Tag: Manual Valves

What is Industrial Ventilation?

Industrial ventilation is a mechanical system that brings in fresh outdoor air into the workplace (factory or manufacturing plant) and removes contaminated indoor air.  Ventilation is used in a factory to provide a healthy and safe working environment for employees and to remove or have control over contaminants released in an indoor work environment.  The ventilation could be achieved by opening a window (natural) or using fans/blowers (mechanical means). Common pollutants that are removed using an industrial ventilation system include: flammable vapors, welding fumes, dust, mold, asbestos fibers, oil mists, toxic chemicals, moisture and more.

Installing proper industrial ventilation is crucial for providing a safe and healthy environment for workers. They are critical to monitoring indoor air quality. A well-designed ventilation system will bring the air into the workspace at a specific speed creating the required air pressure to ensure cost savings for heating and cooling.

The purposes of a well designed industrial ventilation system are:

• Provide a continuous supply of fresh outside air
• Maintain temperature and humidity
• Reduce hazards for fire and explosion
• Remove or dilute contaminants in the air

An industrial ventilation system consists of two subsystems: the fresh air supply and an exhaust system.

The fresh air supply system includes an air inlet, air filtering equipment, heating and/or cooling equipment, fans, ductwork and air distribution registers.

The exhaust system has an air intake area and ducts to remove contaminated air from one area to another area, an air cleaning device, discharge stacks and fans.

 

Limitations of Industrial Ventilation Systems

Some limitations of many if not all industrial ventilation systems:

• They require ongoing maintenance because of contaminant build-up within the system, especially filters.
• Regular and routine testing is needed to identify problems early and implement corrective measures.
• Only qualified persons should make modifications to a ventilation system to make sure the system continues to work effectively.
• Making unauthorized changes to the duct system will pull air into the system from the new location resulting in reduced air flow from other locations. The entire ventilation system airflow will be affected resulting in rapid plugging of the system preventing the system from adequately removing contaminants.

 

Types of Industrial Ventilation Systems

There are three types of industrial ventilation systems: Dilution, Local Exhaust, and Indoor air quality ventilation

 

Dilution System

A Dilution system reduces the number of contaminants in the air by mixing the contaminated air with clean, fresh air. To install a dilution system, large exhaust fans are installed in the walls or the roof of a factory. This type of industrial ventilation system is used when:

• Air pollution is low and toxicity level is low to moderate.
• Contaminants are vapours or gases
• Emissions are uniform and widely dispersed
• Recommended for moderate climatic environments
• Heat is removed by flushing to the outside
• Mobile contaminant sources are controlled

Advantages of Dilution:

• Needs less maintenance.
• Lower equipment and installation costs
• Recommended for small amounts of low toxic chemicals
• Effectively controls flammable or combustible gases or vapors
• Used for mobile or dispersed contaminant sources

Disadvantages of Dilution:

• Not recommended for highly toxic chemicals
• Does not completely remove contaminants so it is not recommended for high concentrations of dust, fumes, gases, or vapors
• Large quantities of heated or cooled makeup air is required.
• Not recommended for irregular emissions of contaminants.

 

What is Make up air?

Make up air is the air used to replace the air that was extracted from the workplace. If not replaced, the workplace could become “starved” of air and result in negative air pressure. The negative air pressure could increase resistance on the ventilation system resulting in less air being moved. To determine the pressure in a workplace:

1. Open a door 3 mm and hold a smoke tube in front of the opening. If the smoke is drawn into the room, the room has negative pressure.  If the smoke is pushed away from the room the room has positive pressure. If the smoke raises straight into the air, then the pressure in the room is the same as the outside pressure.
2. Check the resistance when pushing or pulling a door.
3. If the room has a negative pressure – an easy solution is to install a separate intake fan, located away from the exhaust fans to bring fresh uncontaminated air from the outside. Ideally, the air is clean and warmed in the winter or cooled in the summer; as needed. Check some common questions and optimal placement of intake fan here (What are the main features of dilution ventilation?).

 

Local Exhaust System

A Local Exhaust system captures contaminants at the source and ejects them outside.  It functions on a principal that air moves from high pressure areas to low pressure areas. This difference in pressure is created by a fan that draws air through the ventilation system.

