As with any EXAIR Product, we always recommend the installation of a particulate filter. If there is any oil present in your air supply, an oil filter is also recommended after the particulate filter. Nearly all of our products have no moving parts to wear out and will never require maintenance so long as they’re supplied with clean, condensate free, oil-free air. If the air is not filtered prior, anything contained within the air is going to be passed through into your process. Debris could also eventually clog up the tight orifices in the product itself. Eventually the debris/oil will end up clogging it up and stop performing as it should. This leads to downtime while the root cause of the issue is sorted out, and subsequent maintenance of the product that has been clogged.
I recently worked with a brewing company that had a machine with one of our ¾” Model 120020 Super Air Amplifiers installed. It was used on a canning line and would dry off the cans after a washing operation before being marked with a date code. Up until recently it had worked just fine without any issues. Now they were noticing residual moisture leftover on the cans that was preventing a legible date code from being marked on the outside. Further investigation led them to determine that the outlet flow from the amplifier had been reduced to almost nothing. Since their compressor delivers oil-free air and they used stainless steel piping, they didn’t think it was necessary to install a filter.
The Super Air Amplifier is a maintenance-free product, when supplied with clean, condensate free air of course. After removing the plug from the body, they noticed a significant amount of oil present inside the plenum chamber and around the shim. This was clogging up the nozzle and restricting airflow through the unit. The photo below shows the inside of the amplifier prior to cleaning. The fine-toothed shim at the bottom is hardly even noticeable. In looking upstream, they noticed an oiler that was necessary for many of the other pneumatic components of the machine. This same air supply was being used to supply the compressed air to our Super Air Amplifier.
At our instruction, they installed an oil-filter on a new line dedicated just to this amplifier. And after cleaning the Super Air Amplifier the problem drying off the cans immediately stopped and they were back up in running in no time. Now that they had removed the oil from their air supply, this issue won’t return and they can begin operating the way we intend it to, maintenance free!
A glove manufacturer needed to decrease the reject rate with their natural rubber gloves. They were seeing brush marks in the rubber material which was a visual defect. Their operation used a ceramic hand that was used to form the size of the glove. After the rubber material was applied, it was dipped into water to set the material. It would come out of the water tank, and a mechanism on the conveyor would rotate the hands to “shake” off the excess water. It would then go over brushes to wipe the water from in between the fingers. Much of the water had to be removed before it entered into the coagulation tank because it would affect the stretching ability of the glove. With their current operation, they were seeing the scuff marks from the brushes which was a visual defect. This cost them down time and product rejects. So, they contacted EXAIR to see if we could help.
In looking at their process, they had two conveyors running side by side with each other. This made it a bit more difficult as we could only work on one side. Being that the ceramic hand rotated around twice in 36” before hitting the brushes, I could focus in this area. When it comes to wiping products without touching it, air is required. And EXAIR knows how to use compressed air very efficiently, safely, and effectively. For this application, I suggested our model 110236 Super Air Knife kit. It has an overall length of 36” which could span the target area. It comes with a filter, regulator, and shim set to clean and control the air flow. It would be able to “wipe” the water off the hands like a non-contact squeegee. The air flow from the Super Air Knife will hug the exterior portion of the hand; removing the water from the surface and in between the fingers. They removed the brushes and did not have to worry about brush marks on the glove.
If you require a non-contact wiping in your application, use EXAIR Intelligent Compressed Products to accomplish this. You will not have to keep replacing items that wear or use items that cause damage to your product. EXAIR has the ability to use compressed air to create a strong force without scraping or scratching your material.