Tag: super air knife

Vortex Tubes For Spot Cooling Processes

Published on by Al WooffittLeave a comment

EXAIR’s Vortex Tubes are a great product for many cooling applications. When supplied with a clean and moisture-free source of compressed air, they will generate two streams of airflow, one hot and one cold. They are a low-cost and reliable solution, capable of producing temperatures ranging from -50°F to +260°F. We have flow rates from 2 SCFM to 150 SCFM, producing refrigeration over 10,000btu/hr.

We also have several other product lines that are great for cooling, like our Air Knives or Air Amplifiers. So, why would you choose a Vortex Tube? Our Air Knives and Amplifiers cool primarily by moving large volumes of ambient air. If you have a 400°F part that needs cooling to under 100°F, then hitting it with large amounts of 70°F ambient air is going to rapidly bring the temperature down. This does mean that there is a limit to how low of a temperature you can achieve with these products; our Air Knives and Amplifiers won’t be able to cool below ambient temperatures. Our Vortex Tubes, on the other hand, with temperatures as low as -50°F, can provide much more powerful cooling and targeted cooling.

Now you have determined that a Vortex Tube is right for you, you’ll need to decide between our two different series: 32XX and 34XX. The difference between the two model types comes down to the Cold Fraction, which is determined by where the Control Valve is positioned. When you open the Control Valve (by turning it counterclockwise, as shown by the blue arrow in the photo to the right), it decreases the Cold Fraction, which leads to a reduced flow and a significant drop in temperature in the cold air discharge. Conversely, closing the Control Valve (by turning it clockwise, indicated by the red arrow) boosts the cold air flow, but causes a smaller temperature drop. This ability to adjust is crucial for the Vortex Tube’s flexibility.

 You can set the Cold Fraction as low as 20%, which means that a small portion (20% to be precise) of the supply air is sent to the cold end, resulting in a significant temperature drop. On the flip side, you can crank it up to 80%, meaning that most of the supply air heads to the cold end, but the temperature drop won’t be as drastic. Our 34XX Series Vortex Tubes are designed for cold fractions between 20–50 %, while the 32XX Series caters to 50–80 % Cold Fractions.

So how do you select the right model for you? To determine this, you need to know what temperature and flow will best serve your application. For most situations, the ~20°F produced by an 80% cold fraction is sufficiently cold. At this cold fraction, you will get the most flow (80% of the inlet supplied). Applications like welding or brazing benefit from higher flows. When your starting temperature is hundreds of degrees Fahrenheit, there is little difference in blowing -20°F air vs +20°F. What you need is more volume to strip away the heat as quickly as possible. In this instance, a 32XX series is the way to go.

If you need lower flow, or to achieve freezing temperatures, then the 34XX series would be the best choice. A chocolate maker took advantage of the lower flow rates offered by this type of Vortex Tube as they didn’t want the airflow to disturb the surface of the chocolate as it cooled, affecting the finish. The greater temperature drop allowed for rapid cooling without reducing quality.

Vortex Tubes can produce higher levels of noise than our Knives and Amplifiers, so we would always recommend using hot and cold mufflers with them. This will ensure they stay within OSHA sound standards. And just like with all EXAIR products, it’s a good idea to use a pressure regulator with a gauge right where you’re using it. This is especially crucial for Vortex Tubes if you want to get an accurate temperature.

Whatever your cooling application, our Vortex Tubes will likely be able to help. If you would like to discuss it, please give us a call!

Al Wooffitt
Application Engineer

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Super Air Knife Shim Sets

Published on by jasonkirbyLeave a comment

EXAIR’s Super Air Knife stands out as a premier solution for reducing both compressed air consumption and noise levels when compared to traditional blowoff techniques. This innovative product is offered in a variety of lengths, ranging from 3 inches to 108 inches, and is constructed from materials such as Aluminum, 303 Stainless Steel, 316 Stainless Steel, and PVDF, making it suitable for corrosive environments. Remarkably, even when operating at high pressures of 80 psig, the Super Air Knife maintains a sound level of only 69 dBA for most applications, ensuring a quieter working environment. The design of the Super Air Knife allows it to entrain air from the surrounding atmosphere at an impressive ratio of 40:1, which significantly enhances its force and airflow capabilities. Furthermore, these air knives comply with or surpass OSHA’s stringent standards for maximum dead-end pressure and noise levels, making them a safe and efficient choice for various industrial applications.

Super Air Knife with Shim Set

The Super Air Knife offers exceptional versatility in adjusting both force and airflow, allowing for precise control tailored to specific applications. When initially purchased, the Super Air Knife is equipped with a .002” thick shim, which establishes the gap between the knife’s body and cap, thereby regulating the volume of compressed air that can pass through its meticulously designed slotted orifice. To enhance its functionality, EXAIR provides a shim set as an accessory for the Super Air Knife. This set includes plastic shims of varying thicknesses—.001”, .003”, and .004”—for aluminum models, enabling users to decrease airflow and force by utilizing the .001” shim or to increase them by opting for a thicker shim. For the stainless steel and PVDF variants, the shim set comprises three .002” shims, with stainless steel shims specifically designed for the stainless models and a PTFE shim for the PVDF. Notably, these shims can be stacked to create a larger air gap, which significantly impacts performance; however, it is crucial to recognize that a larger gap results in increased air consumption. For instance, installing a .004” shim will effectively double the force, flow, and air consumption compared to the standard .002” shim, making it essential for users to carefully consider their requirements when adjusting the Super Air Knife’s settings.

To achieve precise control over the force and airflow of your Super Air Knife, in addition to the various shims available for coarse adjustments, utilizing a pressure regulator is an effective strategy. This device allows you to meticulously adjust the input pressure supplied to the Super Air Knife, which significantly influences both the force and flow characteristics. For instance, operating at a pressure of 40 psig results in a consumption of 1.7 SCFM per inch while delivering a force of 1.1 oz per inch. Conversely, increasing the pressure to 80 psig raises the consumption to 2.9 SCFM per inch and enhances the force output to 2.5 oz per inch. EXAIR provides a range of pressure regulators in different sizes, ensuring compatibility with all models of Super Air Knives, from the compact 3-inch versions to the larger 108-inch variants.

 If you have any questions about the Super Air Knife shim sets, or anything regarding EXAIR and our products, please do not hesitate to reach out. We would love to hear from you!

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

It’s The Most Wonderful Time Of The Year…

Published on by Russ BowmanLeave a comment

One could make a good point about “The Most Wonderful Time Of The Year” being right now because…well, the song just says so, right? I can get on board with that, because I’m the world’s biggest sucker for Christmas music:

Of course, that song was used in one of my favorite ad campaigns of all time to describe a season that started a few months earlier:

But I’m going to have to go with “right now” not only for the Christmas music, but for my personal favorite EXAIR seasonal promotion:

Right now, through the end of the year, EXAIR will give you a Safety Air Gun with any Super Air Knife purchase. Not only do you get THE most efficient and quietest compressed air blowing product on the market today (we have data to back that up from a wide variety of products & devices that customers have sent in for Efficiency Lab testing), we’re going to sweeten the deal with free stuff.

First, let’s talk about the Super Air Knives:

  • They come in lengths from 3″ to 9ft. No matter how small, or big, your blowoff needs are, we’ve got you covered. If you need something longer than 9ft, they can be coupled together for a continuous, laminar airflow curtain as long as you need it to be.
Air Knife Coupling Bracket Kit
  • We make them in low cost, lightweight aluminum, tough & corrosion resistant Type 303 Stainless Steel, even tougher & more corrosion resistant Type 316 Stainless Steel, and PVDF (polyvinylidene fluoride) thermoplastic with Hastelloy hardware & PTFE shims for the highest level of corrosion resistance available.
PVDF Super Air Knife Kits include the Air Knife itself (PVDF body, Hastelloy C-276 hardware, and PTFE Shims,) a PTFE Shim Set, an Automatic Drain Filter Separator, and Pressure Regulator.
  • They’re efficient and quiet — for the same reason. See, the compressed air supply exits through a precise, narrow slot between the Cap & Body, which is precision finished, generating a 40:1 entrainment ratio. That means that for every SCFM of compressed air that the Super Air Knife uses, it entrains 40 SCFM of air from the surrounding environment…THAT’S efficiency. In doing so, that entrained air forms a low velocity boundary layer around the powerful, high velocity primary air stream. This layer serves to attenuate the sound level of that hard-hitting curtain of air, resulting in a sound level of only 69dBA.

