Super Air Knife™

ak_sup_pic.JPG
 
Quiet, hard-hitting curtain of air for blowoff, cleaning, drying and cooling.
  • Surprisingly Quiet! - Only 69 dBA! 
  • Reduced Air Consumption!
  • Uniform Airflow!
  • Amplification of 40:1! 

 

What Is Super Air Knife?

EXAIR's Super Air Knife is the latest generation of air knife that dramatically reduces compressed air usage and noise when compared to other blowoffs. The Super Air Knife offers a more efficient way to clean, dry or cool parts, webs or conveyors. It delivers a uniform sheet of laminar airflow across the entire length with hard-hitting force.

Noisy blowoffs become a whisper when replaced with the compact Super Air Knife. Even at high pressures of 80 PSIG (5.5 BAR), the sound level is surprisingly quiet at 69 dBA for most applications! Amplification ratios (entrained air to compressed air) of 40:1 are produced. The Super Air Knife meets OSHA dead-ended pressure and noise requirements.

 

Specials are available. Please contact your distributor. 


 

 

Applications
  • Part drying after wash
  • Sheet cleaning in strip mills
  • Conveyor cleaning
  • Part or component cooling
  • Web drying or cleaning
  • Environmental separation
  • Pre-paint blowoff
  • Bag opening/filling operations
  • Scrap removal on converting operations

 Advantages

  • Quiet - 69 dBA for most applications
  • Minimal air consumption
  • 40:1 air amplification
  • Uniform airflow across entire length
  • Easy mounting - using Universal Air Knife Mounting System or compressed air inlets on each end and bottom
  • Compact, rugged, easy to install

A Model 110024SS 24" (610mm) Stainless Steel Super Air Knife dries bolt covers exiting an electro-polishing tank.

  •  Recessed hardware for easy mounting
  • No moving parts - maintenance free
  • Variable force and flow
  • 316 stainless steel available on special order
  • Stainless steel screws on all models
  • Special lengths available
  • Unlimited system lengths of uninterrupted airflow available
  • Stock lengths to 54 " (1372mm) in aluminum and stainless steel (ss - for temperatures up to 800°F (427°C), food processing or corrosive environments)   

 

How the Super Air Knife Works

Compressed air flows through an inlet (1) into the plenum chamber of the Super Air Knife. The flow is directed to a precise, slotted orifice. As the primary airflow exits the thin slotted nozzle (2), it follows a flat surface that directs the airflow in a perfectly straight line. This creates a uniform sheet of air across the entire length of the Super Air Knife. Velocity loss is minimized and force is maximized as the room air (3) is entrained into the primary airstream at a ratio of 40:1. The result is a well defined sheet of laminar airflow with hard-hitting force and minimal wind shear.


 

 

Smart Use Of Compressed Air

Almost every industrial facility has at least one compressor that is used for hundreds of different tools, equipment and operations. While most applications for compressed air present no real problems, some do. Improper use can translate into unnecessary energy costs, high noise levels and dangerous exposure of personnel to high pressure air.

Reduce Energy Costs

The best way to cut energy costs is through proper maintenance and use of the compressed air system. Leaks and dirty filters require maintenance on a regular basis. Energy savings can also be realized when replacing outdated motors and controls with high efficiency models that often pay for themselves in a short period of time. The most important factor to dramatically boost efficiency is proper use. The Super Air Knife uses only 1/3 of the compressed air of typical blowoffs used in cleaning, cooling and drying operations and can be instantly cycled on and off.

Reduce Noise Levels

High noise level is a common problem for many plants. Compressed air noise often exceeds OSHA (Occupational Safety and Health Administration) noise level exposure requirements, resulting in hearing loss to those working in close proximity. The sound level of the Super Air Knife is quiet at 69 dBA, even at high pressures of 80 PSIG (5.5 BAR). Using the Super Air Knife, it is possible to obtain hard-hitting force without the high noise.

 
OSHA Maximum Allowable Noise Exposure
Hours per day (constant noise)
8
7
4
3
2
1
0.5
Sound Level dBA
90
91
95
97
100
105
110
OSHA Standard 29 CFR-1910.95(a)
 
Eliminate Harmful Dead Ended Pressures

Air can be dangerous when the outlet pressure of a hole, hose or copper tube is higher then 30 PSIG (2 BAR). In the event the opening is blocked by a hand or other body part, air may enter the bloodstream through the skin, resulting in serious or fatal injury. The Super Air Knife has been engineered for safety and cannot be dead ended. It is safe to operate at higher pressures and meets OSHA standard 1910.242(b).

(5) Model 110003 3" (76mm) Super Air Knives blow chips off the fixture, tools and ways on this boring operation.

 
Replacement For Expensive, Noisy Blowers
Energy conscious plants might think a blower to be a better choice due to its slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of bearings, belts and filters. Here are some important facts:
  • Filters must be replaced every one to three months.
  • Belts must be replaced every three to six months.
  • Blower bearings wear out quickly due to the motor that must turn at 17-20,000 RPM in order to generate effective airflows.
  • Poorly designed seals that allow dirt and moisture infiltration along with environments above 125°F (52°C) decrease bearing life.
  • Typical bearing replacement is at least once a year at a cost near $1000 U.S.
  • Many bearings can't be replaced in the field, resulting in downtime to send the assembly back to the manufacturer.
Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often difficult to control since mechanical adjustments are required.

 

 

Blowoff Comparison

 

There are a variety of ways to blow the water from the bottles shown in the photo, but which method is best? The following comparison of drilled pipe, flat air nozzles, a blower and the Super Air Knife proves that EXAIR has the best choice for your blowoff, cooling or drying application.

Our goal for each of the blowoff choices was to use the least amount of air possible to get the job done (lowest energy and noise level). Compressed air pressure required for each was 60 PSIG (4.1 BAR) which provided adequate velocity to blow the water off. The table below summarizes the overall performance. Since your actual part may have an odd configuration, holes or sharp edges, we took sound level measurements in free air (no impinging surface).

(2) Model 110012 12" (305mm) Super Air Knives blow water off bottles prior to labeling.

 
Compare These Blowoffs
 
Drilled Pipe
This common blowoff is very inexpensive and easy to make. For this test, we used (2) drilled pipes, each with (25) 1/16" (1.6mm) diameter holes on 1/2" (13mm) centers. As shown in the test results below, the drilled pipe performed poorly. The initial cost of the drilled pipe is overshadowed by its high energy use. The holes are easily blocked and the noise level is excessive - both of which violate OSHA requirements. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots.
  Flat Air Nozzles
As shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminum and stainless steel from several manufacturers. The flat air nozzle provides some entrainment, but suffers from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers offer flat air nozzles where the holes can be blocked - an OSHA violation. Velocity was inconsistent with spikes of air.
 
  Blower Air Knife
The blower proved to be an expensive, noisy option. As noted below, the purchase price is high. Operating cost was considerably lower than the drilled pipe and flat air nozzle, but was comparable to EXAIR's Super Air Knife. The large blower with its two 3" (76mm) diameter hoses requires significant mounting space compared to the others. Noise level was high at 90 dBA. There was no option for cycling it on and off to conserve energy like the other blowoffs. Costly bearing and filter maintenance along with downtime were also negative factors.
 
  EXAIR Super Air Knife
The Super Air Knife did an exceptional job of removing the moisture on one pass due to the uniformity of the laminar airflow. The sound level was extremely low. For this application, energy use was slightly higher than the blower but can be less than the blower if cycling on and off is possible. Safe operation is not an issue since the Super Air Knife cannot be dead-ended. Maintenance costs are low since there are no moving parts to wear out.
 
 
Blowoff Comparison Statistics
Type of Blowoff
PSIG
BAR
SCFM
SLPM
Horse Power Required
Sound level dBA
Purchase Price
*Annual Electrical Cost
Approx. Annual Maint. Cost
First Year Cost
Drilled Pipe
60
4.1
174
4,924
35
91
$50
$4,508
$920
$5,478
Flat Air Nozzles
60
4.1
257
7273
51
102
$168
$6,569
$1,450
$8,187
Blower Air Knife
3
0.2
N/A
N/A
10
90
$5,500
$1,288
$1,500
$8,288
Super Air Knife
60
4.1
55
1,557
11
69
$480
$1,417
$300
$2,197
*Based on national average electricity cost of 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year.

 
Performance
Super Air Knife Performance with .002" (.05mm) thick shim installed
 
Pressure Supply
Air Consumption
per inch (25mm)
Velocity @ 6" (152mm)
from target
Sound level
@ 3' (914mm)
Force per Inch (25mm)
@ 6" (152mm) from target
PSIG
BAR
SCFM
SLPM
FPM
M/S
dBA
Ounces
Grams
20
1.4
1.1
31
5,000
25.4
57
0.6
17
40
2.8
1.7
48
7,000
35.6
61
1.1
31
60
4.1
2.3
65
9,600
48.8
65
1.8
51
80
5.5
2.9
82
11,800
59.9
69
2.5
71
100
6.9
3.5
99
13,500
68.5
72
3.2
91

 


 

 

Many Lengths Available From Stock in Four Materials

Aluminum

The aluminum Super Air Knife is suited to a wide variety of environments where corrosion or contamination is not a factor. The aircraft grade aluminum construction with plastic shim is very durable for general purpose applications. It can withstand temperatures up to 180°F (82°C).

Aluminum Super Air Knife

Type 303 Stainless Steel

This is the most common grade of stainless steel. It offers good strength and is best suited to mildly corrosive environments. It can withstand temperatures up to 800°F (427°C).

Type 316 Stainless Steel

Some applications require better corrosion resistance than offered by Type 303 Stainless Steel. Type 316 Stainless Steel offers excellent corrosion resistance, better strength properties and resists pitting. It can withstand temperatures up to 800°F (427°C).

 

Type 303 and 316 Stainless Steel Super Air Knife

PVDF (Polyvinylidene Flouride)

EXAIR's Super Air Knife is now available from stock in PVDF (Polyvinylidene Flouride), PVDF offers superior strength and is resistant to UV light, inorganic chemicals, solvents, ozone, weather, fungi, chlorinated hydrocarbons, highly corrosive acids, weak bases and salts. The PVDF Super Air Knife uses PTFE shims, Type 316 Stainless Steel pipe plugs, and Hastelloy® C-276 alloy screws to withstand harsh environments.
 

*HASTELLOY is a registered trademark of Haynes International, Inc.

 

PVDF Super Air Knife

 


 

 

Electronic Flow Control (EFC)

EXAIR's EFC is an electronic flow control that dramatically reduces compressed air costs by turning off the compressed air when no part is present. This minimizes compressed air use for blow off, drying, cooling, conveying and static elimination operations. The EFC combines a photoelectric sensor with a timing control that limits compressed air use by turning it off when no part is present. Visit the EFC page for more information.


 

 

Shim Sets

The compressed air exhausts through a gap which is set with a shim positioned between the cap and the body of the Super Air Knife. Force and flow through the Super Air Knife may be easily increased by adding shims to open the gap. Kits include a shim set (three additional shims). Shim sets for aluminum Super Air Knives include a .001" (0.03mm), .003" (0.08mm) and .004" (0.10mm) thick plastic shim. Shim sets for stainless steel Super Air Knives include (3) .002" (0.05mm) thick stainless steel shims.


 

 

 Dimensions

 

 

Aluminum Super Air Knife
 
Special Lengths Available - Contact Distributor  

   

 

 Stainless Steel Super Air Knife

 Special Lengths Available - Contact Distributor

 

 

PVDF Super Air Knife

 Special Lengths Available - Contact Distributor

 


     
Models
BSP Threads Available - Contact Distributor
Aluminum Super Air Knife Only
Models
Description
110003
3" (76mm) Aluminum Super Air Knife
110006
6" (152mm) Aluminum Super Air Knife
110009
9" (229mm) Aluminum Super Air Knife
110012
12" (305mm) Aluminum Super Air Knife
110018
18" (457mm) Aluminum Super Air Knife
110024
24" (610mm) Aluminum Super Air Knife
110030
30" (762mm) Aluminum Super Air Knife
110036
36" (914mm) Aluminum Super Air Knife
110042
42" (1067mm) Aluminum Super Air Knife
110048
48" (1219mm) Aluminum Super Air Knife
110054
54" (1372mm) Aluminum Super Air Knife

 

Aluminum Super Air Knife Shim Sets
Models
Description
110303
3" (76mm) Aluminum Super Air Knife Shim Set
110306
6" (152mm) Aluminum Super Air Knife Shim Set
110309
9" (229mm) Aluminum Super Air Knife Shim Set
110312
12" (305mm) Aluminum Super Air Knife Shim Set
110318
18" (457mm ) Aluminum Super Air Knife Shim Set
110324
24" (610mm) Aluminum Super Air Knife Shim Set
110330
30" (762mm) Aluminum Super Air Knife Shim Set
110336
36" (914mm) Aluminum Super Air Knife Shim Set
110342
42" (1067mm) Aluminum Super Air Knife Shim Set
110348
48" (1219mm) Aluminum Super Air Knife Shim Set
110354
54" (1372mm) Aluminum Super Air Knife Shim Set

 

Type 303 Stainless Steel Super Air Knife Only
Models
Description
110003SS
3" (76mm) Stainless Steel Super Air Knife
110006SS
6" (152mm) Stainless Steel Super Air Knife
110009SS
9" (229mm) Stainless Steel Super Air Knife
110012SS
12" (305mm) Stainless Steel Super Air Knife
110018SS
18" (457mm) Stainless Steel Super Air Knife
110024SS
24" (610mm) Stainless Steel Super Air Knife
110030SS
30" (762mm) Stainless Steel Super Air Knife
110036SS
36" (914mm) Stainless Steel Super Air Knife
110042SS
42" (1067mm) Stainless Steel Super Air Knife
110048SS
48" (1219mm) Stainless Steel Super Air Knife
110054SS
54" (1372mm) Stainless Steel Super Air Knife

 

Type 303 Stainless Steel Super Air Knife Shim Sets
Models
Description
110303SS
3" (76mm) Stainless Steel Super Air Knife Shim Set
110306SS
6" (152mm) Stainless Steel Super Air Knife Shim Set
110309SS
9" (229mm) Stainless Steel Super Air Knife Shim Set
110312SS
12" (305mm) Stainless Steel Super Air Knife Shim Set
110318SS
18" (457mm ) Stainless Steel Super Air Knife Shim Set
110324SS
24" (610mm) Stainless Steel Super Air Knife Shim Set
110330SS
30" (762mm) Stainless Steel Super Air Knife Shim Set
110336SS
36" (914mm) Stainless Steel Super Air Knife Shim Set
110342SS
42" (1067mm) Stainless Steel Super Air Knife Shim Set
110348SS
48" (1219mm) Stainless Steel Super Air Knife Shim Set
110354SS
54" (1372mm) Stainless Steel Super Air Knife Shim Set

 

Type 316 Stainless Steel Super Air Knife Only
Models
Description
110003SS-316
3" (76mm) Stainless Steel Super Air Knife
110006SS-316
6" (152mm) Stainless Steel Super Air Knife
110009SS-316
9" (229mm) Stainless Steel Super Air Knife
110012SS-316
12" (305mm) Stainless Steel Super Air Knife
110018SS-316
18" (457mm) Stainless Steel Super Air Knife
110024SS-316
24" (610mm) Stainless Steel Super Air Knife
110030SS-316
30" (762mm) Stainless Steel Super Air Knife
110036SS-316
36" (914mm) Stainless Steel Super Air Knife
110042SS-316
42" (1067mm) Stainless Steel Super Air Knife
110048SS-316
48" (1219mm) Stainless Steel Super Air Knife
110054SS-316
54" (1372mm) Stainless Steel Super Air Knife

 

Type 316 Stainless Steel Super Air Knife Shim Sets
Models
Description
110303SS-316
3" (76mm) Stainless Steel Super Air Knife Shim Set
110306SS-316
6" (152mm) Stainless Steel Super Air Knife Shim Set
110309SS-316
9" (229mm) Stainless Steel Super Air Knife Shim Set
110312SS-316
12" (305mm) Stainless Steel Super Air Knife Shim Set
110318SS-316
18" (457mm ) Stainless Steel Super Air Knife Shim Set
110324SS-316
24" (610mm) Stainless Steel Super Air Knife Shim Set
110330SS-316
30" (762mm) Stainless Steel Super Air Knife Shim Set
110336SS-316
36" (914mm) Stainless Steel Super Air Knife Shim Set
110342SS-316
42" (1067mm) Stainless Steel Super Air Knife Shim Set
110348SS-316
48" (1219mm) Stainless Steel Super Air Knife Shim Set
110354SS-316
54" (1372mm) Stainless Steel Super Air Knife Shim Set

