Air Knife

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sakbot Air Knife System

Super Air Knife

intelli_sm Air Knife System

Compact, Silent & effective curtain of air for blowoff, cleaning, drying & cooling.
OSHA Logo
checked box image Surprisingly Quiet! - Only 69 dBA!
checked box image Reduced Air Consumption!
checked box image Uniform Airflow!
checked box image Air Amplification of 40:1!

What Is The Super Air Knife?

EXAIR’s Super Air knife is an advanced generation tool used to blow off liquid or debris from products as they travel on conveyors. The knife consists of a high intensity, uniform sheet of laminar airflow sometimes known as streamline flow across the entire length with hard hitting force. An industrial Super Air knife is a pressurized air plenum containing a series of holes or continuous slots through which pressurized air exits in a laminar flow pattern. The exit air velocity then creates an impact air velocity onto the surface of whatever object the air is directed.

Super Air Knives are aerodynamically engineered and tested to produce an efficient, uniform and high velocity stream of air. Air Knives are designed for 24/7 use, have smooth edges and seams for easier cleaning, can be precisely adjusted without tools for faster change-over’s and are custom sized for your application. Super Air knife dramatically reduce compressed air and noise levels as compared to other blow-off products. The sound level is surprisingly quite at 69 dBA even at high pressure of 80 PSIG (5.5 BAR). It produces air amplification ratios (entrained air to compressed air) of 40:1.Meets OSHA maximum dead-ended pressure & noise requirements. .

Specials are available. Please Contact us for details.
ApplicationsAdvantages
Air Knives Blowoff Product Air Knives Cool Product Air Knives Dry Product

Blowoff

Cool

Dry

  • 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

Click an application picture above to see more information!

  • 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 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

SAKFLNEW Air Knife SystemCompressed 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)

Air Knives blow chips away from boring operation

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

 

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).

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).

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.

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 $208 $6,569 $1,450 $8,227
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 $518 $1,417 $300 $2,235

Performance

Super Air Knife Performance with .002" (.05mm) thick shim installed

SAAIRFLOWPATTERN Air Knife System

Super Air Knife Specii cations

The Super Air Knife is available in standard lengths of 3", 6", 9" 12", 18", 24", 30", 36", 42", 48", 54", 60", 72", 84", 96" and 108" (76, 152, 229, 305, 457,
610, 762, 914, 1067, 1219, 1372, 1524, 1829, 2134, 2438 and 2743mm). Special lengths and unlimited system lengths are available. Any number of Super Air Knives may be installed across a given area.

"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

Special Lengths Available - Contact DistributorSpecial Lengths Available - Contact Distributor

Super Air Knife Dimensions

Stainless Steel Super Air Knife Dimensions


Models

BSP Threads Available - Contact Us

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 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
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

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These files are in the Adobe .PDF format.

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

Case Histories

Case History 103
Case History 105
Case History 123
Case History 169

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