Static Eliminators Solve Multiple Label Printing Issues

Recently, I visited a local customer to look at a specific application. This company prints over 146,000 different labels on plastic film, paper and foil. They called because they were seeing several different static related issues during printing and stacking processes.

On their first application, involving a 60″ wide sheeter, they were having an issue with irregularities as the sheet travels over several rollers where it enters the print head of the machine, then is cut and stacked. At the time of the visit, they were using a competitor’s product after the printer but those products were not effectively removing the static. We were able to determine they were not working by using  our Digital Static Meter which told us there was still a 2.7 kV charge after the treatment area. I recommended the customer replace the ineffective units with our 60″ Ionizing Bar. The Ionizing Bar produces a bulk of positive and negative ions to eliminate the surface static of an object when mounted within 2″ of the surface of the material. The bar features a mounting flange that would allow the customer to use the existing bracket for easy installation.

Ionizing Bars Work
Ionizing Bars – available from 3″ – 108″.

The second machine we looked at was a 42″ 3-sheet press. Our readings ranged from 4.2 kV on the top sheet, 1.4 kV middle sheet and 9.9 kV on the bottom sheet going into the press/print head and around 15.6 kV at the discharge. This unit also had another anti-static device taped in place but was clearly no longer operational. I again recommend the Ionizing Bar for this application as well. After speaking with the operator, he was saying he was also seeing an issue with the sheets lifting and trying to separate as they were being stacked. To remedy this problem I recommended using our Super Ion Air Knife at low pressure to blow ionized air from behind the sheet to help it float onto the stack and remove static at the same time. The Super Ion Air Knife is our Super Air Knife with the Ionizing Bar attached and is capable of dissipating 5kV in less than half a second.

Super Ion Air Knife
Super Ion Air Knife provides laminar sheet of ionized air across the length of the knife.

Lastly, we looked at their smaller sheeting machine and on this unit we were seeing around 3.5 kV as they stack was fed into the feeder and 7-8kV at the end stacker. At the beginning of the process we noticed the customer was using an air blowoff on each side of the sheet stack to assist with lifting and getting some separation between the sheets for the mechanical lifter to feed the machine. At this area they were experiencing some issues as occasionally the lifter would pick up more than 1 sheet and cause a jam which shut the system down. It turns out the airflow across the sheets was actually generating a slight static charge as we were seeing higher readings around 4.2 kV. Since they were already using air, I recommended replacing these blowoffs with our Ion Air Jet. This would aid in reducing the static and result in a more effective separation between the sheets allowing for a cleaner lift. For the sheet itself, we would recommended the Ionizing Bar if they were able to mount within 2″ or the Super Ion Air Knife for further mounting distance.

NEW Ion Air Jet
Ion Air Jet produces concentrated ionized airflow.

 

We realize we can’t look at every customer’s process but any photos or videos you could share of your application, we would gladly review and make a possible recommendation. Please contact one of our application engineers for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

Cooling a Flue Stack with Air Amplifiers

In some cities when you look along the skyline, you see exhaust stacks bellowing out plumes of smoke. I never paid much attention to the structure except that they were tall and in some cases very wide. I received a call from a customer that had a flue stack that exhausts hot gas in their petroleum process. They had an issue with hotspots in the wall of their stack. The customer need to cool the hotspots and decided to contact EXAIR.

Flue Stack
Flue Stack

His stack had a diameter of 6 foot (1.8 meters), and the hotspots were reaching a temperature of 750 deg. F (400 deg. C). This was too hot, and it could cause premature issues with fatiguing of the structure of the stack. He wanted to reduce the temperature to 400 deg. F (204 deg. C) to keep the stack from warping or degrading. Together, we were able to create a solution using our stainless steel Adjustable Air Amplifiers.

Adjustable Air Amplifier
Adjustable Air Amplifier

The customer was able to create a stainless steel circular manifold to mount 40 pieces of the model 6032 around the circumference. This manifold ring would be mounted around the stack near the hotspot. With the high amplification ratio associated with the Air Amplifiers, it can move a large volume of cooler ambient air along the hotspot of the stack. In keeping the stack cool, he could continue operations and reduce his worry for untimely shut-downs and costly maintenance.

Whenever you have something hot and you need to cool it down, the Air Amplifiers could be the solution for you. If you would like to speak to an Application Engineer about your cooling application, you can contact us at EXAIR at 800-903-9247.

 

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

 

“Stack” image courtesy of paulgalbraithCreative Comment License

How To Choose An Air Knife

The EXAIR Super Air Knife has a prominent place near the front of our catalog, and THIRTEEN pages of photos, application details, performance data & specifications. It’s the most efficient and quietest product of its kind on the market, and our most diverse product offering in terms of size range, operational adjustability, materials of construction, and accessories available. For almost any general industrial air blow off application, the EXAIR Super Air Knife is the superior choice in terms of air usage, sound level, and capability.

EXAIR Super Air Knives come in a wide range of lengths, for a wide range of possibilities.
EXAIR Super Air Knives come in a wide range of lengths, for a wide range of possibilities.

As tireless champions of the causes of reducing air consumption and noise, we’re always going to promote these benefits of the Super Air Knife. Still, a caller asked me the other day, “Well, why do you still make the others?”…meaning, of course, our Standard and Full Flow Air Knives. Why, indeed:

*Given the same air supply pressure, the Standard Air Knife generates the highest force of our three styles. The amount of force applied isn’t always a prime consideration…if you think about one of the more “textbook” applications for an Air Knife, it doesn’t take a great amount of force to blow off dust and light debris from a conveyor belt…certainly this is a case where efficiency factors in: the lower air consumption of a Super Air Knife can pay for the cost difference between it and a Standard Air Knife in as little as three months of operation.

The Standard Air Knife has the highest force, for when it's needed.
The Standard Air Knife has the highest force, for when it’s needed.

Of course, if you’re blowing stubborn debris out of tight spaces, like gummy, greasy dirt that’s accumulating in the recesses of a finned tube heat exchanger, that extra force can make all the difference. No; the Standard Air Knife isn’t as efficient or quiet as the Super Air Knife, but it’s still a far cry better than a drilled pipe.

*While the Super Air Knife is pretty compact – you only need a few square inches of profile area to successfully mount it – the Full Flow Air Knife is even smaller, requiring not much more than one square inch of profile for mounting. With ports on the rear face (instead of the ends & bottom for the Super Air Knife,) they can fit in very tight quarters.

Low profile and lightweight, the Full Flow Air Knives are a great fit for tight quarters.
Low profile and lightweight, the Full Flow Air Knives are a great fit for tight quarters.

The Full Flow Air Knife is also the lightest weight for a given length. A 36” Aluminum Super Air Knife, for instance, weighs about 8lbs. The 36” Aluminum Full Flow Air Knife weighs less than 4lbs. Most of the time, 8lbs is a very manageable amount of mass to support, but there are situations where every ounce matters, and if yours is one of them, you’re looking at the Full Flow Air Knife all the way.

*The biggest (in the most literal sense) factor in Air Knife selection is, well…size. We make the Standard Air Knives in lengths to 48”, and the Full Flow Air Knives come as long as 36”. The Super Air Knives, however, are stocked in lengths from 3” to 108”, and can be coupled together for as long of an uninterrupted, steady, laminar air flow as you need.

At the end of the day, a majority of blow off applications can be handled just fine with any of our Air Knives. If you’d like to discuss your application and see which one is best for you, give us a call.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
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