Tag: industrial air curtain

Compressed Air Use In The Agriculture Industry

Published on by Russ BowmanLeave a comment

I didn’t grow up ON a farm, but more than a few of the kids I went to school with did. My wife’s grandpa had a farm, and one of her uncles still does. Farmers have always been the most diversely talented people I’ve ever known. They’re well versed in soil chemistry and plant biology. They have a keen understanding of climate & weather patterns which allows them to sow seed after the last frost in early spring, and gather their last harvest before the first frost of mid-to-late autumn. Most of them are also expert mechanics, welders, and plumbers as well, to avoid costly repair bills on equipment they operate in fairly harsh conditions. And the ones that raised livestock, I’d stack their veterinary knowledge & skills up against just about any vet’s office.

In my twelve years with EXAIR, I’ve had the pleasure of talking with many farmers & other folks in agricultural-type jobs, and a lot of the stuff they use our products for is downright fascinating. Here are two prime examples – one from an agricultural product provider, and one from an actual agricultural job:

*A company that makes irrigation drain pipe uses Model 2485 5″ Standard Air Wipe Kits to cool and dry their extruded 4″ pipe before cutting to length & packaging it for shipment. This replaced a blower operated setup that didn’t completely dry the corrugated outside diameter. The Air Wipe not only blew off almost all the water, all the time, but also allowed them to increase production speed by nearly 10%.

The turbulent air flow from the blower system (left) really just beats on the extruded surface, while the laminar flow of the EXAIR Super Air Wipe (right) strips & sweeps the surface clean & dry.

*Once fruit & vegetables are harvested, most of them go through some sort of cleaning process. EXAIR Super Air Knives are commonly used in conjunction with those processes. Sometimes they’re blowing loose dirt from, say, onions or potatoes, so they don’t turn the wash water into a mud bath. They’re also used to blow the wash & rinse water off, so they’re as dry as possible before packaging or processing. One particular customer uses Super Air Knives for the latter. By replacing blowers with a Model 110236SS 36″ Stainless Steel Super Air Knife Kit to dry freshly washed potatoes, they were able to increase the speed of conveyance…the laminar flow from the engineered Air Knife was better at blowing off the potatoes than the turbulent flow from the blower. Also, since the temperature of the Air Knife’s flow is the same as ambient temperature (because they entrain air from their surrounding at a rate of 40:1 to their compressed air consumption), this extended the time before spoilage. The warmer air from the blower (caused by friction in the rotating elements) was fostering the bacterial growth that leads to spoilage.

Increased potato production + longer shelf life = win/win.

Engineered compressed air products are widely used in agriculture (and, of course, many other industries) for their simplicity, durability, and reliability. If you’d like to find out how EXAIR products can make your life (or at least your job) easier, give me a call.

Russ Bowman, CCASS

Application Engineer
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Combining Products For Total Blow Off Of Objects With Complex Geometry

Published on by Russ BowmanLeave a comment

EXAIR Super Air Knives are extremely efficient at blowing off flat surfaces. The laminar air flow they generate makes a stripping/sweeping action, as opposed to the turbulent flow from a non-engineered blow off, which really just beats on the surface. If the object being blown off, though, has features such as holes, recesses, grooves, bosses, “nooks & crannies”, etc., it may be challenging to get those features 100% blown off, 100% of the time.

If the object you’re blowing off is flat, the laminar air flow from a Super Air Knife is ideal. They come in lengths from 3 inches to 9 feet long.

Depending on the size & shape of the feature presenting the challenge, the first thing we might recommend is to adjust the angle at which the Air Knife’s flow contacts the surface. For most applications, you can optimize performance by blowing at as low of an angle as practical. You may need to aim the Air Knife at a steeper angle, for example, if you’re blowing off something that’s dense (like shot blast or garnet, as opposed to dust or chips), or if it’s somewhat adherent to surface (like grease or mud, as opposed to water or light oil). This can also work if you’re trying to blow out a hole, recess, or groove in an object.

EXAIR manufactures a wide variety of engineered Air Nozzles, designed for safety, efficiency, and quiet operation.

Other times, a dedicated blow off may be necessary to pick up where the Air Knife leaves off. In situations like that, we can specify an appropriately sized Air Nozzle, Air Jet, Air Amplifier, or maybe even a smaller Air Knife, to provide more complete removal of whatever you need to get off of the object. It’s fairly common to use Air Nozzles for these applications, and our Air Nozzles & Jets catalog section is a great tool that can be used for selection. It lists them all, from smallest to largest, with airflow patterns, performance data, and dimensions.

EXAIR offers solutions for plumbing, installation, and aiming the Air Nozzle too:

  • Swivel Fittings are installed on threaded pipe, and provide 50° of angular movement. Just loosen the lock nut, aim the Nozzle, and re-tighten for rigid & secure placement.
  • Stay Set Hoses are likewise be threaded into 1/4 FNPT connections, with the Air Nozzle secured onto the other end. These come in lengths from 6″ to 36″, with 1/8 FNPT or 1/4 MNPT threads for the Air Nozzle.
EXAIR Stay Set Hoses and Swivel Fittings are ideal for installation and positioning of your Super Air Nozzle.

Metal tubing with compression fittings is another option, that can be used to install & aim an Air Nozzle. Copper tubing is relatively easy to bend by hand. Stainless steel tubing usually requires a tube bender tool, with the advantage that it can’t easily be bent by hand…on purpose or by accident. While metal tubing is certainly an option, it is generally reserved for applications where the ability to readjust is not necessary. The Stay Set hoses and Swivel Fittings tend to work better when flexibility is required.

The copper tube used to have a crimped end that was aimed at the part in the chuck. They simply cut it off and used a compression fitting to install the Super Air Nozzle.

If you’ve got a blow off application that’s not working the way you want it to, it’s highly likely that EXAIR has a solution. We would love to share our ideas with you. Give me a call.

Russ Bowman, CCASS

Application Engineer
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Optimizing Your Compressed Air Usage With Engineered Products

Published on by Russ BowmanLeave a comment

The first new car I ever bought was a 1995 Ford Escort Wagon. I’ve mentioned this before in posts about preventive maintenance, the importance of proper filtration, and brand loyalty. Those blogs were primarily about my experiences with that little red wagon, but today I wanted to discuss the primary reason I bought the car in the first place.

I had a 50-mile round trip commute to work, and my old Pontiac Grand Prix with the small block V8 engine was a great ride for sure. Some quick math, however, showed that if I went with something with better gas mileage, I could save quite a bit of money on gasoline. My calculation was almost $1,000 a year, just on driving back & forth to work. After figuring in the rest of my driving for the first year, it was more like $1,400 a year.

Similar to my “upgrade” to a more fuel efficient vehicle, upgrading blowoff, cooling and drying operations using engineered compressed air products is Step #3 in EXAIR’s Six Steps To Optimizing Your Compressed Air System. We’ve assigned an order to these steps in accordance with basic good engineering practice & protocol, but it’s not necessary to follow them in any particular order. In fact, all six steps really don’t apply to every single compressed air system.

Step #3 does apply to most systems, though. I spent a fair amount of time in all sorts of industrial facilities in my previous roles, servicing industrial & chemical pumps, and almost all the time, regardless of the industry or the size of the facility, the maintenance part of the facility used air guns. However, I don’t recall ever seeing an engineered nozzle on one before I came to EXAIR. Since then, I’ve worked with a BUNCH of users to dramatically reduce compressed air consumption by replacing their cheap and inefficient air guns with EXAIR Safety Air Guns, or by retrofitting EXAIR Super Air Nozzles onto their existing air guns. We actually carry adapters to fit our Super Air Nozzles to a number of readily commercially available air guns for that very purpose.