This system is used in areas of high air contamination concentration where there is a greater risk to of exposure to employees. The ventilation system is used for isolated or contaminant sources. This system requires:

• A hood or other device to capture the air pollutants at the source.
• Ductwork as close to the source of contaminants as possible to move the contaminants away from the inside. The material must be compatible with the airstream
• A quality air filter system to clean the air as it moves.
• A fan that moves the air through the system and blows it outdoors
• A stack through which the contaminants are removed.
• The workers are considered in the design, installation, and maintenance of this system.

NOTE: The fan must be the proper type, wheel, arrangement, and size for the application. The fan may require spark resistant construction or other special options.

This system can handle removing many kinds of pollutants including metal fumes and dust. It uses less energy than dilution systems.  This type of industrial ventilation system is used when:

• Inconsistent emissions over time
• High concentration of hazardous materials
• Point sources of contaminants
• Workers are close to the source of contaminants
• Factory is in a severe climate location
• It is required not to turnover air in the factory

Advantages of a Local Exhaust Ventilation System:

• Requires less makeup air because less quantities of air are exhausted
• Reduced energy heating and cooling costs
• Captures the emission at the source and removes it
• The best type of ventilation for highly toxic airborne contaminants, fumes, gases, vapours, and dust.

Disadvantages of a Local Exhaust Ventilation System:

• High cost to design, install, and maintain
• Requires regular maintenance, inspection, and cleaning

 

Indoor Air Quality Ventilation

Indoor air quality ventilation, which provides fresh heated or cooled air to buildings as part of the heating, ventilating and air-conditioning system (HVAC). The parts of an HVAC system include:

• Air inlet
• Air filtering equipment
• Heating/cooling equipment
• Fan
• Ducts
• Air distribution registers
  

The exhaust system consists of:

• Air intake area
• Ducts to move air from one area to another
• Air cleaning device
• Fans to bring the outside air in the factory and to bring contaminated indoor air outside
• Stacks

Nex Flow® Venting Solution

1. Fume and Dust extractors
2. Ring Vac®
3. Air Volume amplifiers

Fume and Dust Extraction system is designed for portable use, especially for intermittent (on- off) applications. They are rugged and long lasting.  This option is beneficial because of its low cost with reduced noise. For soldering applications, spot welding operations, a small, portable less expensive unit using a small amount of compressed air is more cost efficient than a heavier electronically operated unit.

The system is Low cost and durable and consists of:

• An adjustable air amplifier
• 2” lock-line hose, which draws in a large volume
• Magnetic base – which secures to a metal working table
• A hose can be clamped onto the outlet of the amplifier to take the fumes and dust into a container or out to another area.

Ring Vac® may be added and used to convey collected material beyond 10 feet (3 meters). The Model 40002FMS Stream Vac® (link to product) is affordable compact air cleaning system to remove dust, fumes, and other air pollution from work places. When connected to 10 feet (3 meters) 2” hose compressed air line, the system will remove up to several hundred cubic feet of air with welding and soldering fumes, particulate from local grinding operations, smoke and particulate using very little compressed air.   

Air Amplifiers also called “Air Movers” – can be used for moving a large volume of air. Air Amplifiers uses a small parcel of compressed air to produce high velocity and volume, low pressure air flow as the output.  They are ideal blowing or cooling and for venting. Air amplifiers are used to convey powders and dust, exhaust tank fumes, and moves air 12 to 20-fold in duct appliances to 60 times in area with no ducts. The amplifiers use a small amount of compressed air to draw in a flow of up to 17 times the air consumed to remove fumes quickly and efficiently for venting applications. The fumes can be ducted away, up to 50 feet (15.24 m), and the amount of suction and flow is easily controlled.  

If a large amount of air borne dust or fumes need to be collected and moved a long distance, the air amplifier enhances the air conveyor ability to convey these materials over long distances. The reason is that air conveyors produces high vacuum but move less volume as compared to air amplifiers that move high volume but creates less vacuum. Nex Flow air conveyor systems are manufactured in anodized aluminum for most applications and in 304 Stainless Steel for high temperature and corrosive environments. 316L Stainless Steel air operated conveyors are available for food and pharmaceutical applications. An XSPC range conveyor is also available for moving materials that could clog. Air Amplifiers are lightweight, compact and portable so any application where that can be an advantage is ideal for their use, especially if the use is intermittent minimizing the real energy cost of compressed air.

