Tag: ionizing blower

Do I need a Gen4 Ion Air Jet or Intellistat Ion Air Nozzle?

Published on by Russ BowmanLeave a comment

EXAIR has been making a comprehensive line of Static Eliminators for decades. Like any air blowing application, the first consideration in selection is the size & shape of the airflow that’s needed to get the job done. If you’re looking for a tight, focused airflow, we have four products to choose from: a Gen4 Ion Air Gun or Ion Air Jet, or an Intellistat Ion Air Gun or Ion Air Nozzle. So, the next step in selection is whether you want something operated by hand, or mounted in place:

The Ion Air Guns are just hand held & operated versions of the Ion Air Jets/Nozzles.

From there, it’s all about where you’re going to use it, and for what. First, let’s talk about the environment:

  • First off, neither of these can be used around flammable materials or gases. If you need a static eliminator for those kinds of areas, call us and we’ll provide some leads based on your specific requirements.
  • If you’re going to use it in a laboratory or cleanroom environment, the Intellistat Ion Air Nozzle is the clear choice, hands down. It has an ISO 14644-1 Class 5 Cleanroom classification. The stainless steel mounting bracket makes installation & positioning quick & easy.
  • For more industrial environments, consider the compact and rugged construction of the Gen4 Ion Air Jet. They have 1/8 NPT threads for the compressed air connection, and a 5ft cable to attach to the Power Supply. We can also provide them with Stay Set Hoses & Magnetic Bases for ease of mounting & positioning.

Then, details about the nature of the application will be considered:

  • To prevent nuisance shocks to personnel that have to handle the material, you can likely use either. The Gen4 Ion Air Jet DOES have a faster static dissipation rate: 0.18 seconds to dissipate 5,000V, but the Intellistat Ion Air Nozzle can dissipate the charge from 5,000 to 500V in 0.6 seconds. Either way, you need at least 2,000-3,000V for a noticeable ‘zap’ so if the charge is EXTREMELY high, AND you don’t have any more than a second or two, then we can make a case for the Gen4 Ion Air Jet. Otherwise, the environment is the deciding factor.
  • If you need to get the static charge to as low of a level as possible, the balanced ionized air stream from the Intellistat’s +/- 30V offset means it can reliably reduce the static charge to 100V or less, regardless of the material and where it falls on the triboelectric series. This is going to be especially important when you’re trying to prevent damage or faulty operation of sensitive electronics, for instance.
  • Some applications require not only ionized air, but a fairly strong flow of it. We did an Efficiency Lab test for a snack food maker recently where they need to blow open a plastic bag with a gusset on the bottom and set it upright on a conveyor. They also need it to remain open so they can fill it, so they need ionized air to remove static charge. The Intellistat Ion Air Nozzle blew the bag open and dissipated the static charge just fine, but it didn’t have the flow & force necessary to expand the gusset so the bag would sit upright. The Gen4 Ion Air Jet did it every time, though.

No matter what you need to remove static from, EXAIR can help. If you’d like to discuss your application and product selection, give me a call.

Russ Bowman, CCASS

Application Engineer
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Laminate Flooring – Step Up to Protect the Surface

Published on by John BallLeave a comment

A manufacturer of laminated floor planks was having issues with defects prior to packaging.  The planks were made from a high-density fiberboard as the core with a top layer of a picturesque image, then sealed together.  They were getting fine material that was stuck on the surface, making them defective.  The issue was caused after the cutting process.  The fine debris remained on the surface and when the image or the sealing material was applied, it could be seen.  They tried wiping, but the solution caused scratches.  They tried blowing the surface to clear the debris, but due to the static, it would not fall off easily.  They required a good solution to improve the cleaning without slowing the process.  EXAIR’s Static Eliminators are a great product for industrial processes like this. 

In looking at the process, I recommended two pieces of a model 112242 42” Gen4 Super Ion Air Knife Kit.  The planks could come out in two spots or four spots.  (Reference photo above) To reduce compressed air usage, they could turn on or off which side is needed.  The customer asked about the mounting and compressed air attachments.  I mentioned the proper setup for the most effective blowing.  As a benefit, I offered a plumbing kit to help with the compressed air connection.  The PKI option, or Plumbing Kit Installed, has the proper amount of connection to the Super Ion Air Knife to allow for an even force across the entire knife.  I upgraded the model number with the PKI option to a model 112242PKI. 

Gen4 Super Ion Air Knife Kit

This kit will include the Gen4 Super Ion Air Knife with a PKI, a power supply, a filter, a regulator and a shim set.  The Gen4 Power Supply creates both positive and negative ions to remove any type of static.  The filter will remove bulk liquids and debris from the compressed air to keep the product clean and to optimize performance.  The Regulator is used to control the force.  This helps to not overuse the amount of compressed air required for the job.  With a regulator, you can make fine adjustments to get the proper amount of air.  For coarse adjustments, you can change shims to increase or decrease the force.  The customer was happy with the properly sized components to operate a non-contact wiping with the Gen4 Super Ion Air Knives. 

