Air knife eliminated downtime caused by metal shavings
By replacing manual cleaning with an automatic air knife, the Super Air Knife, the customer has saved time, reduced air consumption and achieved a quieter working environment - without compromising on quality.
Background
Dropped profiles led to production stoppage
During a site visit to a customer in the metal industry, a clear bottleneck in production was identified. In connection with the cutting of metal profiles, large amounts of metal shavings were formed and stuck to the profiles.
The problem became particularly apparent in the next stage of the process, where the profiles were transported on a conveyor belt and picked up by a robot for packing. Because chips often remained on the surface, the robot's suction cups could not grip the profiles properly. As a result, the robot dropped profiles an average of eight times a day, leading to unplanned downtime and production losses.
To handle the higher load, the customer had placed two operators at the station: one to run the metal cutter and one to manually blow the profiles clean before the robot took over. The customer now wanted to find a more efficient and sustainable solution that could automate the blowing process.
To streamline the process and reduce manual labour, the customer wanted to introduce an automated solution for blowing clean.
Solution
Customised Super Air Knife optimised the process
After analysing the process, it was suggested to install a Super Air Knife, a compressed air driven solution that delivers a smooth, laminar airflow along its entire length. The air knife was mounted above the conveyor belt and now blows metal shavings away from the profiles in a single step, fully automatically.
Automating the blowing process has eliminated the need for manual cleaning, freeing up an operator previously dedicated to blowing the profiles clean for other tasks. At the same time, the robot has a smooth and clean surface to work with, which has eliminated production stops due to dropped profiles.
The solution has also helped to reduce noise levels and air consumption.
Results and benefits
The implementation of Super Air Knife has brought clear improvements for the customer:
More stable production without interruptions
Blow moulding is now automatic and the robot can pick the profiles without problems. Previous downtime due to dropped parts has disappeared, resulting in a smoother and more reliable production flow.
Freed-up operator capacity
The manual element has been eliminated, which means that an operator who previously spent time blowing the profiles clean can now focus on other parts of the process. This has led to a more efficient use of labour resources.
Reduced compressed air consumption
Thanks to the Super Air Knife's efficient design, it uses significantly less compressed air to achieve the same results as manual cleaning. This means more energy-efficient operation and lower running costs over time, without compromising on cleaning results.
Read more about our EXAIR air knives
Super Air Knife
Quiet and powerful air knife with low compressed air consumption.
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Standard Air Knife
Energy-efficient air knife with low noise level and compressed air consumption.
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Full-Flow Air Knife
Low-cost air knife with full length airflow.
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Super Air Wipe
Round air knife for environments with a temperature up to 425°C.
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Standard Air Wipe
Air wipe for non-corrosive environments with a temperatures up to 65°C.
View productContact one of our experts
Call, email or book a web meeting with one of our experts specialising in EXAIR Compressed Air Products. We will advise you on the most suitable product or solution in order to achieve an efficient and safe industrial process.
A short web meeting is usually a time-efficiently way to gather information to advise on the right product or solution. During a web meeting we can quickly and easily obtain information on the various factors that may influence the choice of equipment and solution to achieve the most effective result. Sometimes a site visit may also be a good idea, depending on your preference. Of course, you can also just call or email!
When suggesting a suitable product or solution we take into account - function, lifespan, quality, choice of material, and operating and maintenance costs. Our goal is to deliver a sustainable solution that creates added value for you as a customer.