The following accessories are available with Nex Flow air amplifiers:

• Hose or pipe to collect or transfer materials, fumes, and dust
• Filters
• Mounting systems including brackets
• Regulators
• PLCFC
• Stainless steel shims for maximum product lifespan
• Pneumatic water separator
• Manual valves
• Replacement parts
• Flanges

NOTE: Pipes reduce the air amplification by 10:1 due to back pressure but still provides more efficient air amplification because venture systems move air or vent gas.

 

Nex Flow air amplifiers are compressed air operated devices that are often used for local ventilation due to their portability.  They are not electrically run so there is no explosion risk. Compact and rugged, they are built to last. If existing systems are not sufficiently strong enough to move the contaminated air, then Air Amplifiers can boost these systems and overcome the losses. This deficiency may be caused by a pressure drop at ventilation entrances.

Filtration is important for maintaining the effective and optimum operation of all Nex Flow air operated products. All Next Flow products used for conveying. such as air amplifiers, air operated conveyors, etc. require clean compressed air. It is essential to use filters to remove water and oil from the compressed air lines. These filters are installed upstream from the air amplifier or air mover in the industrial ventilation system. Air filters should be sized to handle the maximum air flow expected for conveying the contaminated or clean air they are moving. Nex Flow water and oil removal filters are 5 microns and 0.3 microns respectively.

Best Practices for After Installation

It is important to follow through with your employees and train them on the industrial ventilation system. They should be aware of the following:

• How the exhaust system is designed and the intended use.
• The use of the flow restrictors, diverters, and baffles that can alter air movement.

• Keep all hoods, slots, and duct work openings clear of debris, obstructions and buildup which reduces the amount of air entering the ventilation system
• The ideal location to position the employee and the equipment to maximize the amount of air movement into the exhaust hood.
• Employees should continuously observe the ventilation system for damage and flow restrictions. They should be aware of who to report damages to.  A manometer, used to monitor pressure, is a good method of judging if the system require maintenance.
• An employee should perform regular system maintenance, such as changing filters. This will reduce the amount of resistance in the system and improves the systems efficiency.

What does all this mean?

It is important to properly design your industrial ventilation system to achieve the following:

• Provide continual fresh air supply
• Protect workers from heat stroke or cold temperatures
• Reduce fire or explosion risks
• Reduce exposure to airborne contaminants

Although all ventilation systems consist of the same basic principals, each system is designed specifically to meet the requirements of the work environment including the type of work and the rate of contamination release in the factory.  Some important standards and items to consider when designing an industrial ventilation system are:

• OSHA and EPA regulations
• Proper duct design
• Air sampling
• Types of materials used in the construction of the system
• Hazard reduction
• Administrative controls
• Efficient hood design
• Proper fan selection
• Fire and explosion hazards
• Pollution control equipment selection

Our experts at Nex Flow® can help you choose the industrial ventilation system best suited for your manufacturing site or factory. Please don’t hesitate to contact us for more information about our ventilation solutions from a simple Air Amplifier to our Ring Vac® and Fume and Dust Extractor.

What is an Air Nozzle?

An air nozzle controls the direction or characteristics of air flow by converting pressure into the flow. Air Nozzles are the smallest air amplifiers for point application. Frequently Nozzles control the flow rate, speed, direction, mass, shape, and pressure of the stream that emerges. In a nozzle, the velocity of fluid increases at the expense of its pressure energy. Air nozzles are one of the most common products used in a factory environment. They are primarily used for blowing off debris and liquid and for cooling or drying parts. It is using them for cleaning, part ejection, and conveying.

The original compressed air-operated engineered nozzle is a cone that provided the most flow amplification. They are helpful for compressed air applications because they entrain surrounding atmospheric air with the compressed air.

It is often a pipe or tube of varying cross-sectional area and can direct or modify a fluid’s flow (liquid or gas). Inefficient air nozzles consist of an air exit hole for the compressed air at the end of a pipe attachment. The pipe usually has a small hole on the side to release compressed air, reduce dead-end pressure, and create a helpful blow-off force.  

NOTE: Always use filtered compressed air to ensure the air supply remains clean and dry.

Properly engineered air nozzles work by using the Coandă effect – entraining surrounding air and the compressed air in a ring of holes around the bottom or sides of the nozzle. The exiting air is a concentrated, high-velocity, laminar flow stream of amplified air. Standard cone-shaped air nozzles, with air exit holes around the bottom of the nozzle, provide the best flow per unit of air consumption and are best suited for light blow-off and cooling applications, thus providing a low-cost solution for the task. Modern engineered nozzles have holes on the bottom or sides with hole spacing, sizing, and internal design crafted to optimize for the highest force per unit of air consumed.