And, if you order before 12/31/2025, we’ll throw in a FREE EXAIR Soft Grip Safety Air Gun, fitted with a Super Air Nozzle. If you’re using a loud, inefficient air gun for handheld blowoff, you really need to try one of these. They use the primary compressed air stream to entrain ‘free’ air from the surrounding environment as well, which generates a low velocity boundary layer for sound reduction too. The Super Air Nozzle is well suited for a wide range of industrial blowoff applications, and the Soft Grip Safety Air Gun is ideal for hours of continuous use without fatigue.

EXAIR Super Air Nozzles entrain an enormous amount of air from the surrounding environment, making them efficient, and quiet.

Need something right away? EXAIR has you covered there too: all of these (and pretty much any of our other Intelligent Compressed Air Products) are on the shelf and ready to ship, same day, with orders received by 2pm EST. If you’ve got a blowoff application that you’d like to find a safe, quiet, and efficient solution for, we can help…give me a call.

Russ Bowman, CCASS

Application Engineer
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Get More Air Knife Options Than Anywhere Else: Sizes, Materials, and Shims

Published on by Tyler DanielLeave a comment

EXAIR Super Air Knives provide a reliable source of high velocity, laminar airflow for drying, cooling, and cleaning applications. By entraining ambient air at a rate of 40:1, they increase the total airflow while minimizing compressed air usage, making them an efficient and cost-effective solution for a wide range of industrial processes. With lengths from 3 inches to 108 inches, and multiple materials available, there is a Super Air Knife suitable for nearly any application.

EXAIR offers more material and size options from stock than any other manufacturer. Available materials include:

  • Aluminum, which is lightweight, durable, and cost-effective for general industrial use
  • Stainless steel, Type 303 or 316, for applications requiring resistance to corrosion, chemicals, or high temperatures
  • PVDF, for extremely corrosive environments where other metals degrade

Aluminum and stainless steel knives are available up to 108 inches in length, while PVDF is available up to 54 inches. This broad selection means most applications can be served directly from stock without waiting for a custom build. In fact, all stock knives ship the same day to US customers who place orders by 2:00 PM Eastern Time, allowing production lines to stay running with minimal downtime.

For applications that require precise airflow adjustment, EXAIR provides shim sets:

  • Stainless steel knives include three .002 inch shims
  • Aluminum knives include polyester shims of .001, .003, and .004 inch thicknesses.

These shims allow users to increase or decrease both force and flow without replacing the knife, providing flexibility for different product types, conveyor speeds, or cleaning requirements. This capability can improve efficiency, reduce compressed air usage, and ensure consistent results across multiple production lines.

Proper mounting is also critical to achieving optimal performance. All Super Air Knives include ¼-20 tapped holes along the bottom for mounting, and EXAIR offers a Universal Mounting System for precise positioning on conveyors or machine frames. The system includes rods, brackets, swivel clamps, and hardware for easy installation. Correct positioning ensures the laminar airflow makes full contact with the product, maximizing drying, cleaning, or cooling efficiency.

In cases where a stock knife is not suitable, EXAIR produces custom solutions. Special options include:

  • Custom lengths to fit precise application requirements
  • Modified air inlets or additional mounting holes for unique installation needs
  • Alternative materials for applications with unusual chemical or environmental challenges

Manufacturing is handled entirely in our Cincinnati, Ohio facility, giving EXAIR complete control over quality and the ability to quickly produce both stock and custom knives. This ensures that even specialized requirements can be delivered quickly and reliably.

Whether your application calls for a stock Super Air Knife or a custom solution, EXAIR offers the largest selection of sizes and materials, the flexibility to adjust airflow and force, and support from experienced Application Engineers. We can help you select the right material, length, shims, and mounting method to ensure your system operates efficiently and effectively, saving compressed air while improving results.

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com