I saw this machine in the faraway corners of a Thai wire manufacturer’s facility. The manufacturer galvanizes their wire to protect it from corrosion and physical damage, and after the hot dip process, the wire must be wound. But, before the wire can be wound, it travels through this machine, which serves as a sort of quality control for the finish of the galvanization.
As the wire passes from bend to bend, it approaches a final stage in which any excess zinc is removed from the OD of the wire, which, prior to my visit looked like the photo below.
The performance of this homemade blow off was unrepeatable, and the end user had questions about whether the compressed air was being used efficiently. To find out, we connected a Digital Flowmeter, and found that this homemade device was consuming twicewhat a comparable Super Air Wipe requires at the same pressure.
We then connected a Super Air Wipe to find that the blow off was not only stronger, but more uniform from the EXAIR unit. And, the clamshell design of the Super Air Wipe can allow the installation to occur at any point along the process, without requiring that the wire is “threaded” through the Air Wipe.
Today, I had the opportunity to the work with a customer, who produces soft seals for the window and door industry. The soft seals are created through a multi-step process, where drying is critical for the overall quality of the product. After the extrusion of PPE (polyphenyl ethers) material, the seal is run through a water bath. The next step is for the extruded PPE to be dried using compressed air. After drying, a glue is applied to join the PPE soft seal to an aluminum frame. If the PPE was not dry from the water bath, the glue would not bond the aluminum and soft seal together.
The customer wanted to replace their current compressed air drying system. The current system utilized (3) ceramic air wipes to dry off the PPE seal before the gluing process. He was relatively new to the company or the particular line, so he did not have all the history for the production line during our conversation. We were both wondering why three consecutive air wipes were used when one air wipe should be getting the job done, but we never could figure it out regardless. I pointed out that one EXAIR Super Air Wipe will clean off a variety cross sections in one pass. The old air wipes used 7.6 SCFM of compressed air for each air wipe or a total air flow of 22.8 SCFM to dry the rubber seal. Also, the old air wipes created 80 dB of noise. A correctly sized 1/2″ EXAIR Super Air Wipe would lower that noise to 75 dBA and lower the total air consumption to 13.9 SCFM.
By replacing three inferior ceramic wire dryers with one EXAIR model 2400 Super Air Wipe, the customer was able to get the job done better, reduce his noise level and save compressed air. EXAIR has the broadest line of problem solving compressed air products, if you have a problem area or an application you think we may be able to solve, please let us know. We are happy to assist.