Finding The Right Solution Through Dedicated Engineering Support

crate

Plastic crate in need of blow off after washing

An OEM of crate washing equipment in Lebanon recently contacted me about an application on one of their conveyors.  The conveyor carries a plastic crate out of a washer and excess water on the crate was presenting a problem in the application.  In order for the crate to move on to the next step in the machine, a blow off solution was needed, but the exit rate from the washer was inconsistent.  In a given minute there could be 5 crates exit the washer, or there could be 20.  So, the ideal solution needed to have intermittent control options with instantaneous on/off functionality.

We immediately began discussing Super Air Knives, not only because we show plastic crate blow off in one of our many videos, but also because these units are instant on/off with full compatibility with a flow control device.  Utilizing a flow controller, such as the EXAIR Electronic Flow Controller or PLC device, will allow for precise control of the blow off solution, limiting compressed air use to a minimum.

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The first blow off system design

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This layout utilizes Air Knives on each side of the blow off as well as the top

After discussing application details we came to the design shown above, using one 24” Air Knife on the top of the crate and two 9” Air Knives on the sides.  However, this OEM had purchased numerous 2” Flat Stainless Steel Super Air Nozzles in the past (model 1122SS) and had a number available on site.  Modifying the system to utilize the nozzles already on-site, we came to this design:

system-layout

The finalized layout for this blow off system. Click for a larger view.

This layout utilizes (1) 24” Stainless Steel Super Air Knife on the top of the crate and (2) sets of (3) 2” Flat Stainless Steel Super Air Nozzles on the sides, held in place with EXAIR Stay Set HosesNotice the independent pressure regulators for the nozzles and the knife.  This is to allow the customer to balance the air flows, because the 2” flat nozzles will create a higher force than the Air Knife when operating at the same pressure.

In this application we were able to help a returning OEM solve their problem with the right mix of needed products.  Exploring the problem and discussing numerous viable solutions led to the best fit for the application and customer.  That’s precisely why EXAIR Application Engineers are available for any application call or question.  If you’d like to explore an EXAIR solution we’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

 

Super Air Knife Replaces Homemade Manifold

I recently worked on an application with a manufacturer who was having issues with their labeling process. The sticker label is applied to the side of their container by a print roller and then passes by a 6” homemade manifold system with 3 nozzles to help permanently affix it n(see below). They were experiencing irregularities/air bubbles in the label and realized they were getting an uneven airflow which was stronger at each end nozzle but the middle nozzle had very little flow. They were operating at around 80 PSIG and previously tried to lower the pressure but the label would start peeling off. If they increased the pressure they were experiencing tearing and ripping in certain areas of the label. Another issue was the loud noise level. They were having to stop the line and turn off the air so an operator could manually replace the label. They emailed me a picture of the manifold and asked if EXAIR could improve their process.

Homemade Manifold

After reviewing the picture and further discussing their application, I recommended using one of our 6” Aluminum Super Air Knives. The Super Air Knife , with a 40:1 amplification rate (surrounding ambient air to compressed air), provides a high velocity laminar sheet of airflow the entire length of the knife. By continuing to operate at 80 PSIG, the Super Air Knife will produce a velocity of 11,800 feet per minute (6” away from target object) and consume only 17.4 SCFM (2.9 SCFM per inch of knife) with a low noise level of only 69 dBA.

SAK

By replacing the manifold, the customer was able to improve their process, decrease their air consumption and increase their personnel’s safety.

If you are experiencing a similar issue or need help with a different compressed air application, please give us a call.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

EXAIR Nozzles Used In Cold Roll Mill

I spoke with an end user recently about a performance concern with the EXAIR product in their application.  During the phone call I requested a drawing of their system to better understand the application.  They obliged and sent a PDF version of their CAD file, showing their cold roll mill, full of annotations and component number call-outs, multiple views, and even sub assembly descriptions.

Having so many details was great!  And yet I found myself playing a game of Where’s Waldo, only instead of looking for the guy in stripes I was trying to find an EXAIR 1122 2″ Flat Super Air Nozzle in the machine’s schematic.

I scanned the drawing a few times before deciding to zoom in for a better look.  And, lucky for me there was an annotation for “EXAIR 1122 2″ Flat Super Air Nozzle, Qty 13”.  It’s always great to see EXAIR spec’d into a design.

After confirming the installation orientation, I had no concern about how the nozzles were installed (as far as angle of attack and use of the spray pattern), but I wanted to get a peek at the nozzles in use.  This wasn’t possible, but the manifold which houses the nozzles was off of the machine and before long I had the pic below.

Cold Roll Mill Manifold for 1122s

Immediately upon receipt, I could see a potential performance killer – the quick disconnect at the compressed air inlet.  I’ve blogged before about the importance of proper plumbing.  Providing adequate flow of compressed air is just as important as providing adequate pressure.

I advised the end user to step up to a manifold free of quick disconnects, and with compressed air inlets on each end.  They agreed to make the necessary changes before installing back into the machine and I have confidence each nozzle will meet the performance specs we publish in our catalog.

It isn’t often that an EXAIR device doesn’t perform as it should.  Plumbing problems, pressure drops, and contaminated air sources are the most common causes of performance disruption.  If you have an application for an EXAIR product our Application Engineers will provide you with their compressed air application knowledge and experience, give us a call.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

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