Once installed, their defect rate almost dropped to zero.  They were very happy with the cleanliness of the planks; they decided to purchase six more units.  They could place them in different areas of the lamination line to ensure a clean surface.  EXAIR manufactures a variety of Static Eliminator products.  If you feel that static is an issue in your process, you can always contact an Application Engineer to help you.  For the company above, they were “stepping” high.   

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

The Invisible Nuisance: Where Static Electricity Comes From and How to Kill It

Published on by Al WooffittLeave a comment

We’ve all experienced it: the sudden “zap” when touching a doorknob, the frustration of plastic wrap sticking to everything but the bowl, or the sight of dust stubbornly clinging to a freshly painted surface.

While static electricity is a minor annoyance at home, in an industrial environment, it’s a productivity killer. It causes materials to jam, ruins electronic components, attracts contaminants, and can even pose a significant fire hazard.

But where does it actually come from? And more importantly, how do you get rid of it?

Static

At its core, static electricity is an imbalance of electric charges on the surface of a material. Most objects are electrically neutral, meaning they have an equal number of positive protons and negative electrons. Static is generated through a process called turbocharging. When two materials come into contact and then separate, electrons are “ripped” from one surface and transferred to the other.

Common industrial culprits include:

Friction: Material pulling off a roll (webbing) or sliding down a conveyor.

Pressure: Objects being squeezed through rollers.

Separation: Rapidly peeling a protective film or label.

In a perfect world, these charges would bleed off into the air. However, in dry environments or when using insulators (like plastics, paper, and textiles), the charge gets trapped on the surface. It stays “static” until it finds a way to discharge—usually into your hand or a sensitive piece of equipment.

So why is static a nightmare for production? If you are running a high-speed line for example, static electricity manifests in three expensive ways:

Dust Attraction: A charged surface acts like a magnet for airborne contaminants, leading to poor paint finishes or contaminated food packaging.

Product Misbehavior: Sheets of paper might double-feed, or plastic parts might “fly” off a conveyor belt due to repulsion.

Operator Shocks: Repeated painful shocks lead to fatigue and safety concerns for your team.

This is where EXAIR’s Gen4 Static Eliminators come in. You can’t always stop the friction that creates static, but you can neutralize the charge immediately after it’s formed. Unlike simple grounded brushes that need to touch the surface, EXAIR products use ionizing technology combined with compressed air to neutralize charges from a distance.

Some applications call for a fixed-in-place solution, like the (above, from left) Super Ion Air Knife, Super Ion Air Wipe, Ion Air Jet, and Ion Air Cannon. Others are best suited to the hand-held convenience of the Ion Air Gun.

Through the use of the Corona discharge method, EXAIR ionizers create a flood of both positive and negative ions. When this “cloud” of ions hits a charged surface, the surface automatically attracts the ions it needs to become neutral. Several common applications for our products are:

Ionizing Bar: High-speed webs, paper, and flat surfaces.

Ion Air Cannon: Neutralizing parts from a distance or in hard-to-reach areas.

Ion Air Gun: Manual cleaning and neutralizing of parts before painting or packaging.

Super Ion Air Knife: Providing a wide “sheet” of ionized air to clean and neutralize large surfaces simultaneously.

So why choose EXAIR? Our Gen4 technology is designed for rugged industrial use. They are shock less, meaning they are safe for operators to be around, and they require no moving parts, which translates to incredibly low maintenance. By integrating these into your process, you can increase line speeds, reduce scrap, and keep your workplace safe.

Ready to stop the shocks and start the flow? Give us a call!

Al Wooffitt
Application Engineer

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Banner image: Image by TyrusTime from Pixabay

Static-Free Precision: Why Your Lab Needs the EXAIR Intellistat Ion Air Nozzle

Published on by Al WooffittLeave a comment

In high-precision environments like clean rooms, laboratories, and electronics manufacturing, static electricity is more than just a nuisance—it’s a potential deal-breaker. Whether you are assembling delicate circuit boards or cleaning medical slides, even a tiny charge can attract dust or damage sensitive components.

Enter the EXAIR Intellistat Ion Air Nozzle. This mountable, hands-free solution provides a continuous stream of ionized air to neutralize static and clear away contaminants without interrupting your workflow.

While handheld tools have their place, the Intellistat Ion Air Nozzle is designed for bench top and assembly station applications where you need both hands to work. Equipped with a stainless steel adjustable mounting bracket, installation is made easy.

Several key features include:

  • Rapid Static Decay: The nozzle can reduce 1000V down to 100V in just 0.6 seconds, neutralizing static from up to 24 inches away.
  • Clean room Ready: It holds an ISO 14644-1 Class 5 rating, making it suitable for sterile environments like pharmaceutical labs and biotechnology manufacturing.
  • Durable, Dissipative Construction: The body is made from static-dissipative polycarbonate, ensuring it won’t conduct electricity or cause discharge around sensitive circuit boards.
  • Safety & Compliance: It is OSHA compliant for both noise levels and dead-end pressure, and includes a low-voltage 24VDC power supply for added electrical safety.
  • Smart Indicators: Integrated green and red LEDs provide immediate feedback on the unit’s functionality, signaling if the emitter point needs cleaning.

If you’re looking for a high-performance upgrade to your workstation, or you’d like to discuss any other static elimination application, then give us a call!

Al Wooffitt
Application Engineer

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