our team of engineers can design a special Line Vac to meet many applications special requirements, from special materials such as PVC and PVDF to special end connections such as pipe flanges and barbed hose connections.  Let us know the special requirements of your process and we’ll design a solution.

Special Flanged LV
This special 3/4″ Line Vac was designed to evacuate fumes from a silicone wafer etching operation

To go with the Line Vac, we can provide a reinforced, heavy wall, clear PVC conveyance hose in lengths up to 50′.  Additionally, the Line Vac Drum Cover is a fine mesh, non-woven cover built to fit on the top of a 30 or 55 gallon drum.  It is designed to contain the material to the drum and allow the air from the Line Vac to escape.

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Drum Cover, for 30 and 55 Gallon Drums

If you have questions regarding the Line Vac, 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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Don’t Throw the Baby Out With The Bath Water – and How it Applies to Manufacturing

There are many curious sayings from history that are still part of our vernacular, and whose origins are debated.  Examples are ‘Spill the Beans’ and ‘Bite the Bullet.’  One of my first supervisors liked to use the expression ‘Don’t throw the baby out with the bath water.’  Initially, I didn’t quite understand what was meant by this, and then wasn’t sure it was relevant in some instances.  Fast forward many years, I hadn’t thought too much about it, but for some reason, the phrase recently came back into my thinking.

Today the phrase generally means not to get rid of something good when getting rid of something bad (when throwing out the dirty bath water, you don’t want to throw out the baby, too!)  As I look back to the supervisor that used it, it was for situations where the solution was within grasp, but due to recent shortcomings it may seemed out of reach. Scrapping the whole thing (the baby and the bathwater) and trying something new would not be the favorable way to proceed.

I remembered this phrase when recently a customer called in about the 3″ Line Vac they were using.  It was performing OK, but just was’t doing what they had hoped. They asked if it was still returnable under the 30 day guarantee (it was) and how to start the return process.

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EXAIR Line Vac Family

While we aim to make the return procedure simple and efficient, we will most likely ask a few questions.  We’ll ask ‘what are trying to do?’  ‘Can you send in any photos of the installation’ (we solve lots of issues by seeing something that can be easily remedied) and certainly we will ask ‘about the compressed air supply.’ In the recent customer call, the customer was trying to convey dog food, a distance of 25′ vertical and 18′ horizontal –  a fairly challenging distance, but not impossible.  A photo could be sent in if needed and then the discussion turned to the compressed air supply.  It was determined that the compressed air supply line was undersized for the 68.5 SCFM of 80 PSIG compressed air needed to for the Line Vac to operate to its full capability.  We reviewed the Installation and Maintenance Guide and suggested the proper pipe and air hose sizing for this installation. Armed with this new knowledge, the customer set about to modify the installation.

I got an email later that day from the customer.  Results were dramatically improved! Average of first measured trials yielded 50 lbs of material in 46 seconds, one of the fastest conveyance rates recorded for those types of distances. Customer was pleased and was looking forward to keeping the unit and getting the benefit that was expected.

In this case, the baby was not thrown out with the bath water.

To discuss your application and how an EXAIR Intelligent Compressed Air Product can be a benefit at your facility, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Light Duty Line Vac For Part Rejection

Today I worked with a long standing customer that was interested in using the Line Vac technology to provide a method for part rejection.  The parts come out of a bin and travel to the next station for final assembly.  There is an accept/reject analysis system along the way, and it was decided that the Line Vac would offer an easy way to remove the part from the conveyor and transport it to a reject bin.

The parts are very small, with 0.093″ to 0.187″ OD and 0.178″ to 0.335″ lengths.  Part weights were 0.27 grams or less, so a very small and light weight item.  Maximum part processing was estimated at less than 6 parts per minute, so low speed and low transfer rates apply.  The final piece of information was the distance for conveyance, and here it was only a few inches up and then 4′ over to the reject bin.

Based on all the information about the parts, the process and the transfer distance, it was determined that the 3/4″ Light Duty Line Vac would be an ideal choice for the application. The unit is available as part of the  model 132075 Light Duty Line Vac Kit, which includes a Automatic Drain Filter Separator and a Pressure Regulator.  The Pressure Regulator is especially important in this application, as it will allow for pressure adjustment to provide the best performance while keeping the compressed air usage to a minimum.

