Super Air Knife™ Kit
- 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
- 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
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).
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.
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.
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.
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 - 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.
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 - 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 Knives are available in five different model types:
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|
12" (305mm) Super Air Knife tested with .002" (0.05mm) thick shim installed
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
Super Air Knife Standards and Certifications
EXAIR Air Amplifiers 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.
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WARNING! Cancer and Reproductive Harm - www.P65Warnings.ca.gov/product
Awards - Super Air Knives
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.
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.
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.
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. If you have any questions, feel free to contact an Application Engineer at (800) 903-9247 or (513) 671-3322 or [email protected].
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.
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).
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 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
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.
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)|
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.
If you have questions about a product or you need help in determining the best model for your application, fill out our Application Assistance Worksheet! When you submit this information, one of our knowledgeable Application Engineers will respond with a recommendation for the EXAIR product best suited for the application.
If you would rather fax the form, you can download the Application Assistance Worksheet PDF, 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.