Model 110203 3" Alum. Super Air Knife Kit

EXAIR Super Air Knife Kits include a Super Air Knife, shim set, filter separator and pressure regulator (with coupler). It
Model
110203
$445.00

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EXAIR Super Air Knife Kits include a Super Air Knife, shim set, filter separator and pressure regulator (with coupler). It is the most efficient compressed air knife on the market. It delivers a uniform sheet of laminar airflow across the entire length with hard-hitting force. It is engineered to dramatically reduce compressed air usage while entraining ambient air at a ratio of 40:1. Noise levels are greatly reduced when compared to other blowoffs. Available from stock 3" to 108" long and made from aluminum, Type 303 stainless steel, Type 316 stainless steel and PVDF to meet your application needs. Custom sizes and materials available. Super Air Knives offer an efficient way to clean, dry or cool parts, webs or conveyors as well as acting as an environmental separator or air curtain.

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
  • Variable force and flow
  • No moving parts - maintenance free
  • Easy mounting - compressed air inlets on each end and bottom
  • Compact, rugged, easy to install
  • Recessed hardware
  • 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.
  • Special lengths available
  • Unlimited system lengths of uninterrupted airflow available

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. Stainless steel screws are used to eliminate corrosion in damp locations. It can withstand temperatures up to 180°F (82°C).

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. These factors are important to manufacturers of food, pharmaceutical and surgical products that need to minimize contamination by the metal. It can withstand temperatures up to 800°F (427°C).

PVDF (Polyvinylidene Flouridine) - EXAIR’s Super Air Knife is also available from stock in PVDF. 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. 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 275°F (135°C).

Air Knife Models

EXAIR Super Air Knives

The Super Air Knife provides the best performance with a 40:1 air amplification ratio, making it the most efficient. It is the best choice for all applications. The Super Air Knife has a laminar airstream that is uniform, forceful and quiet. Velocity is the highest of all three air knives. Air consumption is lowest of all three air knives. Compressed air inlets are provided on each end and on the bottom. Multiple Super Air Knives can be mounted “end to end” for longer lengths of uninterrupted airflow.

EXAIR Standard Air Knives

The Standard Air Knife provides good performance with a 30:1 air amplification ratio that is less efficient than the Super Air Knife. It is a good choice when a less expensive alternative is required. The Standard Air Knife has an airflow that is also uniform and forceful. It is louder and uses more compressed air than the Super Air Knife. Compressed air inlets are provided on each end. Overall length is 1" (25mm) longer than the airflow length.

EXAIR Full Flow Air Knives

The Full-Flow Air Knife provides good performance with a 30:1 air amplification ratio. The Full-Flow Air Knife is the least expensive and is a good choice for tight spaces. Force is less than the other two styles. Air consumption and sound level falls between that of the Super Air Knife and the Standard Air Knife. Compressed air inlet(s) are provided on the rear. Inlets are available on each end at a small additional charge, however they are not recommended for applications where uniform flow across the length is required.

If you have special requirements, please contact an Application Engineer to discuss it.

Accessories

Universal Air Knife Mounting System

Universal Air Knife Mounting System - The Model 9060 Universal Air Knife Mounting System is used to provide secure, precise positioning for any of the EXAIR Air Knives. The Air Knife can quickly and easily be moved within close proximity of the part to improve effectiveness. It can be mounted on either the top or bottom of most Air Knives (Super Air Knife, Standard Air Knife and Full-Flow Air Knife). The Universal Air Knife Mounting System has a durable, stainless steel construction that is suitable for a variety of industrial applications.

 

The mounting system can also be used with EXAIR Static Eliminators. For the Super Ion Air Knife, it can be mounted on the top. Bottom mounting is possible on Super Ion Air Knives that are 18" (457mm) or longer. For the Standard Ion Air Knife, it can be top mounted on any length. Bottom mounting is possible on Standard Ion Air Knives that are 9" (229mm) or longer.

 

The Universal Air Knife Mounting System can be articulated into any position and provides a maximum extension of 30" (762mm). A 1/2" diameter hole is required for mounting. Alternatively, the bolt can be threaded directly into a 1/2"-13 tapped hole. For any style Air Knife that is 24" (610mm) to 54" (1372mm), use (2) Universal Air Knife Mounting Systems. For knives 55" (1397mm) - 71" (1803mm), use (3). For 72" (1829mm) - 95" (2413mm), use (4). For knives 96" (2438mm) and over, use (5).

Air Knife Plumbing Kits

Air Knife Plumbing Kits - Super Air Knives that are 24" or longer must be supplied with compressed air at multiple inlets on the knife. The Air Knife Plumbing Kits prevent you from searching for the right fittings or using undersized air supply lines. They 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 Brackets

Coupling Bracket Kits - 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. The bottom plate is supplied with a hole to access the bottom compressed air inlets. All models include stainless steel screws.

Air Knife Shim Sets

Air Knife Shim Sets - Compressed air exhausts through a gap in the Air Knife which is set with a shim. Force and flow may be increased by adding shims.

 

Shim sets for aluminum Super Air Knives include a .001" (0.03mm) Amber color, .003" (0.08mm) Green color, and .004" (0.10mm) thick Tan color plastic shim . A Red color .002" (0.05mm) thick shim comes installed in the Super Air Knife. Shim sets for stainless steel Super Air Knives include (3) .002" (0.05mm) thick stainless steel shims. PVDF Super Air Knife shim sets include (3) .002" (0.05mm) PTFE shims.

Super Air Knife Systems

Super Air Knives are available in five different model types:

  • Super Air Knife Only
  • Super Air Knife with Plumbing Kit - includes Super Air Knife and Plumbing Kit (installed).
  • Super Air Knife Kit - includes a Super Air Knife, shim set, filter separator and pressure regulator (with coupler).
  • Super Air Knife Kit with Plumbing Kit - includes a Super Air Knife, plumbing kit (installed), shim set filter separator and pressure regulator (with coupler).
  • Deluxe Super Air Knife Kits - includes a Super Air Knife, EFC, universal mounting system, shim set, filter separator and pressure regulator (with coupler).

Airflow Length

Super Air Knife only

Super Air Knife with Plumbing Kit

Super Air Knife Kit

Super Air Knife Kit with Plumbing Kit

Deluxe Super Air Knife Kit

3" (76mm) 110003, 110003SS, 110003SS-316, 110003-PVDF N/A 110203, 110203SS, 110203SS-316, 110203-PVDF N/A 110003DX, 110003SSDX, 110003SSDX-316
6" (152mm) 110006, 110006SS, 110006SS-316, 110006-PVDF N/A 110206, 110206SS, 110206SS-316, 110206-PVDF N/A 110006DX, 110006SSDX, 110006SSDX-316
9" (229mm) 110009, 110009SS, 110009SS-316, 110009-PVDF N/A 110209, 110209SS, 110209SS-316, 110209-PVDF N/A 110009DX, 110009SSDX, 110009SSDX-316
12" (305mm) 110030, 110030SS, 110030SS-316, 110030-PVDF N/A 110212, 110212SS, 110212SS-316, 110212-PVDF N/A 110030DX, 110030SSDX, 110030SSDX-316
18" (457mm) 110018, 110018SS, 110018SS-316, 110018-PVDF N/A 110218, 110218SS, 110218SS-316, 110218-PVDF N/A 110018DX, 110018SSDX, 110018SSDX-316
24" (610mm) 110024, 110024SS, 110024SS-316, 110024-PVDF 110024PKI, 110024SSPKI, 110024SS-316PKI 110224, 110224SS, 110224SS-316, 110224-PVDF 110024PKI, 110024SSPKI, 110024SS-316PKI 110024DX, 110024SSDX, 110024SSDX-316
30" (762mm) 110030, 110030SS, 110030SS-316, 110030-PVDF 110030PKI, 110030SSPKI, 110030SS-316PKI 110230, 110230SS, 110230SS-316, 110230-PVDF 110030PKI, 110030SSPKI, 110030SS-316PKI 110030DX, 110030SSDX, 110030SSDX-316
36" (914mm) 110036, 110036SS, 110036SS-316, 110036-PVDF 110036PKI, 110036SSPKI, 110036SS-316PKI 110236, 110236SS, 110236SS-316, 110236-PVDF 110036PKI, 110036SSPKI, 110036SS-316PKI 110036DX, 110036SSDX, 110036SSDX-316
42" (1127mm) 110042, 110042SS, 110042SS-316, 110042-PVDF 110042PKI, 110042SSPKI, 110042SS-316PKI 110242, 110242SS, 110242SS-316, 110242-PVDF 110042PKI, 110042SSPKI, 110042SS-316PKI 110042DX, 110042SSDX, 110042SSDX-316
48" (1219mm) 110048, 110048SS, 110048SS-316, 110048-PVDF 110048PKI, 110048SSPKI, 110048SS-316PKI 110248, 110248SS, 110248SS-316, 110248-PVDF 110048PKI, 110048SSPKI, 110048SS-316PKI 110048DX, 110048SSDX, 110048SSDX-316
54" (1372mm) 110054, 110054SS, 110054SS-316, 110054-PVDF 110054PKI, 110054SSPKI, 110054SS-316PKI 110254, 110254SS, 110254SS-316, 110254-PVDF 110054PKI, 110054SSPKI, 110054SS-316PKI 110054DX, 110054SSDX, 110054SSDX-316
60" (1524mm) 110060, 110060SS, 110060SS-316 110060PKI, 110060SSPKI, 110060SS-316PKI 110260, 110260SS, 110260SS-316 110060PKI, 110060SSPKI, 110060SS-316PKI 110060DX, 110060SSDX, 110060SSDX-316
72" (1829mm) 110072, 110072SS, 110072SS-316 110072PKI, 110072SSPKI, 110072SS-316PKI 110272, 110272SS, 110272SS-316 110072PKI, 110072SSPKI, 110072SS-316PKI 110072DX, 110072SSDX, 110072SSDX-316
84" (2134mm) 110084, 110084SS, 110084SS-316 110084PKI, 110084SSPKI, 110084SS-316PKI 110284, 110284SS, 110284SS-316 110084PKI, 110084SSPKI, 110084SS-316PKI 110084DX, 110084SSDX, 110084SSDX-316
96" (2438mm) 110096, 110096SS, 110096SS-316 110096PKI, 110096SSPKI, 110096SS-316PKI 110296, 110296SS, 110296SS-316 110096PKI, 110096SSPKI, 110096SS-316PKI 110096DX, 110096SSDX, 110096SSDX-316
108" (2743mm) 1100108, 1100108SS, 1100108SS-316 1100108PKI, 1100108SSPKI, 1100108SS-316PKI 1102108, 1102108SS, 1102108SS-316 1100108PKI, 1100108SSPKI, 1100108SS-316PKI 1100108DX, 1100108SSDX, 1100108SSDX-316

Super Air Knife Performance

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

12" (305mm) Super Air Knife tested with .002" (0.05mm) thick shim installed

How the Super Air Knife Works

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 Dimensions and Airflow

EXAIR Aluminum Super Air Knife Dimensions
Aluminum Super Air Knife
EXAIR Stainless Steel Super Air Knife Dimensions
Type 303 and 316 Stainless Steel Super Air Knife
EXAIR PVDF Super Air Knife Dimensions
PVDF Super Air Knife

Super Air Knife Standards and Certifications

OSHA Safe!
CE Compliant

EXAIR Super Air Knives comply with OSHA's Safety Requirements, the EU General Product Safety Directive (2001/95/EC) and meet the noise limitation requirements of the EU Machinery Directive (2006/42/EC). All sound level measurements are taken at 3 feet away.

Conflict Mineral Free

Look for this symbol to designate conflict mineral free products throughout our website. EXAIR supports Section 1502 of the Dodd-Frank Wall Street Reform and Consumer Protection Act and we are committed to compliance with the conflict minerals rule in order to curb the illicit trade of tin, tantalum, tungsten and gold in the DRC region. EXAIR is using the CMRT 3.02 template to document our supply chain and commitment to conflict free products.

Awards - Super Air Knives

2014 Plant Engineering Product of the Year Finalist

EXAIR's Long Super Air Knives were a finalist in the 2014 Plant Engineering Product of the Year Awards. The Long Super Air Knife group placed in the Compressed Air category.

2016 Plant Engineering Product of the Year Finalist

EXAIR's Long Stainless Steel Super Air Knives were a finalist in the 2016 Plant Engineering Product of the Year Awards. The Long Stainless Steel Super Air Knife group placed in the Material Handling Systems category.

2017 Design News Golden Mousetrap Finalist

EXAIR's Stainless Steel Plumbing Kit for Super Air Knives was the Winner in 2017 Design News Golden Mousetrap Awards. Stainless Steel Plumbing Kits placed in the Fastening, Joining, and Assembly category.