The five families of EXAIR handheld blowoff products include VariBlast Precision & Compact, Soft Grip, Heavy Duty, SuperBlast, and TurboBlast Safety Air Guns. They’re available with a range of engineered Super Air Nozzles, Extensions, and Chip Shields.

In addition to air guns & nozzles, our Air Knives have a long history of replacing drilled pipes & pipe manifolds with inefficient nozzles used to make a curtain of air flow. The following chart details the savings you can realize from the use of a 24″ Super Air Knife instead of similar devices for a 24″ wide air curtain:

Even though an electric powered blower will use less electricity than the amount of electricity an air compressor uses to supply an engineered product like the Super Air Knife, the maintenance costs make the total cost of ownership eclipse that of the engineered Air Knife.

Our Case Study Library (registration required, but it’s free & fast) documents many real-world situations where customers worked with us to gather & publish “before/after” documentation, proving out the benefits of Step #3. I encourage you to check those out, and if you think you might have an opportunity to do a Case Study with us, we offer discounts or credit for that…give me a call.

Russ Bowman, CCASS

Application Engineer
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Maintenance on Blower Knives Vs Compressed Air Knives

Published on by Jordan T ShouseLeave a comment

The EXAIR Super Air Knives as well as most of EXAIR products have no moving parts! What does that mean, well with no moving parts that means there are no parts to wear out! Other than changing a compressed air filter element here and there (somewhere around $30-$50 bucks) and opening the knife to clean it. That is it!

Clip from the Super Air Knife Install and Maintenance guide

Blowers on the other hand are a whole different story, there are LOADS of moving parts resulting in downtime and numerous replacement parts. I’m just going to cover the main ones!

Belts and Tensioners

Just like you car your blower motor and blower heads are connected by a rubber belt and tensioner to keep it tight and clean. Over time since there is so much vibration and movement these belts can start to wear down or tear, leading to a 1-2 Hour downtime to find and repair the issue. The same thing will happen with the bearing in the Tensioners.

Tearing Belt
Belt Tensioner

Blower Heads and Motors

All high speed rotating equipment will eventually fail, due to normal wear of seals and bearings. So you either need a spare which can be a pricey investment or your operation will be down until you get it repaired or swapped out by the manufacturer.

Blower Motor and Head

Filters

Blowers have an inlet filter installed. However, rather than filtering the compressed air like a compressed air knife (within the enclosed compressed air line) blowers filter the ambient air around the blower (within the application space). So if your facility is dirty and dusty these filters are going to succumb to the various, environmental contaminations rather quickly.

To break that down a little better!

System Maintenance:

  1. Blower System – The intake filter has to be changed periodically as well as the motor and belt has to be checked as a preventive maintenance. Being that the blower motor is a mechanical device, the bearings and belts will wear and have to be replaced.  Without proper maintenance, things can break prematurely.  Loss of production will cost your facility revenue on the bottom line.
  2. Super Air Knife – They do not have any moving parts to wear out. Only compressed air is needed to operate.  The maintenance requirement is to change the compressed air filter once a year.

When you bring the whole picture into view the total cost of ownership is quite clear when you look at loss of output, loss of product, and breakdown of equipment. Yes the power generated in some cases by the compressor can be more than a blower. But when you look at purchase price, installation cost, and maintenance, the compressed air operated, Air Knife is the clear winner.

Compressed air can be expensive, but if you use EXAIR products, you can use the compressed air very efficiently.  You do not have to sacrifice other areas within the total cost of ownership.  If you have a similar application, you can contact an Application Engineer at EXAIR.  We will be happy to discuss the benefits of using the EXAIR Super Air Knives over a blower-type air knife.

Jordan Shouse
Application Engineer

Send me an Email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

Tearing belt image courtesy of jblevine2004 Via Creative Commons

Blower Motor and Head image courtesy of Ragtimer1 Via Creative Commons

Belt Tensioner image courtesy of Cordylus Via Creative Commons