 

NOTE: Always use filtered compressed air to ensure the air supply remains clean and dry.

 

Types of Nozzles

In most factories/manufacturing environments, many types of nozzles satisfy the requirements for specific applications. The challenge is to find the nozzle that provides the best performance at the optimal operating cost.

There are several types of engineered nozzles available:

• • Cone Shaped Air Nozzles are excellent flow amplifiers. They are used for cooling because they have high flow/CFM compared to other engineered nozzles. They dramatically reduce noise pollution in a factory and are suitable for energy conservation. Cone-shaped air nozzles reduce compressed air costs by conserving air. They are compact and have a 10-dBA average noise reduction to improve safety in the work environment. They meet OSHA noise level requirements. Overall, these air nozzles will enhance the production of your factory environment. These Air Nozzles replace an open pipe from 2 mm to 0.5 inches and save 30% in compressed air. Note that not all cone-shaped nozzles are equal, as the internal design impacts performance.
• • Air Mag Air Nozzles is a bullet-shaped finned nozzle with a unique patent design to focus compressed air from the supply line and entrained air from the surroundings to a sharper laminar flow of air with the highest force per SCFM than other bullet-shaped finned nozzles on the market. They have the lowest air consumption for the force produced, lower noise levels, no whistling sound, are rugged, and are made of a single piece for extra strength.
    
    The exit nozzle is oriented to increase force/CFM over other competitive nozzles by 10%. The Air Mag Nozzle comes in the following sizes for various applications:
    • 1/4″ is the average size for air guns. This size is used for most applications and is usually attached to a ¼” pipe or hose.
    • ½” is for heavier blow-off applications. It connects to a ½” pipe or hose and is a standard nozzle used with large air guns.
    • 4, 5, and 6 mm are available for small applications and are usually attached to small copper tubes and smaller – often low-cost – air guns. There is a 1/8″ adaptor for the 6 mm nozzle to adapt it to a 1/8″ pipe.

• More types include

  • A flat Jet Nozzle is a compressed air-operated chamber (flat nozzle, flat jet), which is a smaller length than an air knife. It also has a higher air force and flow design. They are mounting the flat jet nozzle on manifolds of different sizes (holding 2, 4, or 6 units typically or more). Also, use it when a much stronger forced air is required than an air knife can provide. They are very efficient and specially designed to provide a powerful stream of high-velocity laminar flow, a high force for blow-off applications, and cooling where air knives do not provide enough force. The air consumption and noise levels are minimized with the unique design, which converts pressure usually lost as noise and pressure drop into proper flow and energy. Shims can be added to modify the force. This nozzle is used for part cleaning, chip removal, part drying, part ejection, and air assist. Nex Flow takes care in designing our flat jet nozzle and ensures it meets the OSHA noise level requirements.

• • Ring Ionizer-Ionizing Nozzles discharge and clean surfaces of non-conductive materials by incorporating an anti-static pin. For manual use, mounting to a handgun is possible.
• • Laval Effect Nozzle uses an hourglass exit for the existing compressed air to accelerate the exiting compressed air. While they are supposed to reduce overall noise, they tend to have a higher-pitched noise. The force tends to dissipate if the nozzle is not close to the target blow-off. For this type of nozzle, the noise and effectiveness are questionable compared to a nozzle using the Coandă effect.
• • Spray nozzles that use compressed air produce a fine spray of liquids mixed with the compressed air. They include atomizer nozzles and air-aspirating nozzles.

Materials Used to make Nozzles.

Choosing the material that the nozzle is constructed of will determine the unit’s wear. Nozzles, over time, could begin to clean a surface unevenly or over-spraying, which wastes chemicals, water, energy, and operating costs.

• Anodized aluminum is ideal for blow guns and part ejection of heavier viscosity liquids.
• 303/304/316L Stainless Steel is often used for liquid and lightweight part blow-off applications for food, pharmaceutical, and corrosive environmental applications. 316L stainless steel is more expensive but worth the cost when the manufacturing environment has high chloride and salt exposure.
• Cast zinc is rugged and provides extra strength for use in harsh environments.
• Plastic nozzles are of lower cost and are often used but can easily break and, in some applications, may be dangerous with the risk of breaking.
• Copper or brass are optimum for blow-off nozzle materials since they have low friction coefficients.  

