Adjustable Air Amplifier Transfers Plastic Bag Scrap

Many times EXAIR products are used to help sort materials based on their weight or their density by providing a consistent force against a series of targets that should be of the same density or weight, but when they are not, the airflow can be “tuned” to remove the non-conforming parts.

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Model 6042 Aluminum Adjustable Air Amplifier rejects empty pouches.

In this case, our customer (a packaging automation specialist) was working with a form fill and seal machine that was dedicated to making pouches 2” x 8” and filling them with a food product. In some cases, the pouches would not become filled with product and needed to be removed from the line. So, our customer devised a way to mount model 6042 2” Adjustable Air Amplifier along-side the travel of the pouches and set the input pressure and air gap setting to get optimum vacuum capture velocity to suck away empty ones and leave the full ones in-tact. Above you can see a photo that the customer took while mocking up the application at their facility. You can see the hose connected to the output to direct the empty pouches to a wire basket below.

A couple of things in this application made use of the Adjustable Air Amplifier the best choice. The first was the funnel-shaped suction area on the back side of the Adjustable Air Amplifier. This optimizes the Air Amplifier’s ability to draw in ambient air to propel it to the outlet. In doing this the un-filled, light-weight, plastic pouch becomes caught in the high velocity stream and thus gets carried away as desired. The second thing is that since compressed air is the source of power, the customer has infinite adjustability over the amount of suction force that they can apply to the pouch in the application. They can adjust the air gap opening on the Adjustable Air Amplifier to have a coarse adjustment of air consumption as well as vacuum level. Then, they have a finer adjustment that a pressure regulator can provide to really dial in the suction force as they need it to be for removal of the empties.

The idea here is that while Air Amplifiers are generally used for their output flow to cool targets and provide a significant Blowoff force, they can also be used to draw in not only smoke and fumes but also other lightweight items like the empty pouches above.

If you have a need to set up any kind of sorting process, maybe just to separate two different recycling streams or perhaps it is a need to perform a quality control function as shown above, think about EXAIR and our many solutions in this area.

Neal Raker, International Sales Manager
nealraker@exair.com
@EXAIR_NR

Light Duty Line Vac For Paper Trim Removal

Today I worked with a customer that manufactures a wide variety of material handling equipment including coil unwinders.  The engineer was calling because there was a special project for a coil unwinder that could handle a waste piece of paper trim.  As the metal coil is being unwound for delivery to a metal processing machine, the protective paper is pulled off and was to be collected into a waste receptacle for easy handling and disposal/recycling.  The engineer was hoping to replicate an existing system that used a hybrid blower system, with an extra compressed air nozzle, but in a simpler form.

Coil Unwinder

We proposed the use of the 4″ Light Duty Line Vac– shown below.130400The Light Duty Line Vacs offer an effective way to convey small and light materials a short distance. Like the standard Line Vac, the Light Duty Line Vac converts an ordinary hose or tube into a  conveyor for scrap, trim, and bulk materials.

When the process involves moving low volumes of materials over short distances, the Light Duty Line Vac is a great choice. The simplified (2) piece design offers effective conveying at a lower cost. As an added plus, the compressed air consumption is lowered to levels commensurate with handling the lighter materials, at lower volumes and short distances.  Using a pressure regulator to control the supply air allows for tuning of the transfer rate, and keeps air usage to the minimum amount needed.

The Light Duty Line Vacs are available with inlet/outlet diameters from 3/4″ up to 6″.  With no moving parts, maintenance free operation is assured.

ldlvsz
Light Duty Line Vacs – Available in 3/4″, 1″, 1.25″, 1.5″, 2″, 3″, 4″ and 6″ Diameters. All in Stock!

For other larger materials, higher transfer rates, corrosive environments, or abrasive materials, take a look at the other EXAIR Line Vac offerings including the aluminum, 303 and 316 stainless standard Line Vacs, the aluminum, 303 and 316 stainless steel Threaded Line Vacs, high temperature models, standard and threaded Heavy Duty Line Vacs, and lastly the new Sanitary Flanged 316 stainless steel type.

If you would like to talk about Light Duty Line Vacs or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Super Ion Air Knife Removes Foil Dots In Lid Cutting Operation

I recently received an inquiry from a food manufacturer about a packaging line they were having issues with.  The plant fills continuous rows of thermo-formed cups which is then sealed with a single foil lid. Once sealed, a machine cuts the row to separate the cups, which creates small scrap pieces of foil. After the cutting operation, they try to collect as much of the waste trim as possible but some small pieces of foil, they call “dots”, cling to the surface of the cup and cutter due to static charge.  The company installed a vacuum collection hood in this area, to try and help keep the foil pieces or any dust from falling onto the cup during the process. While this did help somewhat, some dots would remain and eventually fall off further down the line, making small piles that needed to be manually cleaned to avoid potential jams, which slowed down their production cycle.

The cups are filled and separated on a 44″ wide, mesh-screen conveyor with individual lanes to process multiple rows of cups. After being cut, the cups are moved to the inspection area and then packaged for shipment.  I recommended they mount a 48″ Super Ion Air Knife above and below the cups and direct the airflow to the end where the vacuum collection hood is located. The idea is, as the ions eliminate the charge, the small foil dots will release and the laminar airflow would keep the parts moving toward the vacuum hood, thus removing all foil trim and preventing any piling of trim further down the production line.

The Super Ion Air Knife produces a sheet of ionized air capable of dissipating 5 kV in just a fraction of a second!

EXAIR offers a wide selection of Static Eliminators for use in a variety of industrial processes. If you are experiencing static concerns in a particular area or to discuss a specific process, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Light Duty Line Vac Used To Move Weatherstrip Trim, Eliminates Production Delay

Last week I was contacted by a custom machine builder who was looking to improve their design of a rubber weatherstrip notching machine for an automotive company. As the weatherstrip enters the machine, there are several cuts taken along the length, resulting in excess scrap trim which drops into a collection bin. The operation is then stopped, so the operator can manually empty the bin into a recycle hopper a few feet away. This was causing a few issues, most notably the delay in production, but also the operators were sometimes forgetting to empty the bin which caused jams in the machine and a messy work area. The machine builder was looking at our Line Vac Conveyors as a more reliable, automated option to convey the material instead of relying on the operator, so they reached out for assistance in selecting the best model.

The lightweight, rubber scrap trim varied in size, with the largest being a piece around 3/4″ wide x 13″ long, and they needed to convey it about 3′ – 4′ with the majority of the run begin gravity fed into the recycle bin. They were hoping to place the Line Vac right at the cutting head, so as the part is being processed, the scrap piece would be pulled in to the suction side, lengthwise, to avoid any blockage or build up. After reviewing all of the information and a sketch of the proposed setup, I recommend they use our Model # 130200 2″ Light Duty Line Vac. The Light Duty Line Vac uses less compressed air than our other air operated conveyors and is the ideal choice when looking to move lightweight or smaller volumes of material a short distance. With this particular application being mostly gravity fed, the Light Duty Line Vac would ensure the material was effectively picked up and delivered to the hopper, eliminating the current manual process.

Light Duty Line Vac
Light Duty Line Vacs are available to ship from stock in sizes ranging from 3/4″ up to 6″.

The Line Vac Air Operated Conveyors have no moving parts or motors to wear out, providing a maintenance free way to move dry material. For help selecting the best option to fit your needs or to discuss how another EXAIR product might be suitable for your application, give us a call.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Super Air Amplifier Removes Unwanted Scrap Material

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EXAIR Super Air Amplifier used for scrap material removal

A few months ago I wrote a blog about using a Super Air Amplifier to remove film from an application workspace and direct it to a waste container.  Earlier this week I had a different end user contact me about a very similar application.

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An image of the complete setup in this application

In this application the Super Air Amplifiers are used in an automotive manufacturing facility to direct scrap material from car doors into the large bags below each station.  The scrap material is lightweight and proves to be problematic if not fed into a contained system.

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The bags where the scrap material is collected

This particular customer was in need of some assistance to duplicate their existing setup, shown in the photos above, into four more workstations.  So, they reached out to us to confirm the model number of the units (which have been “working perfectly”) based on dimensions.

Snip of dims
Dimensions of the units in place; used to determine model number

Using the provided dimensions I was able to confirm the model number is 120022, our 2” Super Air Amplifier.  After confirming this I was able to provide a quotation for the requested Super Air Amplifiers, available to ship from stock.

If you have a similar application or think an EXAIR product may be able to help solve an application problem in your facility, contact an EXAIR Application Engineer.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

When You Can Use An Air Amplifier, or A Line Vac, or…Either?

One of the key applications that we use to promote our Line Vac Air Operated Conveyors is scrap trim removal. In cases where a continuous feed of material needs to be carried away, a properly sized Line Vac is just the thing. They’ll generate a moderate amount of vacuum and conveyance air flow, which can move the material over significant distance, if needed.

I had the pleasure of talking to a long-time customer recently, who has been using EXAIR products to successfully remove the backing strip from a continuous feed of label roll. Instead of the Line Vacs, though, they’ve been using Model 6044 4” Aluminum Adjustable Air Amplifiers. The low density, lightweight film backing doesn’t require much air flow at all to move it, and they only need to carry it away a few feet.

EXAIR's Adjustable Air Amplifier
EXAIR’s Adjustable Air Amplifier: Not always interchangeable with a Line Vac, but…

Recently, though, they introduced a new product with a slightly wider label. The film backing for this has been catching in the 3.02” ID throat of the 4” Air Amplifier, making a BIG mess as it backs up into the machine. They called me for a solution, and I’m glad they did, because (spoiler alert) I had one.

Our Air Amplifiers and Line Vacs both generate a modest vacuum and moderate vacuum flow, but, because they use two different principles of operation to do so, the Air Amplifier makes for a very high vacuum flow, at a lower vacuum level, where the Line Vacs generate a higher vacuum, but a lower vacuum flow.

In some cases, the Air Amplifier is the obvious choice…if you’re moving something that’s already airborne, you don’t need a whole lot of vacuum; you just need the flow to keep it moving. In others, the Line Vac is better suited…like when you’re transferring the bulk contents of a shipping container, where you’ll need a higher vacuum level to pick it up.

In this particular case, either will work…it’s a lightweight material that’s already in motion (no significant amount of vacuum required there), so the throat diameter was the deciding factor: our Model 130400 4” Light Duty Line Vac has a 3.75” throat; which is more than sufficient to prevent jamming. The air consumption on the 130400 (58.5 SCFM @80 psig) is even in the same neighborhood as the 6044 (50 SCFM @80 psig,) so, operationally, it’s almost an even swap as well.

EXAIR's Light Duty Line Vac
EXAIR’s Light Duty Line Vac: Not always interchangeable with an Air Amplifier, but…

If you’d like to find out how EXAIR products can be a viable solution to your problem, give us a call. We’re eager to help.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
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