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Static Problem on your Packaging Line?

Published on February 20, 2023February 20, 2023 by Jordan T ShouseLeave a comment

Pretty much every consumer grade product comes in packaging, so It’s safe to say most manufacturing processes end in a final packaging of the final product! One of the most common issues with Form, Fill, Seal and other general packing systems is Static! That pesky force you can’t see, but you know and can feel the effects! So how can you address those issues? With EXAIR’s line of static eliminators! With a dozen different configurations an Application Engineer can help you pick one to fit into your process and eliminate the static that’s wreaking havoc!

But let’s take a look at a couple of the most common applications!

Bottle Sleeves

Unlike the Coke bottles below, most bottoms now have the thermo shrink on the cap to secure the lid and keep it clean. (You may ask why I used the Coke photo…. well I just liked it!!) But typically a flat sheet of thermo sensitive plastic is fed through a forming block to connect the ends to make a sleeve. Then they are fed over the bottle cut and thermo formed around the bottle. There are a lot of things there that can create static! Check out this blog by Tyler. His customer used a Super Ion Air Wipe to rid the static prior to the forming!

Image courtesy of Kevin Trotman, Creative Commons License Attribution 2.0 Generic (CC BY 2.0)

Filling

Filling a container with product is one of the most common packaging situations we encounter! Why? Because there are so many different operations that go into it. First you have to form the packaging, then clean it, then move it, then fill it, then seal it, then clean before bulk packaging. You guessed it each one of those tasks have the ability to build and be affected negatively by static.

Below is a photo of a line to fill vials with a vaccine, but first these need to be cleaned. Static can cause dirt and dust to stick inside the vial. This is a common use of the GEN4 Super Ion Air Knife, it can eliminate the static, then provide the force to dislodge the dust and dirt. Then you can push it into the air and dispose of it with a downdraft system. And just like the bottling line, they cap the vials with a thin cap cover, you can use the same product to eliminate that static to keep the flaws to a minimum.

Image courtesy of Vaccines at Sanofi, Creative Commons License Attribution 2.0 Generic (CC BY 2.0)

As the temperatures begin to decline, so does the humidity in the air. Drier air results in an increase in static problems. Get ahead of it this year and check out EXAIR’s complete line of Static Elimination products, all available to ship same-day from stock!

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS

Static Eliminators: The Blog!

Published on January 9, 2023February 14, 2023 by Jordan T ShouseLeave a comment

Over the years we have expanded our Static Eliminator’s product line time and time again. Since its close to Christmas and I’m in the giving mood let’s do a full overview!!! Buckle up this is going to be a long one!!

GEN4 Super Ion Air Knife!

The Gen4 Super Ion Air Knife floods an area or surface with static eliminating ions. With a uniform airflow across its length, misalignment to critical surfaces like webs is avoided. The force can be adjusted from a light breeze, to a full out blast of air. The Gen4 Super Ion Air Knife is electrically powered, is shock less and has no moving parts.

How It Works

GEN4 Standard Ion Air Knife!

Similar to the Gen4 Super Ion Air Knife, this product has a good compressed air efficiency. It utilizes the Coanda effect to draw in ambient air at a 30:1 amplification ratio. They come in stocked lengths from 3” (76mm) to 48” (1.22 meters). The Gen4 Standard Ion Air Knife are used in similar applications as well as mold releasing, package cleaning, label applications and plastic bag opening.

GEN4 Ion Bar (NO COMPRESSED AIR NEEDED)

This rugged design is for industrial use to remove static cling from flat surfaces. They range from a length of 3” (76mm) to 108” (2.74 meters). Without the assistance of air, the product has to be within 2 inches (51 mm) from the surface to remove static charges. The Gen4 Ionizing Bar is shock less and works well in applications where blowing air could be a detriment for the process. This would include screen printing, labeling, and large printing process.

GEN4 Super Ion Air Wipe

This product blows ionized air in a 360-degree pattern. They are engineered to remove static and debris from the outside of hoses, plastic pipe, extrusions, and coated wires. With the split design, the Gen4 Super Ion Air Wipe can easily mount around the product without having to rethread. They come in two different sizes with a 2” (51mm) and 4” (102mm) inner diameter. The ionized air has a fast static decay for speedy transfers.

GEN4 Ion Air Cannon

Just like the name, this product will shower an area with ions to remove static. It can reach distances up to 15 feet (4.6 meters). They are used in multiple areas including pre-paint car bodies, containers, shrink packaging, lenses, etc. As an Air Amplifier, a small amount of compressed air will draw in a large amount of ambient air. The ions are carried to the surface from the Gen4 Ion Air Cannon in a laminar air steam. Once the ions coat the surface area, the air flow can gently remove any debris held by static forces.

GEN4 Ion Air Jet and Gun

For manual static removal to target specific areas, the Gen4 Ion Air Gun will work great. This product comes standard with 10 feet (3 meters) of shielded cable for maximum reach. An ergonomic air gun is attached to a Gen4 Ion Air Jet to manually remove static in difficult areas and from “shock” zones. The Ion Air Guns work great for small batch processes used for quality checks or label applications.

Similar to the Ion Air Gun, this product is used for “hands-free” operations. They use a small amount of compressed air to “shoot” the ions onto a surface. They can be operated with a solenoid valve or foot pedal to blow ions during specific times and situations. They can easily be attached to a Stay Set Hose and Magnetic Base for best “hands-free” positioning for optimal cleaning. They work well on small targets for automated systems or inspections areas prior to packaging.

GEN4 Ionizing Point

This single point design is manufactured to remove static on small targets in tight spots. Utilizing the same rugged design of the Gen4 Static Eliminators, this product can remove static in spot areas and help to stop jams in slitting operations. They can also be panel mounted to neutralize duct air.

