EXAIR’s Static Eliminator Variety Provides Solutions for Any Industry

As the weather starts to change and the colder dryer months are upon us, static electricity can become a real nuisance.  Machines will start jamming, alignments will be difficult, dirt will collect to surfaces, and hazardous sparks can shock personnel.  EXAIR manufactures a line of Gen4 Static Eliminators, also called ionizers, to remove these nuisances.

Static is generated from non-conductive surfaces being “rubbed”.  This could be caused from going over rollers on a conveyor, stacking product onto each other, sheet feeding, and even peeling away a backing material.  When a non-conductive surface, or insulator, is moved or separated, electrons are “stripped” and redistribute into different areas on the surface.  Static charges are typically measured in kilovolts (KV), or 1,000 volts, and they can be either positive or negative in nature.

The higher the charge, the stronger the static force.  At a 10 KV static charge, a spark can jump one inch (25 mm) from the surface.   You probably felt that shock when working with plastic or non-conductive materials.  EXAIR has a Digital Static Meter to measure the amount of static voltage on a surface.  It is a great tool for finding problem areas in your process as well as determining the effectiveness of the treatment.

Static is dynamic.  The more you rub or move the material, the higher the static charges can form.  Static can also regenerate itself after the charges have been removed.  With higher static charges, the attraction force to other materials is much stronger.  This attraction could be to other products, dust, lint, and even you.  An undesirable effect of static can be seen with dirty surfaces, tearing, alignment, jamming and shock to personnel.  The EXAIR Gen4 Static Eliminators are engineered to remove both negative and positive static charges in an assortment of designs to best fit the application.

EXAIR manufactures nine different products, including Static Eliminators with air assistance to reach farther distances or Static Eliminators without air when surfaces could be disrupted by air flow. The newest product, the Intellistat™ Ion Air Gun is engineered for clean processes, laboratory and test environments.

The Gen4 ionizers are powered by a 5,000 Vac power supply.  The alternating current, AC, will create both negative ions and positive ions.  No matter the kind of static charge is on the surface, the Gen4 Static Eliminators will be able to remove it.  The power supplies come in either a 2 port or 4 port design; so, you can power multiple Gen4 Static Eliminators with one power supply.  The input power is selectable from either 115Vac or 230Vac in both 50/60 hz. An armored and electromagnetic shielded cable connects the power supply to the ionizer in a single wire design. This will help to protect the cable from abrasions, cuts and splits in industrial areas.

The Intellistat Ion Air Gun is powered with a 24Vdc power supply. The Gen4 Static Eliminators and the Intellistat Ion Air Gun have a shockless design, and they are UL Component Recognized and CE compliant.  I will give a brief description of each product that utilizes this rugged design for optimal static neutralization.

Gen4 Static Eliminators with Air:

Super Ion Air Knife
  1. Gen4 Super Ion Air Knife: This product has the best compressed air efficiency in removing static by combining the Super Air Knife with an Ionizing Bar.  The Gen4 Super Ion Air Knife has a 40:1 amplification ratio and uses the laminar air flow to carry the positive and negative ions to the surface.  The laminar flow allows for a quick static discharge in fast conveyance speeds.  They can also remove static from surfaces up to 20 feet (6.1 meters) away.  EXAIR manufactures stock lengths from 3” (76mm) to 108” (2.74 meters).  Some typical applications for the Gen4 Super Ion Air Knife are found in web cleaning, sheeters, pre-paint dust removal, and shrink wrappers.
  2. 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 Super Ion Air Wipe
  3. 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
  4. 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 Gun
  5. Gen4 Ion Air 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.

    Ion Air Jet
  6. Gen4 Ion Air Jet: 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.
  7.  Intellistat™ Ion Air Gun: This is 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.

The Gen4 Static Eliminators with air can be purchased with kits which will include the power supply (required for ionization), a filter (to clean contamination from the compressed air), and a regulator (to control the blowing force).  In the spirit of compressed air efficiency, EXAIR also offers the Electronic Flow Control, EFC, that uses a photoelectric sensor to turn on the air flow only when the product is under the Static Eliminator.

Gen4 Static Eliminators without Air:

Ionizing Bar
Low cost Ionizing Bars eliminate static cling.
  1. Gen4 Ionizing Bar: 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 shockless 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 Ionizing Points
  2. 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.

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.  For our U.S. and Canadian customers, we are offering a promotion for online orders for a limited time.  You will receive an AC Sensor, a $59.00 value, for free as a Promotional item from now until the end of March 2021 with a qualified purchase.  How can you not give them a try?  If you have an application, you can contact an Application Engineer at EXAIR to help select the correct model and remove that static nuisance.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

The Heavy Duty Line Vac™ moves CO2 Cartridges

Threaded Heavy Duty Family

In trying to cut over-all costs, companies are reviewing process flows throughout their plant.  A CO2 cartridge manufacturer was following that same strategy.  They wanted to move the silk-screening process that marked the outside of the cartridges to a different location.  Currently, the operators would have to pick up bins to move them about 50 feet (15 meters) to the packaging area.  They currently were using blower-type vacuum systems in other parts of their process to move the cartridges through different stages.  But, the bulkiness and noise level of the blower system made them have to find an alternative way; so, they contacted EXAIR.