Advantages of Using an Air Nozzle

Using air nozzles, replacing non-engineered air nozzles, or replacing old nozzles with more efficient products can save high operating costs by using compressed air more effectively. There is also an average 10 dBA reduction in noise, and it meets OSHA standards, which improves the working environment. Nozzles provide precise, repeatable drying and blowing-off capabilities for all applications.

Accessories

Air nozzle is available with the following accessories:

• Copper tubes can be attached to some nozzles to aim the direction of the flow. The copper tube is pressed to fit into the customer’s existing system.
• A rigid-flex hose can be bent into shape to aim the nozzle at the target. It is an all stainless-steel hose that does not break after a few bends like competitive rubber hoses with simple copper inserts. The stainless-steel construction allows for use in any challenging environment. Rigid-flex hose nozzle is resistant to creep and crimping.
• Manifolds to attach more than one nozzle or flat jet nozzle
• Swivels
• Regulators
• Pneumatic Super Separator
• Magnetic base
• PLC Flow Control System (PLCFC)
• Static meters (used with Ionizing nozzles)

Factors to Consider when Selecting a Nozzle

When considering an engineered nozzle, there are several factors to consider. It is recommended, when reviewing specification, to research the distance the force/CFM were taken and the line pressure. Determine if the force and pressure are suitable for your application: test and use brands known for improved performance and quality like ours. Stay wary of copies and ask if you need continuous or intermittent air supply.

Don’t forget to consider sensors and timers when applicable for energy savings. Besides the nozzles themselves – it is also essential to consider the compressed air piping system to ensure efficiency.

Lubricants corrode some materials from the compression process, which leads to leaks and particulates in the air stream. Copper, brass, steel, and aluminum are optimum choices for nozzle materials as they have low friction coefficients.

 

FEATURED PRODUCTS

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How do you determine the best nozzle for the following applications?

Cleaning

For cleaning applications, choose a nozzle with the highest force/unit airflow (Force/SCFM ratio), such as the Air Mag nozzle. It is also essential to consider air consumption. A regulator can be used to cut back the pressure to set the required force. Any additional force above the requirement will use more energy and cost more. Air pressure loss will result from compressed air through a pipe attached to a nozzle.

The higher the airflow through the pipe, the larger the pressure drop and pressure at the entrance of the nozzle. Any extra pressure (for example, 1 SCFM) entering the piping that is the same size as the nozzle – will cause the pressure to drop at the entrance of the nozzle. Therefore, for cost savings, the correct pressure/force must be determined at the entrance of pipping attached to the nozzle so that there is no pressure drop when the compressed air enters the nozzle.

The reduced air pressure/force will also have less noise pollution and provide a safer manufacturing environment for your employees. Air Edgers (Flat Jet nozzles) are also popular for cleaning flat or curved surfaces and have the advantage of having the force varied by adding/removing shims, which control the air exit volume and force.

Other factors that can negatively impact spray nozzle performance are plugging, erosion, corrosion, scale build-up, caking, accidental damage, and improper assembly. These are common in washing and rinsing operations, especially when using caustic solutions. Establishing and implementing a nozzle maintenance program is the most effective way to prevent and minimize costly spray nozzle problems.

Static Control – Ion air nozzles/Ring ionizer nozzles are highly effective at discharging and cleaning non-conductive materials. These nozzles can be mounted on handguns for confined workspaces. These are flexible, light, and easy to use for discharge processes.

Drying

When nozzles are used for drying, the traditional cone-shaped nozzle is recommended. For larger applications requiring several nozzles, more energy will be saved when using the Air Mag nozzles. Anodized aluminum or 303/304 Stainless Steel standard strength nozzles with 1/8″, ¼”, male NPT connection is ideal for blow-off liquids applications. Model 47001 is designed to fit into small spots and is used by many machine builders for blow-off applications. Model 47003 (anodized aluminum), Model 47003S (303/304 Stainless Steel), and Model 47003S-316L (316L Stainless Steel) –with a 1/8″ male NPT connection is ideal for most blow-off applications involving liquids.

Drying large flat or curved surfaces

Air Knives are like rows of linear air nozzles that can be made to very long lengths. Air knives provide uniform airflow across the entire length of the air knife. It provides high velocity and a constant air stream for fast drying and blow-off in a factory setting. Air knives are maintenance-free because there are no moving parts. They are safe because they have low noise pollution. Air knife kits are available, which include an air knife, extra shims, filter, pressure regulator, and gauge.

Cooling

Using standard cone-shaped air nozzles that are efficient at converting pressure to flow is a good choice when selecting nozzles for cooling. These nozzles are better for cooling as they have less force/CFM but more flow/CFM than the more engineered nozzles. Round air amplifiers are essentially very large low-pressure but high-volume nozzles ideal for cooling molded parts and castings. They move large volumes of air using a small amount of compressed air, making it economical to operate.

Ejection of Heavier Liquids

Model 47004 (anodized aluminum), Model 47004S (303/304 Stainless Steel), and Model 47004S-316L (316L Stainless Steel) are a strong force and high flow amplification nozzles with a 1/4″ male NPT connection is ideal for most blow-off applications involving liquids and even lightweight parts and often used for heavier liquid. The 47010 is a higher-force nozzle but has less distance for laminar flow than the 47004. It has an anodized aluminum ¼” female NPT fitting nozzle with a Coandă profile resulting in extremely strong force at a distance. This nozzle is good for blow guns. It has a higher force for less distance for laminar flow.

About Nex Flow

Nex Flow manufactures specialized compressed air solutions that are easy to install and reliable. All products reduce noise in factories to enhance the safety of your environment. Nex Flow manufactures high-quality, economical, specialized compressed air solutions for blow, off, cooling, drying, and moving with representatives worldwide. Choosing Nex Flow means obtaining the best-customized solution, including full technical support. Our customer technical support provides blowing angle and direction tips during installation. All compressed air blow-off, moving, and cooling unit products have a five-year warranty against manufacturer’s defects.

What are the Advantages of an Air Operated Conveyor System?

Air operated conveyors are clean, quick, and efficient machines that are designed to transport or vent a wide variety of lightweight products, raw materials, or fumes from one place to another. They are a family of devices that use air to move products instead of mechanical belts or chains. Internal air conveyor is the term used when the items being moved are in the same pipe or chamber as the air that is moving them. Air transporter systems are popular in material handling and packaging industries. It works by having air flow through louvers to an inner chamber in which items, such as metal scrap, is moved. Internal air conveyors are limited to lengths of about 100 ft. (30 meters) or less due to pressure losses within a pipe.  

Any friction between the product and the system is kept to a minimum. Some system even use ultra-low friction guide materials, such as oil-impregnated Ultra-High-Molecular-Weight (UHMW) or highly polished chrome.  At very high speeds, a week’s worth of dust on a line can create enough friction to reduce line efficiency. Therefore, it is important to keep surfaces clean in these type of systems.

An air conveyor system is used to convey all types of solids, plastic materials, metal pieces, waste, trim removal in a manufacturing environment. It can also be used to vent gas in some cases. The length of the distances transported vertically and horizontally depend heavily on the types of material you are conveying.

 

Different conveying systems are used according to various needs of different industries

• Bulk conveyors move powders, scrap, coal, bottle caps, and grain. Generally these are not used for delicate objects that could be damaged if not moved in a specific orientation such as bottles, although some heavier bottles are conveyed this way.  An air conveyor system can usually convey the same material as bulk conveyors but with significant less capacity. Low capacity applications where bulk system may apply can be ideal for air operated systems.

• Deck conveyors are used to move cans, caps, and cartons or cases. Deck conveyors work like air hockey tables, except that in addition to the lifting holes, there are directional louvers that direct products. It is not uncommon for deck conveyors to be inclined more than 10 degrees. Specialized systems called “tunnel tracks” are used for cans with decks on top and bottom, which sometime serve as vertical elevators.
  
  This type of carrier requires a guide to keep products from falling over. The guide keeps products from lifting off the conveyor and prevents products from tipping over when starting and stopping. Products without flat tops and bottoms may not work well with this specific system because they are not easily guided. However, there are some products/packages designed so they can be moved without a top cover. Other guide arrangements are also possible. For example, some air deck conveyed products such as plastic ketchup bottles may be guided on the shoulders rather than the top.

• Neck ring conveyors are used to move bottles. Due to the friction of the bottle-neck ring against the neck-ring guide, more air pressure is needed when bottles accumulate back to back to get them moving again.

• Airveyors are devices used for handling dusty materials, which is built on the principle of a pneumatic cleaner. The system used is a suction system, whereby the material (soda ash, salt cake, cement, or powdered lime) is drawn from the car through a flexible hose into a vacuum tank designed to recover a large percentage of the dust floating in the air. An air conveyor can sometimes be used and incorporated into these systems depending on the capacity that needs to be addressed.

