The Case For The EXAIR Super Ion Air Knife

One of the best ways, in industry, to generate a static charge is to roll or unroll non-conductive materials such as polymer films, plastic sheet, etc. It’s common to see static charges well in excess of 10,000 volts in such operations, like the one I discussed with a customer recently.

The separation of the non-conductive surfaces (like when this plastic film is unrolled) is capable of generating an incredible amount of static charge. Here are two examples showing 12,400 and 16,900 volts.

One of the best ways, in industry, to dissipate a static charge is to use ionized air.  There are different methods of doing this; one of the most popular is to effect a Corona discharge, via a high voltage, low amperage electric current.  This is precisely what EXAIR’s Static Eliminators provide: a Corona discharge produces a bulk of both (+) and (-) ions in the enormous volume of high velocity air flow generated.  When these (+) and (-) ions flow onto a surface charged with (-) and (+) ions, they cancel each other out, leaving a net neutral charge.  Static, eliminated!

THE best way to accomplish this is the EXAIR Super Ion Air Knife.

From small bottles to wide films, EXAIR Super Ion Air Knives come in a variety of lengths to meet the needs of most any static dissipation application.

By combining an Ionizing Bar with a Super Air Knife, as Super Ion Air Knife provides rapid static elimination AND blow off of any dust, chips, or debris that was being statically held.  The laminar curtain of ionized air not only maximizes the rate of static dissipation, but is also ideal for stripping/sweeping away any debris, leaving a clean, static-free surface.  No more jamming, tearing, nuisance shocks to operators, dust attraction, or any of the other host of problems associated with static electricity.

The ionized air flow can be precisely regulated to whatever level it takes to get the job done.  At 100psig, the powerful, high velocity blast will dissipate 5,000 volts of static charge in 0.18 seconds.  If the material is fragile, or if that kind of air flow might disrupt the process, it’s not a big deal…even at 5psig supply pressure, that same 5,000 volts is dissipated in 0.40 seconds.  That’s how it works on the plastic roll above – with just a whisper of ionized air flow from a Super Ion Air Knife, they consistently reduce the resultant static charge to less than 400 volts…far below the threshold for the nuisance shocks they wanted to avoid.

They’re on the shelf in lengths from 3 inches to 9 feet long, and we can make custom lengths in three days after receipt of an order.  The 115/230VAC GEN4 Power Supplies are available with 2 or 4 outlets, to energize any 2 or 4 EXAIR GEN4 Static Eliminators.

Versatile. Efficient. Effective. Quiet. Safe.  And, readily available.  If you’d like to discuss a static problem, give me a call.

Ion Air Jets Make Beekeeper’s Operation As Sweet As Honey

A honey producer sells their product in specialty glass jars. They pay a premium for these jars, as they enhance the appearance of their product, so the “visual” is obviously very important to them. So much so, that they’re willing to go to great lengths to make sure that the jars are sparkly clean and pristine before filling them with honey.

It’s a given that the inside needs to be clean…it’s a food product, so, of course, there’s a thorough cleaning process for that. The outsides of the jars, though, would sometimes have a little dust or debris left over in the ‘nooks and crannies’ which took away from the crystal clear appearance of the rest of the jar.

They got a Model 8494 GEN4 Ion Air Jet Kit, which they use to remove all of this dust & debris from the outside of the bottle, and then they got another Model 8194 GEN4 Ion Air Jet (which uses the same Power Supply, Filter Separator, and Pressure Regulator from the 8494 Kit) to blow an “insurance” blast of ionized air inside the bottle…just in case. “You can’t be too careful” is a popular mantra for folks who make food products, it seems!

Compact, convenient, easy to use: EXAIR Model 8194 GEN4 Ion Air Jet creates a focused blast of ionized air for static dissipation and cleaning.

Ionized air is extremely effective for ensuring the cleanliness of glass surfaces. Window makers love our Super Ion Air Knives. Some big name sunglasses manufacturers use our Ion Air Jets to ensure the highest quality and consistency of their products. Ion Air Jets and Ion Air Cannons are commonly used to keep optics clean & clear in critical vision inspection systems. If you’d like to find out more about improving “visuals” with ionized air, give me a call.

FREE A/C Sensor With Any EXAIR Static Eliminator Purchase

Model 7929 EXAIR AC Sensor – FREE to end user customers when purchasing ANY EXAIR static eliminator through MArch 31st, 2018

EXAIR will be giving away a free AC sensor with the purchase of any EXAIR static eliminator from January 1st through March 31st, 2018.  This special promotion will apply to all purchases of EXAIR static eliminators – Super Ion Air Knife, Standard Ion Air Knife, Super Ion Air Wipe, Ion Air Cannon, Ion Air Gun, Ion Air Jet, Ion Point, and Ion Bar.  End users ordering within the promotional period will receive the AC sensor shown above, a value of $53.00!

What can a free AC sensor do for you?

EXAIR’s AC sensor provides a non-contact means to verify a voltage presence.  When voltage is detected the tip of the sensor will illuminate and an audible tone is triggered.  This is an excellent method to determine whether voltage is present going into your EXAIR ionizing product or any other device.  Suitable for use in testing wall receptacles, switches, fuses, and junction boxes.

What can an EXAIR static eliminator do for you? 

