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Super Air Knife™

Quiet, hard-hitting curtain of air for blowoff, cleaning, drying and cooling.

What Is The Super Air Knife?

EXAIR’s Super Air Knife is the most efficient air knife on the market. 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. 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 5.5 BAR (80 PSIG), the sound level is surprisingly quiet at 69 dBA for most applications! The Super Air Knife meets WorkSafe Australia noise exposure requirements, and OSHA dead-ended pressure and noise requirements.

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 minimised and force is maximised 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.

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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.

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 minimised risk of tube breakage and eliminated any chance of puncturing the technician’s rubber gloves.

Special Super Air Knives made of plastic are engineered to work under normal operating pressures, providing the same performance as their aluminium and stainless steel counterparts.

This 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.

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

This 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 mould. Each side operates independently.

The Super Air Knife can be modified to include extra mounting holes to suit your application.

Performance

Pressure Supply Air Consumption per Inch (25mm) Velocity at 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

Super Air Knife Performance with .002″ (.05mm) thick shim installed. 12″ (305mm) Super Air Knife tested.

Changing Performance by Adding Shims

The compressed air exhausts through a gap that is set with a shim positioned between the cap and the body of the Super Air Knife. For most applications, the .002” (0.05mm) thick shim installed in the Super Air Knife when it is shipped works best. There are, however, some situations that require more force and flow. Thicker shims will increase the gap opening offering higher velocity and harder hitting force. Air consumption and noise will be slightly higher.

Shim sets for Aluminium Super Air Knives include a .001″ (0.03mm), .003″ (0.08mm) and .004″ (0.10mm) thick plastic shims.

Stainless Steel Super Air Knife shim sets include (3) .002″ (0.05mm) thick stainless steel shims.

PVDF Super Air Knife shim sets include (3) .002” (0.05mm) PTFE shims.

Intelligent 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 realised 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 WorkSafe Australia and 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 5.5 BAR (80 PSIG). Using the Super Air Knife, it is possible to obtain hard-hitting force without the high noise.

WorkSafe Australia Maximum Allowable Noise Exposure
Exposure Time 16* hrs 12* hrs 8 hrs 4 hrs 2 hrs 1 hr 30 min 15 min 7.5 min 3.8 min 1.9 min 57 sec 28.8 sec 14.4 sec 7.2 sec 3.6 sec 1.8 sec 0.9 sec
Sound Level dBA 80 82 85 88 91 94 97 100 103 106 109 112 115 118 121 124 127 130

* The adjustment factor for extended workshifts is taken into account.

OSHA Maximum Allowable Noise Exposure
(Standard 29 CFR-1910.95(a))
Hours per day (constant noise) 8 7 4 3 2 1 0.5
Sound Level dBA 90 91 95 97 100 105 110

Eliminate Harmful Dead-End Pressures

Air can be dangerous when the outlet pressure of a hole, hose or copper tube is higher than 2 BAR (30 PSIG). 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).

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.

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 minimised risk of tube breakage and eliminated any chance of puncturing the technician’s rubber gloves.

Special Super Air Knives made of plastic are engineered to work under normal operating pressures, providing the same performance as their aluminium and stainless steel counterparts.

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

This 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 mould. Each side operates independently.

The Super Air Knife can be modified to include extra mounting holes to suit your application.

Applications

  • Part drying after wash
  • Sheet cleaning in strip mills
  • Conveyor cleaning
  • Part or component cooling
  • 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
  • No moving parts – maintenance
    free
  • Easy mounting – using Universal
    Air Knife Mounting System or compressed air inlets on each end and bottom

  • Compact, rugged, easy to install
  • Stainless steel screws on all models
  • Recessed hardware
  • Stock lengths to 108″ (2743mm) in aluminium, 303 stainless steel, and 316 stainless steel (ss – for temperatures up to 427°C (800°F), 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

Fast moving bottles are blown dry by (2) Model 110012 12” (305mm) Super Air Knives prior to labelling.

Model 110006 6” (152mm) Super Air Knife removes residual water from can bottoms after a rinse process, eliminating water damage to packaging and shipping materials.

Model 110054 54” (1372mm) Super Air Knife dries stamped parts that exit a washer.

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

This Super Air Knife dries off fish in preparation for packaging.

