Super Air Knife Improves Plastic Injection Molder Process

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.

Plastic Injection Mold
Typical Plastic Injection Mold

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.

gh_Super Air Knife 750x696

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.

1126
1″ Flat Super Air Nozzle with Changeable Shims

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.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_BB

 

Injection Mold Photo – “Creative Commons Injection Mold” by Mitch Barrie is licensed under CC BY-SA 2.0

Simplifying Plastics Machining Using The Cold Gun And Chip Vac

I was recently contacted by a plastics manufacturer who was needing some solutions for problem areas in their production processes. The company imports their machines from overseas and they are outfitted with a coolant based, quench system for the tooling. They were wanting to get away from using coolant as the parts were absorbing liquid, causing them to swell, not to mention the mess they were creating, requiring more time and labor to dry and clean the parts manually.

For the first application, replacing the messy misting system, I recommended the customer use our Cold Gun System, Model # 5215. The Cold Gun uses Vortex Tube technology to produce a cold air stream 50°F lower than the incoming compressed air supply temperature. For example, if your supply air was ambient 70°F, you would effectively see 20°F air at the exhaust. This clean, cold air stream can be easily directed to the needed area to prevent any warping or other damage related to heat, while also blowing away the machined fines.

Model # 5215 – includes the Cold Gun, Single Point Hose Kit, 3/8″ Cone Nozzle, 1-1/4″ Fan Nozzle and Filter Separator

The second part of the process involved the recovery of the plastic scrap and chips created during the machining process. Once again, EXAIR has the ideal solution with our Chip Vac, Industrial Vacuum. The Chip Vac creates a powerful vacuum, with no moving parts or motors to wear out, making them virtually maintenance free. The Chip Vac is designed to vacuum dry or wet chips and collect them in a standard, open-top steel drum. Systems are available in 5, 30, 55 or 110 gallon capacities.

From small area clean up to larger scale processes, the Chip Vac has you covered

To discuss how EXAIR products might help improve your machining process, give us a call at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Adjustable Spot Cooler: How Cold Can You Go?

I had the pleasure of discussing a spot cooling application with a customer this morning. He wanted to get more flow from his Adjustable Spot Cooler, but still keep the temperature very low.  He machines small plastic parts, and he’s got enough cold flow to properly cool the tooling (preventing melting of the plastic & shape deformation) but he wasn’t getting every last little chip or piece of debris off the part or the tool.

After determining that he had sufficient compressed air capacity, we found that he was using the 15 SCFM Generator. The Adjustable Spot Cooler comes with three Generators…any of the three will produce cold air at a specific temperature drop; this is determined only by the supply pressure (the higher your pressure, the colder your air) and the Cold Fraction (the percentage of the air supply that’s directed to the cold end…the lower the Cold Fraction, the colder the air.)

Anyway, the 15 SCFM Generator is the lowest capacity of the three, producing 1,000 Btu/hr of cooling. The other two are rated for 25 and 30 SCFM (1,700 and 2,000 Btu/hr, respectively.)

He decided to try and replace the 15 SCFM Generator with the 30 SCFM one…his thought was “go big or go home” – and found that he could get twice the flow, with the same temperature drop, as long as he maintained 100psig compressed air pressure at the inlet port.  This was more than enough to blow the part & tool clean, while keeping the cutting tool cool, and preventing the plastic part from melting.

Model 3925 Adjustable Spot Cooler System comes with a Dual Outlet Hose Kit, and three Generators for a wide range of cooling performance.

If you’d like to find out how to get the most from a Vortex Tube Spot Cooling Product, give me a call.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

2.5″ Line Vac Used In Plastic Part Recovery

I recently worked with an OEM who designed an injection molding machine for their customer. In their design, after the polypropylene parts are formed, they pass through a punch process which creates a scrap piece roughly 1-3/4″ in diameter and 6mm thick but it is very light in weight. The end user was looking for a way to recover these parts in an effort to reduce the amount of waste material in the process but needed an automated solution so they didn’t have to dedicate an operator to manually recover the parts and dump them in the recycle bin. The recovery bin is located close to 25 feet away on the other side of the machining area.

After further discussion,  I recommended they incorporate our Model # 6085 2-1/2″ aluminum Line Vac into their design. The 2.5″ Line Vac has a 2.25″ inside throat diameter which could easily pass the parts and convey them to the collection hopper.

Line Vacs connect to standard ID hose or pipe to create a powerful in-line conveyor

With the recovery bin being located outside of the processing area, they were going to have to run the discharge piping up and over the machines so they were needing something flexible to do so. In addition to the Line Vac, I suggested they use a 30′ section of our 2.5″ conveyance hose. Our conveyance hose is constructed of a durable, clear reinforced PVC, ideal for most general applications and we offer it in 10′ lengths up to 50′, in diameters of 3/8″ to 3″ ID.

Flexible clear PVC hose with smooth bore eliminates material build up.

 

When it comes to moving dry material, like small plastic parts or more abrasive materials like steel shot blasting media, the Line Vacs are the perfect, maintenance-free solution as they have no moving parts or motors to wear out. For help selecting the best option to fit your needs or to discuss how another product might be suitable for your application, give us a call.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Stainless Steel Line Vac turns Super Sack into a Large Vacuum Bag

LV PE pellet application2

I had an interesting application from a guy in Kuwait who worked at a plastics plant. They worked with polyethylene pellets for molding processes. In his introduction, the customer said he was looking for something like our Chip Vac product but he wanted to use it with a super sack platform that they elevate up to a high position to allow for cleaning in and around their silos. I mentioned to him that we do have the Chip Vac available to work with a 110 gallon drum. His response was that he knew about that but was not interested as they were set up to move the larger super sacks around their plant. You can see one such set-up in the above photo.

His problem was that he needed a quick and easy way to get the loose PE pellets into his super sack without using a broom and shovel. We had just the solution.

Many years ago when we introduced the Chip Vac product, we did so as a result of customers who knew about our Line Vac but wanted it to be used on a drum. So, we adapted the Line Vac to have the proper, 2 NPT threads necessary to screw into the larger of the two holes in the top of a typical drum. In this situation, we were working the development that we did so long ago in reverse. So, it was a very easy recommendation to set the customer up with a Line Vac to aid in the vacuuming up of the polyethylene pellets and do so in the manner the customer wanted.

After a little discussion to sort out the type of material and the size Line Vac that the customer wanted, we ended up settling on a 1-1/2” Stainless Steel Line Vac Kit, model 6963. The 1-1/2” size allowed for easy connection of a standard size vacuum hose for easy manipulation around the clean-up area. The customer opted for the stainless steel over an aluminum unit as they wanted to be absolutely certain that the product could stand up to their typically rough conditions. He also wanted the kit so he could mount the Line Vac to his platform and have clean, dry air going to the Line Vac to keep it running well for a longer time. Below is a rough sketch of the customer’s idea about how to marry the Line Vac to his super sack platform.

 

LV setup

You can notice from the sketch that the customer already had his filtration system thought out to allow the conveying airflow back out of the bag.

The key to this application and the feature that I want to point out is the adaptability of the Line Vac to fit into just about any application. We do have the Industrial Housekeeping products available for ready to use solutions. But, if you have a similar situation where you have part of your “system” that you like for one reason or another, we’re more than willing to discuss what you have at your facility to help you best determine how we can implement a solution that you are happy with. Likewise, if we feel that there is a better way to approach your application, we will be sure to let you know that too!

Give us a ring or send us an e-mail to discuss the specifics of your application today. We’re here to help.

Neal Raker, International Sales Manager
nealraker@exair.com
@EXAIR_NR