EXAIR static eliminators solve problems related to process flow, dust and dirt contamination, printing/labeling errors, paint adhesion, packaging disruption, material alignment, tearing/jamming/curling of products during processing, and even harmful shocks.  EXAIR static eliminators provide a non-contact, shockless means to remove static in industrial processes, thereby removing the problems and disturbances created by the static.

If you have a static concern and are in need of a viable, reliable solution, contact an EXAIR Application Engineer.  We’ll be happy to help find the right solution for your application, and will provide an AC sensor with any purchase absolutely free through March 31st.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

More Force is not Always Better for Cleaning Glass

Glass Annealing Machine with model 110230

A float glass company purchased an EXAIR model 110230 Super Air Knife kit to clean the surface of glass sheets.  The production manager watched the video of the performance of the Super Air Knife, and he was amazed at the efficiency, effectiveness, and safety that they could provide.  (We have many EXAIR Product videos here).  After they received the Super Air Knife, they mounted it after the annealing process to remove any specks of dirt and debris prior to the final visual inspection.  They were getting some false rejections from contamination that remained on the sheets, and they believed that they needed more force to better clean the surface of the glass.

The blowing system was operating at 73 PSIG (5 bar) air pressure, the maximum amount that could be supplied at the machine.  With the dynamics of the Super Air Knife, the blowing force could be increased by changing the shim thickness.  The plant manager contacted me about the characteristics in force and flow by changing from the standard 0.002” (0.05mm) thick shim to the 0.003” (0.08mm) or 0.004” (0.1mm) thick shim.  (These shims are Included in the shim set for aluminum Super Air Knife kits along with a 0.001” (0.025mm) thick shim).  As an Application Engineer at EXAIR, I was inquisitive about the application and wanted to do a “forensic” analysis of the system to generate the best suggestion.  So, I had him send me pictures of their setup.

With non-conductive materials like glass and plastic, static can be a huge issue.  Static forces can easily be generated and will cause dirt and debris to “stick” to a surface.  This attraction is very strong and will make it very difficult to remove.  If the static force can be neutralized, then the contamination can easily be removed from a non-conductive surface.

With this understanding, my initial suggestion for the company above was to remove the static charges from the surface of the glass with an EXAIR Static Eliminator.  With the complimentary design of the Super Air Knife, it is simple to mount an Ionizing Bar directly to the Super Air Knife that they currently installed.  I recommended a model 8030, 30” (762mm) long Gen4 Ionizing Bar, and a model 7960 Power Supply to transform the Super Air Knife into a Gen4 Super Ion Air Knife.  The positive and negative ions that are generated by the Gen4 Ionizing Bar can be carried by the laminar air flow of the Super Air Knife to treat the surface.  This combination can work well to remove static charges up to 20 feet (6m) away.  Once the static is removed, the force of the air stream would easily remove any dust or debris from the glass surface.

Gen4 Super Ion Air Knife

As an added note from the picture above, I recommended a different position for the Super Air Knife, or soon to be Gen4 Super Ion Air Knife to optimize the blowing area.  The glass company had the air knife positioned to blow straight across the surface of the glass.  For proper cleaning and better contact time, I suggested to mount the Super Air Knife with the Ionizing Bar about 6” (152mm) above the surface of the glass and angle it to about 45 degrees.  This would increase the contact angle and allow for a better blowing force to remove all the debris.  By adding the Gen4 Ionizing Bar and adjusting the blowing angle, they were able to reduce the air pressure from 73 PISG (5 bar) to 30 PSIG (2 bar); saving compressed air and reducing false rejections.

Pictures are always helpful in analyzing an application.  With the company above, we were able to optimize their cleaning process and reduce the total amount of compressed air required.  If you find that you need more force to clean a non-conductive surface, EXAIR Static Eliminators will resolve these static problems.  If you would like to discuss your application with an Application Engineer at EXAIR, we can go through the “forensics” analysis for optimization.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Removing Static From Diaper Absorbent Material

This is where the absorbent material inside a disposable diaper is made

The image above shows one step in the process of disposable diaper manufacturing.  In this step of the process, the absorbent material is ground through a mill on the top of the “bunker” where it falls down a shaft and onto a mesh screen.  Once on the mesh screen, the material is repressed into the proper size and shape for placing into the diapers.

This manufacturer contacted one of our Russian distributors about the application because the milling of the absorbent material was creating static.  This static caused the material to adhere to the walls of the bunker chute and to unevenly distribute onto the mesh.  This unevenness leads to holes in the pressed/shaped absorbent material which translates to a reject rate of ~1 out of every 20 diapers.

An EXAIR Ion Bar

The ideal solution in this case needed to eliminate the static within the chute to allow for proper distribution on the mesh below and proper material placement into the diapers.  An Ion Bar was originally desired by the customer, but material accumulation on the emitter points was a concern so this solution was removed from consideration.

An EXAIR Ion Air Cannon

An Ion Air Cannon, however, was able to provide the desired solution by mounting outside of the chute and feeding a low volume of ionized air to remove the static.  The ionized airflow from the Ion Air Cannon is strong enough to permeate the full volume of the application, but low enough to not disturb the absorbent material within the process. Using an Ion Air Cannon allowed this manufacturer to eliminate defects and wasted materials, increase their throughput, and improve the quality of their products.  Defects dropped from 1/20 diapers to less than 1/1000.

If you have a similar application or similar needs, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE