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

Line Vac for Matrix Removal from Labelling Application

We have been able to specify Line Vacs for a variety of interesting applications that generally tend to be classified as “hopper loading” types of applications. But sometimes, we also get to see them used for other tasks for which they are perfectly matched in their ability. One is for movement of yarn/string as shown in this video originally mentioned in Brian Farno’s blog “Yet Another Way to Help You, Customer”.

Matrix Removal 1Matrix Removal

Another great application is in the labeling process (1. Line Vac; 2. Conveying hose; 3. Compressed air supply and on/off valve). After the labels have been applied to their respective product, there is a waste stream that is referred to as “the matrix”. No, I’m not talking about the movie, but rather the release liner that labels are affixed to in bulk format prior to being used. The normal method for taking up this waste stream was to use a winder. However, after some amount of time, the winder inevitably becomes filled with the matrix and must be emptied. The Line Vac presents a unique advantage in that it can pull the matrix from the machine and simply blow it out to a waste receptacle. The above photos are the most recent incarnation of this system. Below is an older system that has a little different twist.

Matrix Removal 2Matrix Removal 3

If you have a labeling system giving you trouble due to the winding process getting fouled, give the Line Vac products a try. We have models from 3/8” hose size up to 4” hose size which can accommodate various sizes of product moving through.

Neal Raker, Application Engineer