For their process, they would start with a steel cap.  The metal caps would run through a series of different forms where round punches would “redraw” the metal into a final diameter and thickness.  Once it is finished through this process, it would look like a test tube.  The metal tubes would have the ends heated and pressed with a set of different dies to create the “neck” region.  The “neck” section would be cut and lathe to make a sealing edge.  The cylinders would then go through a washing and drying system to clean.  Once dried, they would travel to the filling station where the cylinders would be partly filled with liquid CO2, and then capped.  The bare steel cylinders would move through a zinc-coating process for protection and appearance.  The filled cartridges would then be inspected by quality control prior to screen printing on the outer diameter.  The finished CO2 cartridges had an outer diameter of ¾” (19mm) (reference photo below).  Once they are printed, the shipping staff would carry them to their department for packing.

The process flow change for this company was to move the silk-screening process about 50 feet (15 meters) from the current position.  With an EXAIR Air Operated Conveyor or Line Vac™, the QC department can transfer the cartridges to the screen printer near the packaging department.  This would stop the needless handling of the filled bins between the printing station and the packaging station.  Not only did this speed up packaging, but it also ergonomically helped the operators from lifting and carrying.

Heavy Duty Line Vac Kit

For the material, distance, and size; I recommended the model 152125 1 ¼” Heavy Duty Line Vac Kit.  This Line Vac is made from a hardened alloy material which makes them resistant to abrasion and wear.  The throat diameter has a clearance of 1” (25mm) which is enough to carry the ¾” (19mm) diameter cartridges.  With a kit, it will also include a filter, regulator and a bracket.  The filter will help keep the Line Vac and the cylinders clean.  The regulator will allow for flexibility in conveyance rates, distances, and speeds.  The bracket helps to mount the Line Vac to a sturdy base for support.    With the small footprint and compact design, it was easy to set up and use as a simple conveyor.

After installation, the Production Manager was amazed by the simplicity of the design and the ease of operation.  He could also reduce maintenance cost without having to change intake filters, check bearings, monitor electrical controls, and replace any failed motors within the blower-type system.  The EXAIR Line Vacs do not have any moving parts to wear; so, they are reliable and long-lasting.  Overall, as compared to the blower-type systems; the cost, set-up, and operation were greatly improved with the EXAIR Line Vac.  They were so happy in meeting the criteria above; the Production Manager mentioned that he would be replacing their existing blower systems when they fail.  And as mentioned above with all the transfers to the different stations, there would be many spots for the EXAIR Line Vac to be used.

If you need to convey materials like cartridges, steel shot or abrasive products, the Heavy Duty Line Vac could be a blessing for you.  Not only can they transfer material safely and quickly, but they also will ergonomically help in saving the backs and knees of your operators.  How can this get any better?  Until the end of October 2020, we are running a promotional ad for our U.S. and Canadian customers.  You will receive a 2” Flat Super Air Nozzle, a $72.00 value, free with qualified purchases online.  If you would like to discuss any of your conveying application, please contact an Application Engineer at EXAIR.  We may have a solution for you.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Safety Air Gun Promotion: Now Through September 30th!

August 1st through September 30th EXAIR is running a promotion that’ll get you a free 1” Flat Super Air Nozzle with the purchase of any promotional VariBlast, Soft Grip, or Heavy Duty Safety Air Gun. Inexpensive air guns are commonly seen through a variety of industrial supply companies. Most consist of poorly made parts or materials that will wear out and break quickly. In addition, their performance is commonly akin to that of an open-ended pipe and can necessitate an extremely high compressed air consumption.

In addition to wasting unnecessary air, they’re also VERY loud. Many of these guns do not adhere to the sound level restrictions set forth by OSHA in 29 CFR 1910.95. All of EXAIR’s Safety Air Guns are available with Chip Shields to protect operators from debris and adhere to dead-end pressure requirements as outlined by OSHA 29 CFR 1910.242(b). It’s much easier to implement safe products upfront than after you’ve had a random inspection by OSHA. As anyone who’s experienced one can attest to, they don’t just fine you once. You’ll get fined for each individual location in your facility where operators are using air guns that don’t adhere to the proper standards.

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EXAIR offers (4) different styles of Safety Air Guns with a wide range of different force levels, flows, and accessories. The VariBlast Compact Safety Air Gun is a powerful gun that allows you to adjust the force delivered from the gun depending on the trigger valve pressure. Pull the trigger just a little for a light force, or all the way for maximum force without having to adjust your air pressure. It’s small and compact, but powerful while still light and ergonomic. blog_SGSAG_500x

The Soft Grip Safety Air Gun has a durable cast aluminum body suitable for rugged industrial use. The large trigger makes for easy operation and a convenient hook at the top allows the gun to be easily stored. Chip Shields for worker safety and extensions for hard to reach areas are available up to 72” long.

