Super Air Knife Cools Laminated Packaging Material

I recently worked with one of our distributors on a Super Air Knife application for a manufacturer of flexible packaging material. They create the plastic material that is commonly wrapped around the outside of a wide variety of different containers. The material exits the laminating machine at about 129°F (54°C) and must be cooled to close to room temperature before it is able to be rolled without the material sticking together.

Model 110012, positioned to maximize counter-flow

They performed a test with a Model 110012, recording the temperature after the knife and determined that it would be suitable for them. Prior to using the Super Air Knife, they had been using a series of fans to cool down the material. This worked to some degree, but they had been experiencing quality issues as a result of inadequate levels of cooling and were forced to slow down the laminating machine in order to compensate. By implementing the Super Air Knife, they were able to cool the material down to ambient temperatures without having to slow production. As an added measure, they ordered a second knife to install on the underside to further decrease the temperature of the material.

Graph showing the effectiveness of a Super Air Knife vs. fans or no cooling method.

The laminar airflow of the Super Air Knife is critical to the success of any cooling application. A fan “slaps” the air which provides random spikes of air at moderate velocities. The uniform, high velocity, laminar sheet of air from the Super Air Knife, in addition to the low compressed air consumption, makes it a much more effective cooling method than fans. The design of the Super Air Knife allows it to entrain ambient air at a rate of 40:1, maximizing the force and flow from the knife while keeping compressed air usage to a minimum.

The design of the Super Air Knife allows it to entrain air from the top and bottom, creating a 40:1 air amplification ratio.

Super Air Knives are available in a range of different materials and sizes. From stock EXAIR carries knives from 3”-108” in Aluminum, 303 Stainless Steel, 316 Stainless Steel, and 3”-54” in PVDF (Polyvinylidene Fluoride) for superior resistance to highly corrosive materials. In addition to being an excellent tool for cooling, the Super Air Knife can solve a wide range of drying and blowoff applications. If you have an application that would be better served with one of EXAIR’s Super Air Knives, reach out to us today and get yours on order! We ship same day from stock with orders received by 3:00 pm EST, stop wasting time with ineffective cooling or blowoff methods!

Tyler Daniel
Application Engineer
Twitter: @EXAIR_TD

Custom Solution From Stock For A Pick And Place Application

Even if you’re just a casual, infrequent reader of our blogs, you likely know that EXAIR Corporation is proud of our abilities to customize solutions for “out of the box” compressed air product applications. Oftentimes, this is offered as a custom engineered product, developed from a user’s specifications when one of our stock products just won’t work for one reason or another. For instance, when an exotic material of construction is required for heat or corrosion concerns, a special length or size is needed for space constraints, etc.

An Air Amplifier with a PTFE plug (left,) a curved Super Air Knife (center,) and a flanged Line Vac are just a few ways EXAIR has provided custom solutions.

Other times, though, we can use a stock product for something other than what everyone else uses it for.  We’ve sold Air Amplifiers for use in vacuum chucking, and pick-and-place applications – those are normally the realm of our E-Vac Vacuum Generators.  Speaking of E-Vacs, they’ve been used to deflate basketballs.

And speaking of E-Vacs (still,) I had the pleasure of helping a long-time customer solve a new problem in their growing manufacturing business.  They put their consumer products in blister packages, and recently converted one of the lines that picks & places the plastic “blister” onto the cardboard “backer” from two at a time, to six at a time.  They were using a Model 810003M E-Vac High Vacuum Generator, which worked fine, every time, with two Model 900762 1″ x 1/2″ Oval Vacuum Cups, but when they put four more of those Vacuum Cups on, they weren’t able to pick all six “blisters” every time.

These plastic blisters are smooth and non-porous, so this a “textbook” application for a High Vacuum Generator.  They’re also VERY lightweight, and were picked in a horizontal motion, so the 27″Hg that the Model 810003M can generate wasn’t actually necessary.  By replacing it with a Model 800003M E-Vac Low Vacuum Generator, the extra vacuum flow solved the problem, with no increase in compressed air consumption, which was critical for this area of their operation.

EXAIR E-Vac Vacuum Generators and Vacuum Cups are a reliable, low cost solution for most any pick & place application.

EXAIR Intelligent Compressed Air Products can solve many of your industrial/commercial challenges.  Our catalog documents the ones they’re aimed at.  Others need to be addressed by knowledge and experience…and maybe a little theory to practice.  If that’s the case, call an EXAIR Application Engineer.  We’re here to help, and we’re pretty good at it.

EXAIR’s Super Air Knife Eliminates Problem of Fused Packages

The EXAIR Super Air Knife – high force with precision flow

An Argentine food manufacturer recently reached out to our distributor in Buenos Aires (AYRFUL) to discuss a potential application for EXAIR products.  The need became clear when a packaging line for soon-to-be-frozen food began experiencing problems with excessive water on the surface of the packages.  In this process, the packages are rinsed to remove any unwanted debris, and then sent into a large freezer before distribution to local groceries.

The excessive water on the packages would become ice, which would fuse the packages together when stacked in boxes for transporting to retail centers.  This fusing caused rips in the packaging when they were separated, thereby creating unsellable goods, ultimately leading to returns for this manufacturer.  And, the residual water also increased the total weight of the packed packages, enough to increase the actual weight when bulk packed.  This increase in actual weight led to an increase in freight costs from their courier.  So, this manufacturer needed a way to remove the residual water, reduce defects and returns, and simultaneously lessen the freight cost.

Model 110048 Super Air Knife (inside red box) blowing off residual water after rinsing and before freezing. See note on plumbing below.

The solution they found was a 48” EXAIR Super Air Knife, model 110048, mounted using (2) Universal Air Knife Mounting Kits.  The Super Air Knife in this application provided a precision airflow to blow off the water from the top of the packages, after rinsing and before freezing.  Removing the water at this stage, as shown above, eliminated the problem of fused packages, rejected products, returns, and increased freight.  And, the Super Air Knife was able to do this at a low operating pressure, fed from a single compressed air inlet.

(Note – EXAIR recommends plumbing multiple compressed air inlets for Air Knives longer than 18”.  For this model, 110048, we recommend compressed air be supplied to (3) compressed air inlets.  Plumbing less inlets will reduce the compressed air flow into the knife, which reduces possible operating pressure.  In this case, the lower operating pressure was acceptable, however, we still recommend to plumb (3) compressed air inlets on a 48” Super Air Knife.)

Plumbing specifics aside, this solution still brought tremendous value for the customer.  They were able to solve the root cause of a multi-faceted problem with an engineered solution.  If you have an application in need of an engineered solution, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer

Super Ion Air Knife Removes Foil Dots In Lid Cutting Operation

I recently received an inquiry from a food manufacturer about a packaging line they were having issues with.  The plant fills continuous rows of thermo-formed cups which is then sealed with a single foil lid. Once sealed, a machine cuts the row to separate the cups, which creates small scrap pieces of foil. After the cutting operation, they try to collect as much of the waste trim as possible but some small pieces of foil, they call “dots”, cling to the surface of the cup and cutter due to static charge.  The company installed a vacuum collection hood in this area, to try and help keep the foil pieces or any dust from falling onto the cup during the process. While this did help somewhat, some dots would remain and eventually fall off further down the line, making small piles that needed to be manually cleaned to avoid potential jams, which slowed down their production cycle.

The cups are filled and separated on a 44″ wide, mesh-screen conveyor with individual lanes to process multiple rows of cups. After being cut, the cups are moved to the inspection area and then packaged for shipment.  I recommended they mount a 48″ Super Ion Air Knife above and below the cups and direct the airflow to the end where the vacuum collection hood is located. The idea is, as the ions eliminate the charge, the small foil dots will release and the laminar airflow would keep the parts moving toward the vacuum hood, thus removing all foil trim and preventing any piling of trim further down the production line.

The Super Ion Air Knife produces a sheet of ionized air capable of dissipating 5 kV in just a fraction of a second!

EXAIR offers a wide selection of Static Eliminators for use in a variety of industrial processes. If you are experiencing static concerns in a particular area or to discuss a specific process, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer