EXAIR commonly works with plastic injection molding companies. They produce top quality plastic parts from both commodity and engineering-grade resins for many diverse industries. The customer reached out to us with a problem. A mold that they were running was having some issues. The parts were not releasing and ejecting properly, causing the need to use a mold release, which was slowing down the process by a manual operation to the process. Also, the parts were seeing push pin marks, causing cosmetic issues with the parts. The customer wanted to explore using compressed air to blow the parts free.
Based on the mold size and layout, a pair of 12″ Super Air Knives was installed. The knives are oriented to blow straight down along the face of the mold, one knife per part tree. The strong laminar flow of air hits the parts causing them to release and drop without the use of release agents. Also, the push pin marks are within normal standards, eliminating the the cosmetic concerns.
This is just one example of how intelligently using compressed air can help improve a process. By using air knives for wide areas or using a 1″ Flat Super Air Nozzle for very small parts, or anywhere in between, we can help to solve your part ejection issues and make your process run better, faster, and with higher quality.
If you would like to talk about Super Air Knives, Flat Nozzles or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
Recently, I was able to work with a gentlemen from a stamping company that produces small metal stamped lids for the cosmetic industry. He was frustrated because the current blow off setup, a copper tube and nozzle (shown below), was too weak and narrow to be effective with parts ranging from 1″ to 2.5″ wide. Whenever a lid did not get completely discharged, the machine would jam and double hit on the next cycle, ruining (2) parts in the process, not to mention, potentially damaging the the tooling.
After reviewing the process, which is very high speed, we wanted a strong, concentrated blast of air that matched the part profile to maximize the air flow contact patch. We agreed the model HP1125 – 2″ High Power Flat Super Air Nozzle would be a good nozzle to implement and test. In addition to the Nozzle, the customer ordered the model HP1132SS Shim Set, to allow for flow and force adjustment of the nozzle to obtain the best possible performance under production conditions. The HP1125 nozzle provides 2.2 lbs of force with the standard .025 patented shim installed, and can be decreased or increased by changing the shim to .020″ or .030″ thick. Preliminary testing has proven successful, and reliability testing and data collection is underway.