• Apron Conveyor is made from linked apron plates with hinges on its underside, thus creating a looped carrying surface where huge and heavy materials are placed.  A mechanism, usually composed of several metal rollers, is placed inside the apron conveyor belt. The apron conveyor is used to deliver many materials across several phases of production. Many industries consider apron conveyors to be a lifeline in their industry, including manufacturing, agricultural, and chemical industries.

• Screw conveyor or auger conveyor is a mechanism within a tube that uses a rotating helical screw blade. It is used to move liquid or granular materials including food waste, wood chips, aggregates, cereal grains, animal feed, boiler ash, meat and bone meal, municipal solid waste, and many others.  The rate of volume transfer is proportional to the rotation rate of the shaft. Although air conveyors are not able to handle the large capacity that screw systems must deal with – rare application can arise.

• Chain Conveyors are used for moving products down an assembly line and/or around a manufacturing or warehousing facility. Chain conveyors are primarily used to transport heavy unit loads, e.g. pallets, grid boxes, and industrial containers. These can be single or double chain strand in configuration.This type of carrier system utilizes a powered continuous chain arrangement, carrying a series of single pendants. The chain arrangement is driven by a motor, and the material suspended on the pendants are conveyed.

• Bucket elevator (also called a grain leg) is a mechanism for hauling flowable bulk materials (most often grain or fertilizer) vertically.
• Vacuum Pump – while not specifically a type of conveying system, electrically operated vacuum pumps are utilized often for venting purposes to move gaseous products of all types, including corrosive gas products.   The gases are conveyed by the vacuum action and sometimes vented to the atmosphere. Air conveyors are better suited when handling corrosive or high temperature gas because they do not use electricity, can be supplied in appropriate materials, are lightweight and compact for easy installation, and virtually maintenance free.

 

Examples of air conveyors

• Ring Vac: Simply clamp a standard hose size to each end of the Ring-Vac to create high energy conveying system. There are no moving parts for maintenance free operation with capacity and flow controlled using a pressure regulator. Any size longer than  3” (76mm) can be prohibitive for most applications due to high compressed air requirements but 4” and 5” units are available.  The anodized aluminum and high temperature stainless steel Ring-Vac Air Conveyor can move all types of solids in large volumes over great distances with no moving parts.
• XSPC Conveyors: Like the Ring Vac, XSPC conveyors are compact, easy to use, portable, and ideal especially for intermittent use in material transfer.  The difference is that the inside of an XSPC conveyor is straight and smooth so materials, such as textiles, cannot clog.

Air conveyors are most widely used to move lightweight objects such as empty containers, boxes, and trays at speeds often exceeding 1,000 fpm. However, they are not limited to lightweight materials. There are many different types of air operated conveyor systems that are designed to convey different types of products or perform specific tasks.

What are the advantages of using an Air Operated Conveying Systems?

Air operated conveyors easily move items at faster speeds than conventional conveyors.  They are also ideal for moving scrap where conventional conveyors would become quickly clogged or contaminated with debris. The inside diameter can be twice the diameter of the part/material being moved to help prevent clogging.

Air conveyors typically have minimal moving parts and no pockets to collect debris and water, which makes them safe and easy to clean and maintain. The original patent was for coal since it was used to safely vent air in remotely for various explosion-proof settings. Coal comes in a variety of sizes and easily breaks down into smaller, highly flammable particles. Air conveyors are designed to keep coal dust contained and not attract and accumulate dust. This means that they require much less frequent cleanings than belt conveyors moving coal would need. Maintenance is also greatly reduced on air conveyors versus conveyor belts, because the only bearings are on the blowers, which are typically located well outside the area where they would encounter dust and other small particles.  

Air conveyors are also useful when transporting sharp or abrasive materials. Metal scrap and recycling centers are perfect applications for air conveyors because long ribbons of razor sharp metal can easily snag other types of conveying equipment.

Applications of Air Conveying Systems

• Venting Gas
• Combining Air Operated Conveyors with Air Amplifiers
• Hopper loading
• Trim removal
• Filling operations
• Material transfer
• Food ingredients
• Coal
• Grain
• Scrap
• Abrasive or corrosive chemical industry products and fumes

Venting Gas

In a transmission line or a scrubber, the compressed air technology replaces an electrically operated vacuum pump for venting purposes. Electrically operated vacuum pump requires maintenance and a more complicated configuration.