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The Heavy Duty Safety Air Gun also comes with a durable cast aluminum body and incorporates a rugged composite rubber grip. Also with a wide trigger, these guns can be used for hours without fatigue. The Heavy Duty Safety Air Gun is available with Chip Shields and extensions up to 72”.

As part of the promotion, you’ll receive one free Model 1126 1” Flat Super Air Nozzles. Delivering a 1” wide, high velocity airflow, these nozzles utilize EXAIR’s patented shim design to maximize entrained airflow while reducing noise levels. They also offer a great deal of adjustability, shim sets in varying thicknesses are available to allow you to either reduce force and flow, or increase it depending on the application. Don’t wait until after the promotion ends, get your Safety Air Guns on order now so you can take advantage of this great promotion!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Promotional Item: Gen4 Static Eliminators and a free AC Sensor

As the weather gets colder and the air gets dryer, static electricity can become a real nuisance in a production plant.  Machines will start jamming, alignments will be difficult, debris will collect on surfaces, and hazardous sparks can shock personnel.  EXAIR manufactures a large line of Gen4 Static Eliminators to remove this static nuisance.  And beginning January 1st, 2019; EXAIR will be giving away a free AC Sensor, a $57.00 value, with a purchase of any of the Gen4 Static Eliminators.

EXAIR stocks eight different product lines in two different styles, Gen4 Static Eliminators with Air and Gen4 Static Eliminators without Air.  In conjunction with a power supply, these ionizers can create both negative ions and positive ions to remove any type of static charge that is on the surface.  The Gen4 Power Supplies come in either a 2 port or 4 port configuration; so that, you can power multiple Gen4 Static Eliminators at once.  From the power supply to the ionizer, an armored and electromagnetic shielded cable is used in a single wire design. This helps to protect the cable from abrasions, cuts and splits in industrial areas.   The Gen4 Static Eliminators have a shockless design, and are UL Component Recognized and CE compliant.  I will give a brief description of each product that utilizes this rugged industrial design for optimal static neutralization.

Gen4 Static Eliminators with Air:

Gen4 Super Ion Air Knife
  1. Gen4 Super Ion Air Knife: This product has the best compressed air efficiency in removing static by combining the Super Air Knife with an Ionizing Bar.  The Gen4 Super Ion Air Knife has a 40:1 amplification ratio and uses the laminar air flow to carry the positive and negative ions to the surface up to 20 feet (6.1 meters) away.  The laminar air flow also allows for a quick static discharge in applications with fast conveyance speeds.  EXAIR manufactures stock lengths from 3” (76mm) to 108” (2.74 meters).  Some typical applications for the Gen4 Super Ion Air Knife are found in web cleaning, sheeters, pre-paint dust removal, and shrink wrappers.

    Gen4 Standard Ion Air Knife
  2. Gen4 Standard Ion Air Knife: Similar to the Gen4 Super Ion Air Knife, the Gen4 Standard Air Knife has a good efficiency at 30:1 amplification ratio.  It utilizes the Coanda effect to draw in ambient air, and 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 Super Ion Air Wipe
  3. 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 pipes, 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 decay in removing static for speedy transfers.

    Gen4 Ion Air Cannon
  4. 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 by 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 Gun
  5. Gen4 Ion Air 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 to pre-treat within “shock” zones.  The Ion Air Guns work great for small batch processes used for quality checks or label applications.

    Gen4 Ion Air Jet
  6. Gen4 Ion Air Jet: 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 target area.  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 Static Eliminators without Air:

Gen4 Ionizing Bar
  1. Gen4 Ionizing Bar: This rugged design is for industrial use to remove static cling from flat surfaces. They range in length from 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 compact, shockless and works well in applications where blowing air could be a detriment.  The applications would include screen printing, labeling, and large printing processes.

    Gen4 Ionizing Point
  2. Gen4 Ionizing Point: This single point design is manufactured to remove static on small targets in tight spots.  Utilizing the same rugged design, this product can remove static in spot areas and help to stop jams from slitting operations. They can also be panel mounted to neutralize areas using ducted air.
Model 7929 EXAIR AC Sensor – FREE to end user customers when purchasing ANY EXAIR Gen4 Static Eliminator through March 31st, 2019

Now how about that free promotional item, the AC Sensor, with a purchase of any of the Gen4 Static Eliminators above?  This device, as mentioned above, has a $57.00 value which you can get for free.  This sensor provides a non-contact way to verify if voltage is present.  A red light at the tip will glow, and an audible tone is sounded when voltage is detected.  The model 7929 AC Sensor is an ideal tool to quickly verify that power is going to your ionizer.  This instrument will also work for finding power in receptacles, junction boxes, switches and breaks in power cords.  Batteries will be included, so you can start using it right after receiving the robust Gen4 Static Eliminators.

If you are an end-user and located within the United States or Canada, you can take advantage of this offer until March 31st, 2019.  An Application Engineer at EXAIR will be happy to assist you with your application and a solution with the Static Eliminators.  And if you qualify, a free AC Sensor.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb