Super Air Knife™ – 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 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.
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.
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).
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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
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.
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 € |
| 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.
Stainless Steel Super Air Knife
Special Lengths Available – Contact us.
PVDF Super Air Knife
Special Lengths Available – Contact us.
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 | —————— |
» PVDF tuning (PDF)
» Universal Air Knife Mounting System (PDF)
» Air Knife Shim Set (PDF)
» Aluminum Super Air Knife Coupling Bracket (PDF)
» Stainless Steel Super Air Knife Coupling Bracket (PDF)
» Universal Air Knife Plumbing Kit – Model 9076 (PDF)
» Universal Air Knife Plumbing Kit – Model 9077 (PDF)
» Universal Air Knife Plumbing Kit – Model 9078 (PDF)
» Universal Air Knife Plumbing Kit – Model 9079 (PDF)
» Stainless Steel Plumbing Kit 24″-42″ (PDF)
» Stainless Steel Plumbing Kit 48″-108″ (PDF)
| 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.
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 |
Air Knife Plumbing Kit
Super 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 |
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.
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
- 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.
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.
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.
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.