Stainless Steel Super Air Knife removes lime from conveyor belt.

An aggregate company crushed limestone into powder, and they were having issues in losing falling off of their conveyor belts.  The conveyor moved the lime from their processing plant to an outside silo for storage.  The conveyor was 60” wide and had a “cracked” pattern for gripping and moving the powder.  So, the surface of the belt was very rough.  As the conveyor went around the end to dump the powder in the silo, some of the material would stick in the valleys of the “cracked” pattern.  At the head pulley, as the belt made its return, the material would collect on the floor underneath.  For safety concerns, they would have to stop the operation to clean up the floor.  The customer wondered if the EXAIR Industrial Housekeeping Product would help them in their cleanup efforts.

EXAIR Heavy Duty Dry Vac Family

Yes, it will.   When it comes to industrial vacuums, wouldn’t it be nice to have a durable, long lasting vacuum that is quiet?  There is such a vacuum that has these qualities; the EXAIR Heavy Duty Dry Vac System.  This vacuum system has no moving parts, no motors to fail, or bearings to wear.  They only require compressed air to operate.  The Heavy Duty Dry Vac is used to vacuum solid materials like plastic, sand, and even denser materials like steel shot.  So, it would work great with the lime material.  The vacuum pumps are made from a hardened alloy construction to resist wear and abrasion, and it is designed to generate a strong vacuum level.  This would have been a great solution for cleaning for this company above.  But, as an Application Engineer, I was able to provide a better solution, the EXAIR Super Air Knife System.  Instead of cleaning the mess afterwards, we can stop the mess from happening.

Super Air Knife Kit

EXAIR can create a non-contact wiping process at the dumping end of the conveyor.  We have that ability with our Super Air Knife System.  At EXAIR, we pride ourselves in energy efficiency.  Compressed air is expensive to make, so why not use it as effectively as you can?  The Super Air Knife has a 40:1 amplification ratio which allows 40 parts of ambient “free” air for every 1 part of compressed air.  I recommended a model 110260SSPKI, 60″ Stainless Steel Super Air Knife Kit for this application.  This Super Air Knife is made from Stainless Steel for chemical compatibility with lime. 

EXAIR stocks the Super Air Knife at the 60” size for a continuous even blowing force across the entire length.  The kit included a filter, a regulator, and a shim set to “dial” in the minimum amount of force to remove the material without blowing the lime powder into the ambient air.  The “PKI” suffix at the end of the model number indicates our Plumbing Kit.  This option is Installed on the Super Air Knife to allow for easy installation and to allow for the proper inlet airflow to get a consistent blow-off device.  After installing the model 110260SSPKI, the powder was no longer collecting on the floor underneath.  If we look at the cost of the increase in lime material and the removal of custodial duties, the Return on Investment, ROI, was only 27 days.  The photo below shows the floor before installing the Super Air Knife.

Lime powder collection

Spillage is wasteful, costly, and time consuming to clean up.  If you have excess waste from your conveying system, EXAIR will have the product to help you.  For the aggregate facility above, the Super Air Knife Kit made it possible to increase production efficiencies with a short ROI.  And, since they liked the durability of our Industrial Housekeeping Products, they still purchased the Heavy Duty Dry Vac for cleanup in other areas in their facility.  If you want to improve your aggregate conveying operations with non-contact blowing or housekeeping, you can contact an Application Engineer to review your possibilities.   


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

Heavy Duty Line Vac Saves Backs and Shoulders!

Recently, I worked with a customer that was looking for a way to make a difficult job easier, reducing stress and strain on the body and preventing injury.  The customer was in the Environmental Services & Hazardous Waste Management area and regularly was called out to service acid neutralization tanks. These are commonly found in hospitals, laboratories, and schools, to neutralize lab wastewater before it is discharged to the sanitary sewer.  The systems typically utilize limestone chips to aid the in process.

Acid Neutralization Tank
                       Typical Acid Neutralization Tank Layout Sketch

Periodic maintenance includes the removal and disposal of the spent limestone chips, tank cleaning and replenishment with new limestone chips.  Some of the tanks are tall and narrow, making access to the limestone chips difficult, especially near the tank bottom. Current procedures involved small shovels and unnatural body positions to try to reach the bottom-most material.  A better way had to be found.

The customer came across the EXAIR website and found the Line Vac product line. After watching the demonstration video, he knew he had found his solution!  The Line Vac is a compressed air operated device that turns any hose or tube into a powerful in-line conveyor. Based on the height of the tanks and the size and weight of the limestone, we agreed the 2″ Heavy Duty Line Vac would provide the power and durability to empty the tanks in a timely manner, and safely and efficiently.  The customer would use a tow behind compressor so that a reliable source of compressed air would always be available.

hdlvkit (2)
Heavy Duty Line Vac Kit – Includes Auto Drain Filter Separator and Pressure Regulator

The Heavy Duty Line Vacs are available in sizes from 3/4″ up to 3″ in both smooth end and threaded connections for use with hose or pipe for conveyance.

To discuss your application and how an EXAIR Line Vac can make your transfer process easier and safer, 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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