Efficiency Lab

Does your company currently use a blowoff product similar to EXAIR’s that you’d like us to evaluate? Ship it to the EXAIR Efficiency Lab! Our qualified staff will test it for FREE, using EXAIR’s calibrated testing equipment. We’ll compare the performance of your existing product (air consumption, effectiveness, noise levels, efficiencies, etc) with the EXAIR Intelligent Compressed Air® products. The results will be published in a comprehensive report that includes a cost savings analysis. For most applications, EXAIR products can help you improve your efficiency AND typically pay for themselves in a matter of weeks.

To participate in our Efficiency Lab testing, please complete this Product Efficiency Survey to give us the details about your current application and blowoff set up. You can also feel free to contact an Application Engineer for more information at (800) 903-9247 or (513) 671-3322.

After completing the form, your product can be shipped to:
Efficiency Lab
EXAIR Corporation
11510 Goldcoast Dr.
Cincinnati, OH 45249-1621

This offer is available to all customers in the U.S. and Canada only. Some restrictions might apply.

Products must be shipped to EXAIR freight prepaid. EXAIR will pay the return shipping via UPS ground.

If you cannot send in your product, fill out this Product Efficiency Survey to give us the details about your current application and we will estimate the savings for you.

Compare These Blowoffs

There are a variety of ways to blow the water from the bottles shown in the photo below, 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.

Super Air Knife bottle blowoff

 

 

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 blower used had a ten horsepower electric motor and was a centrifugal type blower at 18,000 RPM. The table at the bottom of the page 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).

 

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.

 

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.

 

blower air knife

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 the EXAIR 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

EXAIR Super Air Knife

The Super Air Knife pair 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 at 69 dBA. 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.

EXAIR Super Air Knife

OSHA Maximum Allowable Noise Exposure

High noise levels are 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)

 

Special Super Air Knives

EXAIR manufactures special Super Air Knives suited to specific application requirements. The shape, dimensions and materials of construction can be modified to fit existing machines and environments.

 

Special Curved Super Air Knife

A special curved stainless steel Super Air Knife holds test tubes in place on a rotating index table.

This curved stainless steel Super Air Knife was manufactured for a laboratory that uses the force of the airflow to hold test tubes in place on a rotating index table. They were able to eliminate the mechanical clips and latches that slowed the test tube removal. This holding method minimized risk of tube breakage and eliminated any chance of puncturing the technician’s rubber gloves.

Special PVC Super Air Knife

A PVC Super Air Knife designed to withstand a phosphorus environment.

EXAIR manufactures special Super Air Knives made of plastic. These products are engineered to work under normal operating pressures, providing the same performance as their aluminum and stainless steel counterparts.

This special PVC Super Air Knife was manufactured for a picture tube plant. The softer material was less likely to scratch the picture tube surface and was chemically resistant to the phosphorus which coated the inside.

Special Flat Super Air Knife

A flat Super Air Knife, only 11/16" thick, blows plastic fibers from a mold used to make integrated circuit chips.

The flat Super Air Knife is used in a molding machine for integrated circuit chips. Prior to molding the black plastic shells around the silicon wafers, they blow the mold cavity clean of any fine plastic fibers left by the previous cycle. The flat design constructed of corrosion resistant stainless steel was made to fit the tight space of the molding machine.

Special Double-Sided Super Air Knife

The double-sided Super Air Knife provides two uniform sheets of laminar airflow.

The double-sided Super Air Knife provides two uniform sheets of air in opposite directions. It is ideal for blowing water from two or more columns of stacked parts (like printed circuit boards) as they are lifted out of a bath or the open halves of a mold. Each side operates independently.

Super Air Knife Modified with Extra Mounting Holes

Stainless steel Super Air Knife modified to include extra mounting holes.

As in this example, the Super Air Knife can be modified to include extra mounting holes to suit your application.

Use our Application Assistance Worksheet to submit information about your application. When you submit this information, we will respond with our recommendation for the EXAIR product best suited for the application. Please complete the Application Assistance Worksheet and click submit or print the completed .pdf file and fax it to us at (513) 671-3363. For immediate help, call our Application Engineering Department at 1 800-903-9247.
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Material Aluminum
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