Today's industrial scene is fast-changing and competitive, which means businesses need to constantly improve their processes to increase efficiency and cut costs without compromising quality. Modern factories rely on the performance of their processes and their equipment to achieve their production targets – and this includes blow off systems.
As technology progresses and the industry's needs change, so too does your equipment. If you utilize a comprehensive blow off system, there are key upgrades you need to look out for as system elements become inefficient.
In this post, Air Force 1 (AF1) will take you through what to look for when considering upgrades to your blow off system to maximize your efficiency and production rate.
What is a Blow Off System and What is it Used For?
A blow off system is a specialized equipment setup used to remove unwanted materials ranging from dust, debris, moisture, and contaminants from surfaces or products. It utilizes high-velocity air streams to effectively blow away any unwanted particles, making sure that products that leave your factory are clean and dry before further processing, packaging, and shipping.
Blow off systems can include air knives, blowers, and various nozzle configurations. These systems are useful in several industries and several applications, including:
Product Drying: When it comes to processes such as printing, coating, or painting, blow off systems are used to remove moisture from surfaces and ensure that adhesion is optimal.
Cleaning Components: Blow off systems are essential for cleaning parts and various equipment by removing dust, debris, and shaving that accumulates during production.
Material Handling: In conveyor systems, blow off systems can be used to help clear materials from surfaces, thereby preventing potential contamination and smooth operation.
Packaging: Before packaging, blow off systems are used to ensure products are free of dust or particles to maintain product integrity and cleanliness.
Static Control: Some blow off systems are integrated with static control features, using ionized air to neutralize the presence of static electricity on products, which can attract dust and debris.
Cooling Applications: In certain processes, blow off systems can provide cooling to components by directing airflow, which can be crucial in high-speed manufacturing environments.
General Factors to Consider When Considering an Upgrade
A timely fabrication process improvement can easily address common issues such as low productivity, excessive downtime, and concerns regarding compliance. But how do you determine if your facility actually requires an upgrade? Let’s explore some general factors before we get into the nitty-gritty.
Recurring Equipment Breakdowns and Unplanned Downtime
Every business is going to experience setbacks. They are unavoidable at times, and most of the time, the fix should be rather simple. However, if your operation is experiencing regular malfunctions and frequent downtime, that’s a clear warning sign that means you may be due for an upgrade.
Key Indicators:
Increased Maintenance Costs: High maintenance expenses can surpass the device’s cost for upgrade, meaning it is more cost-effective to upgrade than it is to repeatedly repair.
Repeated Breakdowns of Critical Systems: When essential elements of your blow off system are failing, especially frequently, that’s either a sign that it’s time for an upgrade or that you need a professional to see if everything is connected correctly.
Excessive Wear and Tear on System Components: Excessive wear and tear on your blow off system is a clear indication of issues with the process design or control systems.
Wishlist for Your New Blow off System
What do you need in a blower system upgrade? That’s something you need to consider before you move forward with looking to finance a new system. There are a few upgrades you may question yourself over:
Need more power?
Looking to increase conveyor line speed?
Want improved drying rates?
Aiming to cut electrical costs?
When working in the world of manufacturing, you’re operating in a field that’s competitive, meaning both large and small manufacturers are working towards reducing their net costs to get a project done. Getting a fresh blower system upgrade can make a great deal of difference.
Choosing to make an upgrade can be an intimidating decision because of the initial upfront costs. However, there’s proof in the industry that modernizing and upgrading can save businesses more money that far outweighs the cost.
Diving Deeper into Signs Your Blower System Needs a Serious Upgrade
Increased Energy Consumption
Perhaps one of the most telltale signs that your blow off system is in need of an upgrade is a noticeable increase in your facility’s energy consumption. An older system, particularly those that rely on compressed air, can be very energy inefficient.
As these systems get older, natural wear and tear can cause them to lose their original efficiency, meaning the system has to work harder to achieve its previous results. This means it has to use more energy.
If you’re noticing that your energy costs are increasing, it’s time to bring in the pros to give your system a review and begin conversations about upgrading. You can get a better idea of what your facility will need to maximize efficiency while conserving energy (and cost) over time.
Inconsistent Drying or Cleaning Results
Don’t just inspect the machine; inspect the products. When looking at your products, do you notice that they’re coming out of the blow off system still moist or unclean? You might notice some areas of the product are totally clean and dry while others have debris and residue left behind. This is a no-go – subpar product doesn’t fly.
This inconsistency can lead to serious production delays, quality control issues, and some very dissatisfied customers. If your blow off system is outdated or just performing poorly, you can expect to receive shotty results, identifying that you need to upgrade your current system.
Inability to Meet Production Demands
As your production lines become quicker and more efficient, your blow off system needs to be on par. If your system is slowing down production or simply struggling to keep up with the volume, it’s time to upgrade.
An upgraded blow off system designed to handle higher throughput will not only keep up with the high demand, but it’s also going to maximize product quality while reducing production time.
Noisy Operation
Listen – it’s normal for even high-tech blow off systems to make some degree of noise, but if you’re noticing a significant increase in noise levels, there could be an issue with your current system such as internal wear. Older systems that use compressed air can be very loud, leading to uncomfortable working conditions and maybe even possible safety concerns if the issue is deeper than expected.
Modern blow off systems and air knives are specially designed with noise reduction at the top of mind, ensuring a quieter, more peaceful and safer working environment.
Savings, Savings, Savings
The upfront cost of upgrading your blow off system can be a deterrent for many businesses, especially smaller ones. However, investment into this innovative technology is essential to saving money further down the line. If you consider the increased production, reduced downtime, increased product quality, efficiency, and more, businesses can amplify their income through production by upgrading their current system.
Here’s a breakdown of where an upgraded system can save you money:
Energy Efficiency: Modern blow off systems consume less energy, reducing utility bills and operational costs.
Reduced Maintenance Costs: Upgraded systems are more reliable, requiring fewer repairs and part replacements, thus lowering maintenance expenses.
Increased Production Efficiency: A new system can handle faster production speeds, eliminating bottlenecks and increasing output.
Better Product Quality: Improved drying and cleaning result in fewer defects, reducing rework or waste and enhancing customer satisfaction.
Lower Noise Levels: Newer systems operate more quietly, decreasing the need for noise reduction measures and improving the work environment.
Choose Air Force 1
At Air Force 1, we design, build, and install custom blow off systems using our specially manufactured air knives, patented air cannons, and direct-drive blowers. Our expert team consults with you to create solutions that not only meet but often exceed expectations, whether for small or large-scale projects. We deliver high-quality systems on time and within budget.
Our engineers and designers collaborate closely with you at every stage, from initial consultation to system design and installation. We begin with an on-site consultation to gain a deep understanding of your needs, using client-provided data such as drawings and video to define the project scope.
We pride ourselves on making business easy for you. Our goal is to provide outstanding service to all national and international customers while delivering products quickly and efficiently. We offer professional installation services to minimize downtime and handle everything from imports and customs clearance to on-time deliveries. Every order is dispatched via the safest and fastest method to ensure it arrives intact and on schedule.
