While writing my blog last week on all of the features & benefits of the Gen4 Ion Air Jet, I couldn’t help but think of some of the very interesting and successful uses I’ve seen in my nine years (as of this past Monday) as an Application Engineer at EXAIR Corporation. In honor of my workaversary, this week’s edition is Russ’ Top 9 Ion Air Jet applications:
A medical device manufacturer uses Ion Air Jets to remove dust from plastic extrusion as it goes through a puller belt. The small diameter (0.05″ to 0.10″) made the Ion Air Jet a more efficient fit than the Super Ion Air Wipe, which is commonly used for extrusions like this, but is most effective for larger diameters.
A maker of large scale automated machinery has provided Ion Air Jets (as well as other EXAIR quiet, efficient, and safe compressed air products) on machines they’ve been selling their customers for years. When they started machining their own plastic parts, the Ion Air Jet was their first thought for a solution when plastic chips started sticking to their drill bits.
A commercial printer makes displays, signs, etc. from a variety of static-prone materials such as acrylic, polycarbonate, and styrene. They use CNC routers to cut them to size & shape, form the edges, and add dimensional detail. Ion Air Jets blow the dust & shavings away, and keep them away, greatly reducing the prep time between routing and assembly.
A weather sealing/stripping manufacturer uses Ion Air Jets to remove statically charged dust from their rubber & foam product extrusions, allowing for increased line speeds and better cuts for the products they cut for specific seal packages for the residential & commercial door and automotive industries, among others.
A major provider of electrical and electronic contactors uses Ion Air Jets to blow off contact strip as it rolls off large reels to remove protective film and static.
A manufacturer of wire marking machinery installs Ion Air Jets on their machines that are used to print on products with especially static-prone jackets, to ensure clean and crisp markings
A cable manufacturer that caters to the computer & electronic industries uses Ion Air Jets to remove static & dust as foil is applied to PVC coated wire. This eliminates the static charge that was causing inconsistencies when the adhesive was heated to activate.
A wholesale food equipment distributor uses Ion Air Jets to blow out bottles during the sterilization process, prior to filling.
A maker of specialty polymers uses Ion Air Jets to keep fine powders from accumulating in the entries into their hoppers.
If you have a problem with static, the Ion Air Jet is just one of the solutions EXAIR Corporation can provide. If you’d like to find out more about how we can help, give me a call.
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This week I worked with a gentleman, who was having a problem cleaning a honeycomb web after a sawing operation. The honeycomb was a paper based material, and the sawing operation would create a large amount of dust. This dust filled his honeycomb, which made the product appear inconsistent to his customer on incoming inspections. This was leading to the customer questioning the quality of the product.
His process featured a blower that was incredibly noisy and still left some material on the product. During the winter, the problem was further exasperated by the dry air, which led to the dust being statically charged and clinging to the honeycomb even more. In spite of his quality and production issues, the customer was looking to expand his production to meet demand. The blower he was using had been custom-made for his machine, so he was open to any ideas. Also, the blower had no way of removing static electricity from the material.
I recommended he use an 84″ Super Ion Air Knife to clean his 80″ honeycomb web. The customer mounted the air knife perpendicular to the surface of the honeycomb 4″ away from the surface. One of my concerns with the operation was creating even flow. To do this on a long span, I recommended he use have the plumbing kit installed at EXAIR, which allows the air knife to create an even flow along the length of the knife y preventing any restrictions which may occur from poorly sized inlet fittings, hose or tube. The Super Ion Air Knife cleaned the honey comb with ease, while maintaining a quiet 69 dBA, and without the expensive maintenance required by the blower.
We always enjoy solving problems for the end users of our products. Last fall I worked with a company in Lebanon needing to remove static dust from small caps as they travelled down a conveyor line. We discussed the needs of the application, I made model number recommendations, and the system was installed. Using a 3” Super Ion Air Knife and a Light Duty Line Vac, the end user was able to eliminate the static, remove the dust, and vacuum away the dust as needed.
Now, this same end user is aiming to repeat the application, only this time for a larger cap. The setup is identical – the caps travel left-to-right on the conveyor track, they are blow off with ionized air from an EXAIR Super Ion Air Knife, and the dust is collected with a Light Duty Aluminum Line Vac. The only revision to this system (and retroactively applied to the last) was to reposition the Super Ion Air Knife so that the caps spend more time in contact with ionized air. This allows for increased throughput, should the application ever require increased production.
It’s great to solve problems for our customers. It’s even better when the solution worked so well that it leads to repeat business.
If you have an application in need of an EXAIR device, but aren’t sure which one to use or where to start, contact an EXAIR Application Engineer.