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The EXAIR Family of Line Vacs

 

EXAIR manufactures 3 styles of Line Vac- Light Duty, Standard, and Heavy Duty with either smooth bore hose or NPT threaded ends.  They are offered in 4 types of materials- Aluminum, Type 303 and Type 316 Stainless Steel, and a hardened alloy construction. An important factor in material selection is the abrasiveness of the material to be conveyed.

To discuss your application and how an EXAIR Intelligent Compressed Air Product can help your process, 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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Creative Uses for the Line Vac Air Operated Conveyors

Last week a customer called in looking for some help in solving a minor issue in the plant. The customer is a specialist in the filament winding business making all types of products from many types of fibers, such as Polyester, Nylon, Nomex®, PTFE and Kevlar®.

At the end of a run, there will be a small amount of thread left on several bobbins.   There is not enough thread to save for a future run, and so the customer has to strip the remaining thread off, to be able to reuse the bobbin.

I remembered that an EXAIR Application Engineer had done some testing on thread, using a Line Vac to pull and unwind a spool. See here for that demonstration.

The customer sent me the below photo, helping us to visualize the application better, and then went even further by shipping a couple of sample bobbins with some thread still remaining.

After running a few tests, it was determined that the smallest Line Vac available , the model 6078 – 3/8″ Aluminum Line Vac, produced the fastest results due to the narrow throat diameter in conjunction with the thin thread.  A brief demonstration of the test can be found below.

Using just 5.6 SCFM at 80 PSIG of compressed air, the Line Vac quickly unwound the bobbin, providing a simple, cost-effective way to automate what had been a tedious manual process.

The Line Vac conveyor are ideal for moving large volumes of material over long distances, using a small amount of compressed air. The material flow rate is easily controlled by use of a pressure regulator.  No moving parts or electricity assures maintenance free operation.  EXAIR offers the Line Vac in sizes from 3/8″ up to 5″ in diameter, in materials including aluminum, Type 303 and Type 316 Stainless Steels, and a Heavy Duty model with hardened alloy construction.

To discuss your application and how a Line Vac or another EXAIR Intelligent Compressed Air Product can help your process, feel free to contact EXAIR and one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Heavy Duty Line Vac is a Simple Solution When Mechanical Conveyors Fail

 

Line Vacs can convey many things.
Line Vacs can convey many things.

 

A manufacturing plant had a machine that would process 6mm ceramic beads into small medical components.  They used a screw type conveyor to move the ceramic beads from a large container into a hopper above the machine.  In this situation, the customer called EXAIR prior to determining which mechanical component failed.  They contacted the conveyor manufacturer for assistance.  Because of the complexity of the conveying system, it would take time to evaluate.  They had to determine if it was the motor, the gear box, the shaft, or electrical system.  Depending on which item that failed, there was a good chance that it would not be in stock.  With this length of downtime, it would cost the company much money and delays in shipments. The operation had to be shut down until they could find a way to keep the hopper filled with ceramic beads.  Being that they were under the gun, they contacted EXAIR to see if we could help.

Heavy Duty Line Vac

Heavy Duty Line Vac

In discussing their layout, the hopper was 10 feet away from the supply container, and the opening of the hopper was 10 feet above the floor.  These lengths were well within the limits of the EXAIR Air Operated Conveyors.  I suggested the model 152200 Heavy Duty Line Vac Kit.  This unit has the highest conveyance rate, and it can move items in the range of plastic pellets to steel shot.  It does not have any moving parts, so it makes it very simple, reliable, and long lasting.  The Heavy Duty Line Vac is made of a hardened steel that makes it very resistant to abrasion.  The next question he asked was if we had it in stock.   We did!!!  EXAIR stocks every cataloged model number for same day shipping with orders placed before 3 p.m. EST.  We were able to ship the Heavy Duty Line Vac that same day to get his operation back up and running.  He did mention to me afterwards that he wished he had at least one Heavy Duty Line Vac on his shelf as a backup system.  It could have saved his company an entire day of downtime.

If your company relies on mechanical conveying systems to move product, you may want to have an EXAIR Air Operated Conveyor on hand just in case of an emergency.  When things go wrong, you do not want to be down any longer than needed.  If you need help in sizing the correct Line Vac for your application, you can contact an Application Engineers at EXAIR.

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