There are two options available depending on the nature of the gas that you want to vent:

• A compressed air flow amplifier, which utilizes the Coandă effect
• An air operated conveyor, Ring Vac and XSPC which uses a Venturi effect.

A compressed air flow amplifier is very quiet and moves large quantities of air. It is an ideal solution when venting clean gas short distances because very little vacuum is required. The compressed air exits a small gap in the amplifier and goes over a series of ” Coandă ” angles converting air pressure to flow. This solution is ideal for venting fumes, dust, and grime. It is complex to manufacture and costs more. This unit requires more air pressure to operate.

An air operated conveyor uses a series of holes to blow the compressed air in one direction creating a vacuum to draw in and move the gas. The Venturi system has several holes, the number depending on the size of the unit, which pulls the air behind the unit creating a vacuum, drawing in any gasses and then pushes them away. It is an ideal solution for moving gas longer distances aided by the extra vacuum. An air operated conveyor is required when the gas is contaminated and there is a possibility that it could deposit material on the Coandă angles of an amplifier, which could stop the venting effect over time.  Since the compressed air enters through a different vent, there is less opportunity for dirt deposits if the gas is contaminated. The air operated conveyor produces a higher vacuum but does not move as much air volume as an air amplifier. The Venturi system is a simple unit to manufacture and costs less. It requires less air pressure to operate. It is available in aluminum, stainless steel (standard), with special units made in Teflon, other plastics and metals.

Therefore, due to the design, cost of manufacture, and requires less air pressure to operate, the Venturi system is often the ideal solution for gas venting applications.

 

FEATURED PRODUCTS

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[one_third][image src=”https://www.nexflow.com/wp-content/uploads/2017/07/am40-3.png” size=”” width=”” height=”” align=”center” stretch=”0″ border=”0″ margin_top=”” margin_bottom=”” link_image=”” link=”https://www.nexflow.com/products/energy-efficient-blow-off-products/air-amplifiers/standard-fixed-air-amplifiers/” target=”_blank” hover=”” alt=”” caption=”Standard (Fixed) Air Amplifier” greyscale=”” animate=””][button title=”View Product” link=”https://www.nexflow.com/products/energy-efficient-blow-off-products/air-amplifiers/standard-fixed-air-amplifiers/” target=”_blank” align=”center” icon=”” icon_position=”” color=”#27367a” font_color=”” size=”1″ full_width=”” class=”” download=”” rel=”” onclick=””][/one_third]

 

Combining Air Operated Conveyors with Air Amplifiers

If a large amount of air borne dust or fumes need to be collected and moved a long distance, the air amplifier enhances the air conveyor ability to convey these materials over long distances. The reason is that air conveyors produces high vacuum but move less volume as compared to air amplifiers that move high volume but creates less vacuum.

 

How do I select an Air Conveying System?

The factors to consider are:

• Material properties: Consider the characteristics of the material that needs to be moved or removed. What is the particle size and shape, bulk density, moisture content, abrasiveness, friability, cohesiveness, static charge, explosivity, toxicity, melting point, and more?
• Conveying distance: What is the overall distance as well as horizontal or vertical direction of the pipe?
• Available air pressure and velocity
• Transfer capacity: Includes the material properties and the transfer distance.
• Transfer rate: How fast and how often does the material need to be transferred.
• Energy Consumption: Compressed air supply availability

Accessories and Attachments

• Mounting bracket to mount the air operated conveyor
• Clamp to stabilize a hose to each end
• Threaded to thread on a standard pipe for threaded units
• Inlet suction attachment
• Air filters
• Air Regulators
• Air Amplifier

Nex Flow Advantages

Nex Flow air operated conveyor system are lightweight and use no electricity.  The parts are readily installed and easy to use. There is a threaded version as well as clamp on, sanitary flanged units, and other flanged units (optional). They are portable and ideal for continuous and intermittent applications. Our system utilizes compressed air for a powerful, efficient venture action along the length in a compact design for high capacity conveying over long distances. Nex Flow’s products are made from material that is treated to ensure longevity in the product’s life cycle and designed for ease of use and provides simple control of material flow for maintenance free operation.  

Our air conveyor systems are manufactured in anodized aluminum for most applications and in 304 Stainless Steel for high temperature and corrosive environments. 316L Stainless Steel air operated conveyors are available for food and pharmaceutical applications. An XSPC range conveyor is also available for moving materials that could clog.