Intellistat Ion Air Gun

This is one of EXAIR’s newest product that is a lightweight solution for static and particle removal. The patent-pending air gun comes complete with a 24Vdc power supply and a 6mm compressed air tubing. There is a red and green LED lights to signify the production of ionized air for visual feedback. The engineered air nozzles are quiet and OSHA safe. The emitter point inside that creates the ions can be easily changed for replacement. The applications range from circuit boards, electronic manufacturing, laboratories, clean rooms, and scientific testing.

Intellistat Ion Air Nozzle

And if you need a hands-off product that meets all the requirements the Intellistat Ion air guns does. The Intellistat Ion Air Nozzle is your answer!

If you find that static is creating process problems, wasting time, and costing you money, EXAIR has a large line of Static Eliminators that can help you. If you have an application, you can contact an Application Engineer at EXAIR to help select the correct model and remove that static nuisance.

Jordan Shouse
Application Engineer

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Twitter: @EXAIR_JS

November’s Promo Features Cool Products

Published on November 14, 2022January 4, 2023 by Brian FarnoLeave a comment

That’s right, with the start of November this year we also start our Cold Gun promotion. This promotion runs from the start of November until December 31, 2022. The best part is that Cold Guns have a long history of providing spot cooling solutions for industry. Cold Guns have been cooling product and processes for over 35 years! Take advantage of the current promotion today!

The EXAIR Cold Gun promo is a great way to receive an additional tool to extend the use of the Cold Gun. With the purchase of a promotional Cold Gun System w/ Single Point Hose Kit or promotional High Power Cold Gun System w/ Single Point Hose Kit you will receive a Dual Point Hose Kit for free. This is a $48.00 USD value. The Cold Gun will drop your compressed air temperature by 54°F when operating at 100 psig inlet pressure. Choose the standard point tip or the 1″ fan tip to blow the cold air. The total length of the flexible discharge hose is around 11″. If more coverage is needed, the promotional Dual Point Hose Kit gives around 5-6″ of straight hose before splitting into two smaller lines that offer both point or fan tip nozzles as well. This dual point can be used to reach both sides of larger diameter cutters and components that need a blast of cool air.

The Cold Gun is easily setup in any machine that has a ferrous metal surface thanks to its integrated magnetic base that will hold the unit in place even when the machine is moving or vibrating. If you do not have ferrous metal available for the magnetic base, using rigid piping or even something like u-bolts to hold the unit into place is a common practice of customers who need the cooling and know the Cold Gun will perform.

Lastly, if you aren’t certain whether the Cold Gun is the solution, we have an entire team of Application Engineers here to discuss the application, and it is also backed by our 30-day guarantee so our US and Canadian based customers can order one, test it in their facility for 30 days. If they are not pleased with the performance for any reason, the item can be returned to EXAIR. If you want to discuss your application, contact us today!

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

EXAIR Chip Vac Systems For Durable, Quiet, and Effective Industrial Housekeeping

Published on March 21, 2022March 21, 2022 by Russ BowmanLeave a comment

Back when typewriters were an author’s main tool, movies & TV shows would often show an author experiencing a condition known as “writer’s block”, sitting at his desk with a wastebasket overflowing with crumpled papers representing failures-to-launch of their latest work.

For you younger folks, a “typewriter” is a standalone word processor with an integral printer.

The reason I tell you all this, dear reader, is because I had a bad case of “writer’s block” going on with this blog until I had the pleasure of discussing Industrial Housekeeping Products with a caller from a major tire manufacturer. Their needs were typical – and familiar:

Electric powered shop vacuums did the job, but….
They’re loud.
They break down.
They can’t use them everywhere. Their safety rules say they’re not allowed to run them in areas where the floor, equipment, etc., gets wet. (That’s a good rule, by the way…electrocution is serious business).
They’ve got compressed air drops EVERYWHERE…maybe more common even than 115VAC receptacles.
Since it’s a tire plant, they’d be used to vacuum up exactly what you’d expect: scrap bits of rubber, ranging from shavings to pellet-sized chunks.

If they were using it for particularly dense or abrasive material, we’d have talked about the Heavy Duty Dry Vac. If it was for dusty materials (especially critical dust containment of toxic or hazardous materials), the Heavy Duty HEPA Vac would have been discussed. If liquid transfer was involved, we’d have talked about Reversible Drum Vacs, EasySwitch Wet-Dry Vacs, or Chip Trapper Systems. If it was for small jobs and something handheld was desirable, the Vac-u-Gun might have been worth a look (actually…more on that in a minute). But this was a “textbook” fit for a Chip Vac System – consider:

Compressed air powered – no electric motor to burn out.
No moving parts – supply it with clean air, and it’ll run darn near indefinitely, maintenance free.
Compressed air powered, part 2 – no risk of electrocution.
Quiet – at 77dBA, the Chip Vac is 50% quieter than typical electric vacs.

Whatever your needs, EXAIR has a Chip Vac System to meet them!

If you’ve got an open top drum, Model 6193 (55 gallon) or 6193-30 (30 gallon) comes with everything you need for a basic setup. Model 6293 (or 6293-30) adds a Drum Dolly and Tool Holder. Or, for a complete system, ready to go right out of the box, Model 6393 (55 gallon), 6393-30 (30 gallon) or 6393-110 (110 gallon) adds the Drum, a 20ft compressed air supply hose with shutoff valve & gauge, and upgrades to a Static Resistant Hose and Heavy Duty Aluminum Tools. For smaller jobs and/or if space is a premium, Model 6193-5 comes with a 5 gallon container, and Model 6293-5 adds a drum dolly to that.