 

PVDF Super Air Knife Only
Models
Description
110003-PVDF
3" (76mm) PVDF Super Air Knife
110006-PVDF
6" (152mm) PVDF Super Air Knife
110009-PVDF
9" (229mm) PVDF Super Air Knife
110012-PVDF
12" (305mm) PVDF Super Air Knife
110018-PVDF
18" (457mm) PVDF Super Air Knife
110024-PVDF
24" (610mm) PVDF Super Air Knife
110030-PVDF
30" (762mm) PVDF Super Air Knife
110036-PVDF
36" (914mm) PVDF Super Air Knife
110042-PVDF
42" (1067mm) PVDF Super Air Knife
110048-PVDF
48" (1219mm) PVDF Super Air Knife
110054-PVDF
54" (1372mm) PVDF Super Air Knife

 

PVDF Super Air Knife Shim Sets
Models
Description
110303-PVDF
3" (76mm) PVDF Super Air Knife Shim Set
110306-PVDF
6" (152mm) PVDF Super Air Knife Shim Set
110309-PVDF
9" (229mm) PVDF Super Air Knife Shim Set
110312-PVDF
12" (305mm) PVDF Super Air Knife Shim Set
110318-PVDF
18" (457mm ) PVDF Super Air Knife Shim Set
110324-PVDF
24" (610mm) PVDF Super Air Knife Shim Set
110330-PVDF
30" (762mm) PVDF Super Air Knife Shim Set
110336-PVDF
36" (914mm) PVDF Super Air Knife Shim Set
110342-PVDF
42" (1067mm) PVDF Super Air Knife Shim Set
110348-PVDF
48" (1219mm) PVDF Super Air Knife Shim Set
110354-PVDF
54" (1372mm) PVDF Super Air Knife Shim Set

 

Accessories
Model #
Description
9060
Universal Air Knife Mounting System
9001
Automatic Drain Filter Separator, 3/8 NPT, 65 SCFM (1841 SLPM)
9032
Automatic Drain Filter Separator, 1/2 NPT, 90 SCFM (2548 SLPM)
9002
Automatic Drain Filter Separator, 3/4 NPT, 220 SCFM (6230 SLPM)
9005
Oil Removal Filter, 3/8 NPT, 15-37 SCFM (425-1048 SLPM)
9006
Oil Removal Filter, 3/4 NPT, 50-150 SCFM (1415-4248 SLPM)
9008
Pressure Regulator with Gauge, 1/4 NPT, 50 SCFM (1416 SLPM)
9033
Pressure Regulator with Gauge, 1/2 NPT, 100 SCFM (2832 SLPM)
9009
Pressure Regulator with Gauge, 3/4 NPT, 220 SCFM (6230 SLPM)
9020
Solenoid Valve Only, 120V, 50/60Hz, 1/4 NPT, 40 SCFM (1133 SLPM)
9021
Solenoid Valve Only, 200-240V, 50/60Hz, 1/4 NPT, 40 SCFM (1133 SLPM)
9034
Medium Solenoid Valve, 120V, 1/2 NPT, 100 SCFM (2832 SLPM)
9035
Medium Solenoid Valve, 240V, 50/60Hz, 1/2 NPT, 100 SCFM (2832 SLPM)
9036
Large Solenoid Valve, 120V, 3/4 NPT, 200 SCFM (5664 SLPM)
9037
Large Solenoid Valve, 240V, 50/60Hz, 3/4 NPT, 200 SCFM (5664 SLPM)
9065
Large Solenoid Valve, 24VDC, 1 NPT, 350 SCFM (9911 SLPM)

 


 

 

Installation and Maintenance Sheets

Super Air Knife
Air Knife Shim Set
Aluminum Super Air Knife Coupling Bracket
Stainless Steel Super Air Knife Coupling Bracket
Universal Air Knife Mounting System
Universal Air Knife Plumbing Kit - Model 9076
Universal Air Knife Plumbing Kit - Model 9077
Universal Air Knife Plumbing Kit - Model 9078
Universal Air Knife Plumbing Kit - Model 9079