Airknife systems promise big savings for drying
An
Air Control Industries product story
Edited by the Engineeringtalk editorial team
Jan 13, 2005
Blower driven "airknife" systems offer a clean and cost effective means of achieving optimised drying of manufactured components, bottling/packaging lines, paint finish surfaces and textiles.
Effective drying, cleaning and cooling of conveyorised components/materials is difficult to achieve.
This is illustrated by the many varied techniques employed across different industries.
One of the most common approaches is the use of compressed air taken from a central compressor-generated supply that is tapped for general use throughout a company's shop floor/production areas.
Unfortunately, the use of such compressed air sources for "surface blowoff" and cooling is extremely inefficient and can result in contamination of product with oil and condensate.
Compressed air systems also suffer from high noise levels, plus potential health and safety risks due to the high pressures involved.
Added to these factors are the high running costs of continuously operating compressors.
In contrast, blower driven "airknife" systems, such as offered by Air Control Industries of Chard, offer a clean and cost effective means of achieving optimised drying of manufactured components, bottling/packaging lines, paint finish surfaces and textiles.
They are also effective for cleaning, cooling and spreading of such materials as oil, wax, chocolate and batter.
They are even suitable for large components and high volume handling applications.
The potential cost savings that airknife systems can offer over conventional compressed air options can be really significant.
For example, a compressed air installation employing sixteen 48mm nozzles used in an array covering 200mm supplied at a pressure of 5bar will deliver 11kl/min.
This would cost GBP 3.30/h if the average UK compressed air tariff of GBP 0.005/kl is applied.
So over a 48 week year (8 hour, 5 day week) the cost would be GBP 6336.
By comparison, four 200mm long Airknives, providing an unbroken jet of air, powered by a 7.5kW powered blower would cost around GBP 3200 less a year to run (UK electrical tariff of GBP 0.04kW/h).
Because based on this tariff, one 7.5kW fan costs GBP 0.30/h resulting in a weekly cost of GBP 12/week, and an annual total just GBP 575.
One company, Supergalss Insulation of Stirling, Scotland reports a recurring annual saving of GBP 128,000 following an investment of GBP 32,000.
And the Decoma Sybex company at Banbury (manufacturer of moulded bumper systems to leading car manufacturers) says that improved drying and de-ionisation processes fulfilled by airknife systems from Air Control Industries has resulted in scrap through moisture related contamination being eradicated.
Superglass Insulation , Stirling, manufactures mineral wool insulation products for domestic, commercial and industrial use.
In return for receiving a rebate of GBP 80,000 of its Climate Change Levy payments, the company is required to meet challenging energy targets.
Working with the help of Action Energy and Energy Consultants the company implemented various measures to reduce compressed air consumption.
One of the main issues was the use of compressed air for removing surface water and as a result of changes made Superglass now benefits from annual savings of GBP 128,000.
"We previously used an air bar to remove surface water from a metal collection belt system", explained Steven Whyte, Project Electrical Engineer.
"On hearing about the benefits of Air Control Industries' (ACI) airknife system and free demonstration option, we decided to assess the Airknife's capabilities".
"Working off a radial-bladed blower at a much lower pressure, the airknife immediately provided an improved performance".
"We have since replaced five compressed air systems with ACI's Airknives, resulting in significant ongoing cost savings from a one-time investment of GBP 32,000".
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