Super Air Knife2022-04-22T09:34:04+02:00

Super Air Knife™ – Quiet, hard-hitting curtain of air for blowoff, cleaning, drying and cooling.

 Luftmesser Super Air Knife Air curtain
  • Surprisingly Quiet! – Only 69 dBA!
  • Reduced Air Consumption!
  • Uniform Airflow!
  • Amplification of 40:1!

What is the Super Air Knife?

The 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 us.

Air Knife in Überlängen an einem Stück

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.

Super Air Knife Funktion

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

Dry

Blowoff

Cool

PVDF (Polyvinylidene Fluoride) Super Air Knife

Super Air Knives in PVDF (Polyvinylidene Fluoride) offers superior strength and are 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. The PVDF Super Air Knife is suitable for manufacturing processes that involve electroplating, solar cells, lithium ion batteries, transfer of acids and caustic chemicals, brine, solvent recovery, semiconductors, and medical devices. It can withstand temperatures up to 275oF (135oC).

  • 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
  • Recessed hardware
  • No moving parts – maintenance free
  • Variable force and flow
  • Stainless steel screws in all models
  • Special lengths available
  • Unlimited system lengths of uninterrupted airflow available
  • Stock lengths to 108 ” (2743mm) in aluminum, 303 stainless steel, and 316 stainless steel (ss – for temperatures up to 800°F (427°C), food processing or corrosive environments), and PVDF up to 54″ (1372mm) for superior corrosion resistance.
Super Air Knife, Modell 110024SS

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

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).

Compare these Blowoffs

ineffective drilled pipe

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.

ineffective flat air nozzles

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.

 

ineffective blower

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.

exceptional exair super air knife

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.

 

The target for each blow-off device was to consume the least amount of air possible to perform the task (at the lowest energy and noise levels). The required air pressure for each device was 4.1 bar inlet pressure, (60 PSIG), at which an adequate speed was provided to blow the water off. The table below summarizes the general performance. Since the workpiece you are actually about to blow off may have an irregular structure, holes or sharp edges, the noise level measurements were made in free air (without hitting a surface).

Blowoff Comparison Statistics
Type of Blowoff 24″ PSIG BAR SLPM Horse Power Required Sound level dBA Purchase Price *Annual Electrical Cost Approx. Annual Maint. Cost First Year Cost
Drilled Pipe 60 4,1 4.924 26,10 91 45 € 4.669 € 840 € 5.509 €
Flat Air Nozzles 60 4,1 7.273 38,03 102 190 € 6.803 € 1.320 € 8.123 €
Blower Air Knife 3 0,2 N/A 7,46 90 5.000 € 1.334 € 1.370 € 2.704 €
Super Air Knife 60 4,1 1.557 8,20 69 559 € 1.467 € 280 € 1.747 €
*Based on national average electricity cost of 8.6 cents per kWh or 3 cents per standard cubic metre. Annual cost reflects 40 hours per week, 52 weeks per year.
Super Air Knife Performance with .002″ (.05mm) thick shim installed, tested with Super Air Knife 110012 (30cm long)

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 SLPM M/S dBA Grams
20 1,4 31 25,4 57 17
40 2,8 48 35,6 61 31
80 5,5 82 59,9 69 71
100 6,9 99 68,5 72 91

Aluminium Super Air Knife

Special Lengths Available – Contact us.

Aluminium Super Air Knife Dimensions

Stainless Steel Super Air Knife

Special Lengths Available – Contact us.

Edelstahl Super Air Knife Abmessungen

PVDF Super Air Knife

Special Lengths Available – Contact us.

PVDF Super Air Knife Abmessungen

Many lengths available from stock in four materials:

Material Temperatures up to
Aluminum 82° C
Type 303 Stainless Steel (= WNr. 1.4305) 427° C
Type 316 Stainless Steel ( = V4A) 427° C
PVDF (Polyvinylidene Flouride) 135° C

For further information contact us.

Models

BSP Threads Available – Contact us.

Super Air Knife
Super Air Knife length Aluminum Model Type 303 Stainless Steel Model Type 316 Stainless Steel Model PVDF Model
3″ (76mm) 110003 110003SS 110003SS-316 110003-PVDF
6″ (152mm) 110006 110006SS 110006SS-316 110006-PVDF
9″ (229mm) 110009 110009SS 110009SS-316 110009-PVDF
12″ (305mm) 110012 110012SS 110012SS-316 110012-PVDF
18″ (457mm) 110018 110018SS 110018SS-316 110018-PVDF
24″ (610mm) 110024 110024SS 110024SS-316 110024-PVDF
30″ (762mm) 110030 110030SS 110030SS-316 110030-PVDF
36″ (914mm) 110036 110036SS 110036SS-316 110036-PVDF
42″ (1067mm) 110042 110042SS 110042SS-316 110042-PVDF
48″ (1219mm) 110048 110048SS 110048SS-316 110048-PVDF
54″ (1372mm) 110054 110054SS 110054SS-316 110054-PVDF
60″ (1524mm) 110060 110060SS 110060SS-316 ——————
72″ (1829mm) 110072 110072SS 110072SS-316 ——————
84″ (2134mm) 110084 110084SS 110084SS-316 ——————
96″ (2438mm) 110096 110096SS 110096SS-316 ——————
108″ (2743mm) 1100108 1100108SS 1100108SS-316 ——————
Accessories
Model Description
9060 Universal Air Knife Mounting System
9076 Air Knife Plumbing Kit for length up to 42″
9077 Air Knife Plumbing Kit for length 48″-54″
9078 Air Knife Plumbing Kit for length 60″-84″
9079 Air Knife Plumbing Kit for length 90″-108″
9240 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 24″ length
9241 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 30″ length
9242 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 36″ length
9243 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 42″ length
9244 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 48″ length
9245 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 54″ length
9246 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 60″ length
9247 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 72″ length
9248 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 84″ length
9249 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 96″ length
9250 Plumbing Kits for Stainless Steel and PVDF Super Air Knives for 108″ length
900517 Universal Air Knife Mounting System Stainless Steel 303/304
9055 EFC (40 SCFM), 1/4″ NPT
9056 EFC (100 SCFM), 1/2″ NPT
9057 EFC (200 SCFM), 3/4″ NPT
9064 EFC (350 SCFM), 1″ NPT
Super Air Knife Shim Sets
Airflow length Aluminum Model Stainless Steel 303SS Model Stainless Steel 316SS Model PVDF Model
3″ (76mm) 110303 110303SS 110303SS-316 110303-PVDF
6″ (152mm) 110306 110306SS 110306SS-316 110306-PVDF
9″ (229mm) 110309 110309SS 110309SS-316 110309-PVDF
12″ (305mm) 110312 110312SS 110312SS-316 110312-PVDF
18″ (457mm ) 110318 110318SS 110318SS-316 110318-PVDF
24″ (610mm) 110324 110324SS 110324SS-316 110324-PVDF
30″ (762mm) 110330 110330SS 110330SS-316 110330-PVDF
36″ (914mm) 110336 110336SS 110336SS-316 110336-PVDF
42″ (1067mm) 110342 110342SS 110342SS-316 110342-PVDF
48″ (1219mm) 110348 110348SS 110348SS-316 110348-PVDF
54″ (1372mm) 110354 110354SS 110354SS-316 110354-PVDF
60″ (1524mm) 110360 110360SS 110360SS-316 ——————
72″ (1829mm) 110372 110372SS 110372SS-316 ——————
84″ (2134mm) 110384 110384SS 110384SS-316 ——————
96″ (2438mm) 110396 110396SS 110396SS-316 ——————
108″ (2743mm) 1103108 11033108SS 1103108SS-316 ——————

Air Knife Mounting System

– Provide precise positioning for your Air Knife! –

The Air Knife Mounting System is used to provide secure, precise positioning for any of the Exair Air Knives. It can be mounted on the top or bottom of most Air Knives (Super Air Knife, Standard Air Knife). The Mounting System has a durable, stainless steel construction that is suitable for a variety of industrial applications.

Universelles Air Knife Befestigunssystem
Universal Air Knife Mounting System is used to provide precise positioning for Air Knife.

Universal Air Knife Mounting System
Model Description
9060 Universal Air Knife Mounting System
Installation and Maintenance sheet: » Universal Air Knife Mounting System

Air Knife Plumbing Kit

Air Knife Plumbing KitSuper Air Knives that are 24″ (610mm) to 42″ (1067mm) must be supplied with compressed air at multiple inlets on the knife. The Air Knife Plumbing Kits make it easy to ensure proper airflow to each inlet. The provide properly sized compressed air hose or pipe and fittings to interconnect the bottom or end compressed air inlets for best performance. Plumbing Kits for aluminum Super Air Knives include a pressure gauge to monitor pressure at the Super Air Knife, which is an indication of proper air supply.They also include nitrile/PVC hose and brass fittings. Plumbing kits for stainless steel Super Air Knives include cut to length type 316 stainless steel pipe and fittings and will also work on PVDF Super Air Knives.
Air Knife Coupling Bracket Kit

Some applications require a Super Air Knife that is longer than our 108″ (2743mm)length. Coupling Bracket Kits that join two Super Air Knives together are available. The kit includes two rigid plates along with the assembly screws.

Accessories
Model Description
110900 Aluminum Coupling Bracket Kit
110900SS Type 303 Stainless Steel Coupling Bracket Kit
110900SS-316 Type 316 Stainless Steel Coupling Bracket Kit
xxxxx Contact us for suitable filters and maintenance units
Verlängerung von Air Knives
The Model 110900 Coupling Bracket Kit is used to join two aluminum Super Air Knives.

Shim Sets change the force and flow

The Super Air Knife includes a 0,05mm installed Shim and is for most applications suitable. Some applications need higher force and flow. Force and flow can be increased by installing additonal shims that open the air gap.

Abstandsfolien
Shim-Sets could be buy as accessories:
• 3 Plastic Shims: 0,03 mm + 0,08 mm + 0,10 mm dick (Aluminum Air Knife)
• 3 Stainless Steel Shims: 0,05 mm thick (Stainless Steel Air Knife)
• 3 PTFE-Shims: 0,05 mm thick (PVDF Air Knife)
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.

FAQ’s

What kind of temperature resistance due air curtains offer?2022-04-22T09:07:08+02:00
  • Air curtain made of aluminium with a plastic shim up to 82 °C
  • Air curtain made of aluminium with a stainless steel shim up to 205 °C (custom built)
  • Air curtain made of stainless steel with a stainless steel shim up to 427 °C*
  • Air curtain made of PVDF with a PVDF shim up to 135 °C

*Temperatures above 427 °C can cause intracrystalline corrosion which obstructs the air gap.

Why is the Air Knife’s (air curtain’s) airflow not uniform/laminar?2022-04-22T09:12:14+02:00

Our Air Knives are designed to deliver a uniform/laminar airflow from the outset. If this is not the case, there may be some soiling on the inside of the Air Knife. Please open and clean the Air Knife following the operating instructions.

For lengths of more than 18″, the air knife must be fed via multiple compressed air inputs (up to 6 inputs depending on the length) in order to ensure a uniform airflow. In the case of the PVDF Air Knife, the material can also cause changes in the homogeneity of the airflow.
A guide for restoring a uniform airflow is available here.

Is a hole not enough? Why should I use air curtains?2022-04-22T09:14:14+02:00

Did you know that a single 3-mm hole consumes as much compressed air as a Super Air Knife model with a length of 152 mm (6″)? Additionally, an air knife offers a low noise level (below 70 dBA given an unobstructed blow-off path) and does not have a dead end (safety at work).

The amortisation period if you replace holes with optimised blow-off nozzles is less than 6 months.

Can the compressed air products be operated with water?2022-04-22T09:19:41+02:00

To be able to answer this question, we need to investigate the specific use case. For example, the Super Air Knife could be operated with water to cool a workpiece or flush away loose residues. Experience shows that the water jet initially has a uniform outflow and then eddies further away from the air curtain. This means that use with water is possible.

If you need 360 ° wetting with water, we recommend our Super Air Wipe annular nozzle. The input pressure is up to 2 bar.

Of course, we also have legacy atomiser nozzles in various designs in our portfolio. They are suitable for cooling, washing, wetting, moistening, lubricating, etc.

We are happy to advise you on the right choice of product.