Application Spotlights

Air Shielding A Laser Lens

The Problem

A dirty lens can affect the quality of cameras, sensors and lasers. Today’s visual inspection systems are highly accurate tools used to monitor dimensions, temperature, finish quality, labelling and much more. These products require c...

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Bakery Creates Clean Break In Icing

The Problem

A bakery had a problem applying the icing to their snack cakes. As the baked sponge cakes moved down the conveyor, a continuous ribbon of icing was applied to the individual cakes. Trying to make a clean break in the icing was next to i...

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Drying Crates Following A Washing Operation

The Problem

A bottling plant places their filled bottles into plastic crates as a final step of their process. When the empty plastic crates are returned from the various retail markets, they must first be washed and sanitised prior to using them a...

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Super Air Knife Replaces Fan Cooling

The Problem

A manufacturer of automotive electronics had a problem cooling computers as they exited a wave solder machine. In order to be handled and tested, the computers had to be first cooled to 27°C (81°F). Initially, they had tried banks of ...

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Smoke Containment During Engine Test

The Problem

The last step in an engine assembly process is “burn-in” on a test stand. Each engine is connected to a dynamometer and run for a period of one to five minutes. Residual machining oil on the head produced smoke during the test, and ...

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Tank Blowoff Operation

A company that refurbishes large tanks runs the tanks through an oven on a conveyor line to burn off the old paint. Only one tank at a time can be processed and each tank takes 6 minutes to complete the journey. Super Air Knives are used for blowoff at the ...

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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 ...

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Airflow Pattern

Aluminium Super Air Knife

The Aluminium Super Air Knife is suited to a wide variety of environments where corrosion or contamination is not a factor. The aircraft grade aluminium 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 82°C (180°F).

Aluminium Super Air Knife

Dimensions

Type 303 Stainless Steel Super Air Knife
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 427°C (800°F).

Type 316 Stainless Steel Super Air Knife
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 minimise contamination by the metal. It can withstand temperatures up to 427°C (800°F).

Stainless Steel Super Air Knife

Dimensions

PVDF (Polyvinylidene Fluoride) Super Air Knife

EXAIR’s Super Air Knife is available in PVDF (Polyvinylidene Fluoride), 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 135°C (275°F).27°C (800°F).

HASTELLOY is a registered trademark of Haynes International, Inc.

PVDF Super Air Knife

Dimensions

Models

Super Air Knife Only
Airflow Length Aluminium Model Type 303SS Model Type 316SS Model PVDF Model
3″ (76mm) BP110003 BP110003SS BP110003SS-316 BP110003-PVDF
6″ (152mm) BP110006 BP110006SS BP110006SS-316 BP110006-PVDF
9″ (229mm) BP110009 BP110009SS BP110009SS-316 BP110009-PVDF
12″ (305mm) BP110012 BP110012SS BP110012SS-316 BP110012-PVDF
18″ (457mm) BP110018 BP110018SS BP110018SS-316 BP110018-PVDF
24″ (610mm) BP110024 BP110024SS BP110024SS-316 BP110024-PVDF
30″ (762mm) BP110030 BP110030SS BP110030SS-316 BP110030-PVDF
36″ (914mm) BP110036 BP110036SS BP110036SS-316 BP110036-PVDF
42″ (1067mm) BP110042 BP110042SS BP110042SS-316 BP110042-PVDF
48″ (1219mm) BP110048 BP110048SS BP110048SS-316 BP110048-PVDF
54″ (1372mm) BP110054 BP110054SS BP110054SS-316 BP110054-PVDF
60″ (1524mm) BP110060 BP110060SS BP110060SS-316 N/A
72″ (1829mm) BP110072 BP110072SS BP110072SS-316 N/A
84″ (2134mm) BP110084 BP110084SS BP110084SS-316 N/A
96″ (2438mm) BP110096 BP110096SS BP110096SS-316 N/A
108″ (2743mm) BP1100108 BP1100108SS BP1100108SS-316 N/A
Super Air Knife with Plumbing Kit
Super Air Knife with Plumbing Kit installed.
Airflow Length Aluminium Model Type 303SS Model Type 316SS Model PVDF Model
24″ (610mm) BP110024PKI BP110024SSPKI BP110024SS-316PKI N/A
30″ (762mm) BP110030PKI BP110030SSPKI BP110030SS-316PKI N/A
36″ (914mm) BP110036PKI BP110036SSPKI BP110036SS-316PKI N/A
42″ (1067mm) BP110042PKI BP110042SSPKI BP110042SS-316PKI N/A
48″ (1219mm) BP110048PKI BP110048SSPKI BP110048SS-316PKI N/A
54″ (1372mm) BP110054PKI BP110054SSPKI BP110054SS-316PKI N/A
60″ (1524mm) BP110060PKI BP110060SSPKI BP110060SS-316PKI N/A
72″ (1829mm) BP110072PKI BP110072SSPKI BP110072SS-316PKI N/A
84″ (2134mm) BP110084PKI BP110084SSPKI BP110084SS-316PKI N/A
96″ (2438mm) BP110096PKI BP110096SSPKI BP110096SS-316PKI N/A
108″ (2743mm) BP1100108PKI BP1100108SSPKI BP1100108SS-316PKI N/A
Super Air Knife Kits
Kits include a Super Air Knife, shim set, filter separator and pressure regulator (with coupler).
Airflow Length Aluminium Model Type 303SS Model Type 316SS Model PVDF Model
3″ (76mm) BP110203 BP110203SS BP110203SS-316 BP110203-PVDF
6″ (152mm) BP110206 BP110206SS BP110206SS-316 BP110206-PVDF
9″ (229mm) BP110209 BP110209SS BP110209SS-316 BP110209-PVDF
12″ (305mm) BP110212 BP110212SS BP110212SS-316 BP110212-PVDF
18″ (457mm) BP110218 BP110218SS BP110218SS-316 BP110218-PVDF
24″ (610mm) BP110224 BP110224SS BP110224SS-316 BP110224-PVDF
30″ (762mm) BP110230 BP110230SS BP110230SS-316 BP110230-PVDF
36″ (914mm) BP110236 BP110236SS BP110236SS-316 BP110236-PVDF
42″ (1067mm) BP110242 BP110242SS BP110242SS-316 BP110242-PVDF
48″ (1219mm) BP110248 BP110248SS BP110248SS-316 BP110248-PVDF
54″ (1372mm) BP110254 BP110254SS BP110254SS-316 BP110254-PVDF
60″ (1524mm) BP110260 BP110260SS BP110260SS-316 N/A
72″ (1829mm) BP110272 BP110272SS BP110272SS-316 N/A
84″ (2134mm) BP110284 BP110284SS BP110284SS-316 N/A
96″ (2438mm) BP110296 BP110296SS BP110296SS-316 N/A
108″ (2743mm) BP1102108 BP1102108SS BP1102108SS-316 N/A
Super Air Knife Kits with Plumbing Kit
Kits include a Super Air Knife with Plumbing Kit installed, shim set, filter separator and pressure regulator (with coupler).
Airflow Length Aluminium Model Type 303SS Model Type 316SS Model PVDF Model
24″ (610mm) BP110224PKI BP110224SSPKI BP110224SS-316PKI N/A
30″ (762mm) BP110230PKI BP110230SSPKI BP110230SS-316PKI N/A
36″ (914mm) BP110236PKI BP110236SSPKI BP110236SS-316PKI N/A
42″ (1067mm) BP110242PKI BP110242SSPKI BP110242SS-316PKI N/A
48″ (1219mm) BP110248PKI BP110248SSPKI BP110248SS-316PKI N/A
54″ (1372mm) BP110254PKI BP110254SSPKI BP110254SS-316PKI N/A
60″ (1524mm) BP110260PKI BP110260SSPKI BP110260SS-316PKI N/A
72″ (1829mm) BP110272PKI BP110272SSPKI BP110272SS-316PKI N/A
84″ (2134mm) BP110284PKI BP110284SSPKI BP110284SS-316PKI N/A
96″ (2438mm) BP110296PKI BP110296SSPKI BP110296SS-316PKI N/A
108″ (2743mm) BP1102108PKI BP1102108SSPKI BP1102108SS-316PKI N/A
Deluxe Super Air Knife Kits
Deluxe Kits include a Super Air Knife, EFC, Universal Mounting System, shim set, filter separator and pressure regulator (with coupler).
Airflow Length Aluminium Model Type 303SS Model Type 316SS Model PVDF Model
3″ (76mm) BP110203DX BP110203SSDX BP110203SSDX-316 N/A
6″ (152mm) BP110206DX BP110206SSDX BP110206SSDX-316 N/A
9″ (229mm) BP110209DX BP110209SSDX BP110209SSDX-316 N/A
12″ (305mm) BP110212DX BP110212SSDX BP110212SSDX-316 N/A
18″ (457mm) BP110218DX BP110218SSDX BP110218SSDX-316 N/A
24″ (610mm) BP110224DX BP110224SSDX BP110224SSDX-316 N/A
30″ (762mm) BP110230DX BP110230SSDX BP110230SSDX-316 N/A
36″ (914mm) BP110236DX BP110236SSDX BP110236SSDX-316 N/A
42″ (1067mm) BP110242DX BP110242SSDX BP110242SSDX-316 N/A
48″ (1219mm) BP110248DX BP110248SSDX BP110248SSDX-316 N/A
54″ (1372mm) BP110254DX BP110254SSDX BP110254SSDX-316 N/A
60″ (1524mm) BP110260DX BP110260SSDX BP110260SSDX-316 N/A
72″ (1829mm) BP110272DX BP110272SSDX BP110272SSDX-316 N/A
84″ (2134mm) BP110284DX BP110284SSDX BP110284SSDX-316 N/A
96″ (2438mm) BP110296DX BP110296SSDX BP110296SSDX-316 N/A
108″ (2743mm) BP1102108DX BP1102108SSDX BP1102108SSDX-316 N/A
Super Air Knife Shim Sets
Shim sets for Aluminium Super Air Knives include an amber colour .001″ (0.03mm), a green colour .003″ (0.08mm), and a tan colour .004″ (0.10mm) thick plastic shim. A red colour .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.
Airflow Length Aluminium Model Type 303SS Model Type 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 N/A
72″ (1829mm) 110372 110372SS 110372SS-316 N/A
84″ (2134mm) 110384 110384SS 110384SS-316 N/A
96″ (2438mm) 110396 110396SS 110396SS-316 N/A
108″ (2743mm) 1103108 1103108SS 1103108SS-316 N/A
Super Air Knife Coupling Bracket Kits
Airflow Length Aluminium Model Type 303SS Model Type 316SS Model PVDF Model
N/A 110900 110900SS 110900SS-316 N/A

Accessories

Super Air Knife 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 are available.

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Universal Air Knife Mounting System
Provide precise positioning for your air knife

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.

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Super Air Knife Plumbing Kits

Super Air Knives that are 24″ or longer must be supplied with compressed air at multiple inlets on the Air Knife. EXAIR’s Air Knife Plumbing Kits make it easy to ensure proper airflow to each inlet.

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EFC Electronic Flow Control
Turn off the compressed air when it isn’t needed

EXAIR’s EFC™ is a user-friendly electronic flow control for compressed air that is designed to minimise compressed air use on blowoff, 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. The timing control permits easy tuning to the application requirements while providing flexibility in sensing distance.

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Filters, Regulators, Valves &More

With proper filtration of dirt, moisture and oil from the compressed air supply, EXAIR compressed air products will operate for years with no maintenance required. Use a 5 micron or smaller filter separator on the compressed air supply. To prevent problems associated with oil, use a 0.03 micron or smaller oil removal filter on the compressed air supply.  Pressure regulators permit easy selection of the operating pressure, providing infinite control of flow, force and air consumption.

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Installation and Maintenance Sheets

pdf
Super Air Knife

352.77 KB

pdf
Air Knife Shim Set

109.65 KB

pdf
Aluminium Super Air Knife Coupling Bracket

268.09 KB

pdf
Stainless Steel Super Air Knife Coupling Bracket

264.28 KB

pdf
Universal Air Knife Mounting System

439.57 KB

pdf
Super Air Knife Plumbing Kit - Model 9076

211.77 KB

pdf
Super Air Knife Plumbing Kit - Model 9077

221.25 KB

pdf
Super Air Knife Plumbing Kit - Model 9078

123.02 KB

pdf
Super Air Knife Plumbing Kit - Model 9079

191.52 KB

pdf
24” to 42” Stainless Steel SuperAir Knife Plumbing Kit

183.79 KB

pdf
48” to 108” Stainless Steel Super Air Knife Plumbing Kit

197.95 KB

Air Knives PDF Brochure

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