Proper Compressed Air Supply Plumbing Equals Success

EXAIR manufactures and stocks Super Air Knives in lengths ranging from 3”-108”. They’re designed to dramatically reduce compressed air usage when compared to similar blowoffs while still maximizing both force and flow. With an air entrainment ratio of 40:1, it’s the ideal solution for a variety of applications that necessitate a wide, laminar sheet of high velocity airflow.

I recently worked with a customer who makes wooden pallets. They were using a Model 110048 48” Super Air Knife to remove sawdust from the pallets prior to stacking them. When the grooves are cut into the pallet to accommodate the forks from a forklift or pallet-jack, there’s a good amount of sawdust that remains on the pallet. They would prefer to not have sawdust all over the finished pallets that they send to customers, so they looked towards a Super Air Knife to provide a curtain of air capable of removing that sawdust just prior to stacking them.

They purchased the Model 110048, but after installing it they didn’t get the level of force they had been hoping for. After some initial discussions, we identified that the issue lied with the plumbing of the air supplied to the knife. A 48” Super Air Knife will need to be fed with compressed air to (3) of the ¼ NPT air inlets. This ensures that an adequate volume of air is fed to the full length of the knife, keeping a consistent airflow.

Not only had they been plumbing compressed air to just (1) air inlet, but they were also using a restrictive quick-disconnect fitting. The I.D. of a quick connect fitting restricts the overall volume of air that can be passed through it. Length of the pipe or hose is also critical as the diameter of the pipe will need to be larger for longer runs or greater volumes. Accompanying any Super Air Knife is our Installation & Maintenance Guide which outlines the necessary requirements for each available length that we have available as well as how many air inlets need to be supplied with compressed air.

SAK pipe sizing

To confirm that air supply was the issue, they installed a pressure gauge directly at the air inlet to the knife. Line pressure was around 90 PSIG, but when they opened the valve and supplied air to the knife the pressure gauge dropped all the way to 35 PSIG. We’ve talked about pressure drop before here on the EXAIR Blog, the only way to confirm this is to take a pressure reading directly at the air inlet.

They removed the quick disconnect fitting, increased to a 1/2″ supply hose in place of 1/4″, and plumbed compressed air to each end and the center air inlet. On all Super Air Knives, compressed air inlets are available on either end as well as on the bottom. After fixing their plumbing, they noticed a dramatic increase in both force and flow and the pressure directly at the air inlet increased to 85 PSIG. The sawdust was easily blown off of the pallets and the customer was pleased that their pallets were free of sawdust.

sak pallet

At EXAIR, we stand by our products with the Unconditional 30 Day Guarantee. If you’ve just purchased a new product and aren’t seeing the results that you were hoping for give us a call. Our highly-trained team of Application Engineers is ready and standing by to investigate the application and provide support to help make sure you’re getting the most out of our products. Most of the times the solution is simple, but we won’t be satisfied until we find a resolution!

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

EXAIR’s Super Air Knife Removes Moisture From Plastic Bottles Prior to Labeling

EXAIR’s Super Air Knife is THE best solution for compressed air blowoff operations that require a wide sheet of compressed air. We’ve been manufacturing Air Knives for over 35 years, with the Super Air Knife making its first appearance back in 1997. Since then, the Super Air Knife has undergone a few enhancements over the years as we’re constantly trying to not only introduce new products but also improve on the ones we have. We’ve added new materials, longer single piece knives, as well as additional accessories. But, by and large, the basic design has remained the same. As the saying goes: “If it ain’t broke, don’t fix it!”.

The Super Air Knife utilizes a source of compressed air to create a laminar sheet of high velocity air. This supplied compressed air mixes with ambient air that is entrained into the primary airstream. The Super Air Knife entrains ambient air at a rate of 40:1, making it VERY effective in a variety of drying, cleaning, and cooling applications. Available in lengths ranging from 3”-108” and in a variety of different materials of construction, there’s a Super Air Knife available for just about any application.

Any time you have product moving along a conveyor that needs to be cleaned, dried, or cooled off, a Super Air Knife is the ideal fit. I recently worked with our Argentinian Distributor on an application involving drying off plastic bottles just prior to applying a label to the outside. After the bottles are molded, they go through a washing operation to remove contaminants from the inside and outside of the bottles before they’re filled. After filling, a label must be applied to the outside of the bottle. Before installation of the Super Air Knives, they were allowing the bottles to air dry. As they moved along the conveyor, most of the residual water did come off and wasn’t causing any issues.

SAK and Mounting System

They were looking to increase production rates so that they could keep up with demand, however when they increased the speed of the conveyor there was still a good amount of residual water remaining on the bottles. This prevents the label from adhering properly to the outside of the bottle. Not only did this result in an added step to inspect the bottles, but those that weren’t labeled properly had to have the label removed and cleaned off before a new one could be put on. This actually ended up being less productive than just running the conveyor at a slower speed.

They came across the EXAIR Super Air Knife and decided to try (2) 110036 aluminum Super Air Knives to remove excess moisture just prior to labeling. The plant handles a wide variety of different sized bottles, so they also utilized the Universal Mounting System so that they could easily adjust the positioning of the knife based on the job. With the Super Air Knives in place, they were able to effectively run the operation nearly 20% faster without any problems.

With the quiet and efficient Super Air Knives in place, they were able to increase production rates in order to fulfill their orders on time. If there’s an application in your facility that could necessitate the use of an EXAIR Super Air Knife, give us a call. With 16 different lengths available from stock in 4 different materials, same day shipping with orders placed by 3:00 ET, AND our unconditional 30 day guarantee, there’s no excuse not to give one a try!

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

Air Entrainment & EXAIR’s Intelligent Compressed Air Products

Air entrainment is a term that we bring up quite often here at EXAIR. It’s this concept that allows many of our products to dramatically reduce compressed air consumption. The energy costs associated with producing compressed air make it an expensive utility for manufacturers. Utilizing engineered compressed air products that will entrain ambient air from the environment allow you to reduce the compressed air consumption without sacrificing force or flow.

Entrainment
EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

Products such as the Super Air Knife, Super Air Nozzle, Air Amplifier, and Super Air Wipe all take advantage of “free” air that is entrained into the primary supplied airstream. This air entrainment occurs due to what is known as the Coanda effect. Named after renowned Romanian physicist, Henri Coanda, the Coanda effect is used in the design of airplane wings to produce lift. As air comes across the convex surface on the top, it slows down creating a higher pressure on the underside of the wing. This creates lift and is what allows an airplane to fly.

nozzle_anim_twit800x320
EXAIR Super Air Nozzle entrainment

This is also the same principle which is allowing us to entrain ambient air. As the compressed air is ejected through a small orifice, a low-pressure area is created that draws in additional air. Our products are engineered to maximize this entrained air, creating greater force and flow without additional compressed air. Super Air Amplifiers and Super Air Nozzles are capable of up to a 25:1 air entrainment ratio, with just 1 part being the supplied air and up to 25 times entrained air for free!! The greatest air entrainment is achieved with the Super Air Knife at an incredible ratio of 40:1!

This air entrainment principle allows you to utilize any of these products efficiently for a wide variety of cooling, drying, cleaning, or general blowoff applications. In addition to reducing your compressed air consumption, replacing inefficient devices with engineered products will also dramatically lower your sound level in the plant. Sound level in some applications can even be reduced down to a point that would eliminate the need for hearing protection with the OSHA maximum allowable exposure limits set at 90 dBA for an 8-hour shift.

If you have inefficient blowoff devices in your facility, give us a call. An Application Engineer will be happy to help you select a product that will “quietly” reduce your compressed air consumption!

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