Introduction
In the modern production world, process optimization is important to increase efficiency, save costs and ensure product quality. Especially in the food industry, where speed and hygiene are crucial, a small process problem can have major consequences. A good example is the drying process within a production line. When packages are wet before they are labeled, it can lead to labeling problems, product rejection and disruptions in production.
At DOVAC, we received a request late last year from the Brunink Group to help think about a drying solution for their customer, who wanted to dry wet animal food packaging quickly and effectively for further processing. Brunink chose us because of our extensive experience in industrial air technology and our ability to deliver customized solutions. Our team has successfully handled similar challenges before, which gave them the confidence to involve us in this project. In this blog, we take you step by step through this process and show how DOVAC air knives combined with DOVAC side channel blowers provided an efficient and cost-effective solution.
The challenge: Wet packing material and labeling issues
Brunink Group’s client produces animal food in wet packaging. Before the labels could be applied to the packages, they had to be completely dry. When moisture remains, it can lead to:
- Poorly adhering labels, loosening or sticking crookedly.
- Contamination of the labeling machine, leading to additional maintenance and downtime.
- Increased waste rates due to failed labeling.
So the challenge was to implement a drying method that was not only effective, but also fit within the speed and space of the production line. The available space in the production line was limited, so the solution had to be compact. In addition, the drying process had to be fully synchronized with the high speed of the assembly line without disrupting the production flow. Traditional hot air drying was not an option because it would consume too much energy and was not focused enough.
Deeper technical explanation: How does the drying process work?
For the drying process to work optimally, several technical aspects had to be carefully calculated. The speed of the conveyor belt played a crucial role: the air flow had to be strong enough to effectively remove all the moisture without damaging the packaging. This required precise tuning of air speed and pressure.
In our calculations, we took into account:
- The amount of fluid that had to be removed per second.
- The width and height of the package to determine the optimal placement of the air knives.
- Proper air pressure and blowing direction to prevent turbulence and moisture build-up.
In addition, we tested different air knife configurations to find the most efficient solution. In the end, an arrangement with four stainless steel air knives at an 18-degree angle proved to give the best results.
The solution: air knives and side channel fans
After thorough analysis and calculations by our team in collaboration with the Brunink Group, we arrived at a solution with four stainless steel air knives, driven by a powerful DOVAC blower.
How do air knives work?
Airknives are narrow openings through which compressed air flows at high speed. This air gap is generated by a side channel fan, creating a powerful, directed airflow. This has several advantages:
- Directed drying: Airflow is precisely directed to the wet surface, effectively removing excess moisture without wasting energy.
- High speed: The powerful airflow removes moisture quickly and effectively, significantly speeding up the drying process and minimizing waiting times in the production line.
- Energy savings: Compared to conventional hot air dryers, this solution consumes less energy because the airflow is directed more efficiently and no additional heating is required.
- No contact: Because it is a non-contact method, the packaging remains intact and hygienic. This is especially important in the food and pharmaceutical industries, where hygiene and product integrity are paramount.
- Flexibility: Air knives can be easily adapted to different product shapes and sizes, making them widely applicable in various industries.
- Low maintenance: Unlike mechanical drying methods, air knives are virtually maintenance-free because there are no moving parts in direct contact with the product.
Why a side channel fan?
A side channel blower is a powerful type of fan that draws in and expels air under high pressure. For this application, a DOVAC blower was chosen that provided optimal power and pressure to feed the DOVAC air blades. A major advantage was that the blower could be implemented directly under the machine, eliminating the need for long lines. Unlike a compressor, which is often located in a separate technical room and consumes additional energy, this allowed the blower to operate more efficiently with less pressure loss. This resulted in evenly efficient air distribution across the packages, while saving energy costs.
Implementation: From idea to reality
The implementation process proceeded in the following steps:
- Analysis and calculations: We determined the required air pressure, the best position of the air knives and the speed of the conveyor belt.
- Choice of materials: Since this was a food-related application, we chose stainless steel air knives to meet hygiene requirements.
- Test phase: Before final installation, a test rig was created to validate drying performance.
- Installation and fine-tuning: The air knives and side channel fan were installed and adjusted to function perfectly within the production line.
The result: An optimized drying process
The installation of the air knives and side channel fans led to perfectly dried packaging exactly at the right time in the production line. As a result:
- Improved labeling accuracy.
- Drastically reduced the dropout rate.
- Production line not hampered by additional downtime for maintenance.
In addition, the customer saved energy compared to conventional drying techniques and production efficiency was increased. This made the investment immediately profitable.
Applications in other industries The benefits of air knives and side channel blowers are not limited to the pet food – industry. This technology is also successfully applied in:
- Packaging industry: For drying bottles, cans and containers before applying labels or printing. This prevents labeling and printing problems and ensures that packages enter the next production step clean and dry. In addition, air knives can be used to remove dust and contaminants before packaging is sealed, increasing product quality.
- Automotive: Removal of water after car washes and paint processes. After cleaning or coating automotive parts, quick and even drying is essential to prevent staining, corrosion and quality problems. In addition, air knives are used when cleaning vehicle parts before they are assembled or painted, which helps prevent adhesion problems.
- Pharmaceutical industry: Drying of medicine vials, ampules and medical instruments. In this industry, hygiene is critical, and air knives offer an efficient, non-contact method of drying products quickly and evenly without risk of contamination. In addition, they can be used in the production of tablets and capsules, where they help remove powder residue for further processing.
- Pool and Jacuzzi: Efficient air supply is important for even bubble distribution and optimal comfort. Precise tuning of airflow optimizes both the intensity and distribution of bubbles, contributing to energy savings and longer equipment life.
- Food industry: Drying vegetables, fruits and packages before they are sealed or labeled. This not only helps improve shelf life, but also reduces the chance of bacterial growth. Air knives are also used to remove excess starch or spices from products such as chips and snacks, helping to ensure a uniform final product.
- Glass and metal industry: removing coolants and production residues after machining. Air knives help dry glass sheets before they are coated or printed and ensure metal products are free of oil or metal chips before they are packaged or further processed.
Conclusion: Why choose air knives and side channel fans?
This case with the Brunink Group demonstrates that airknives side channel fans offer an efficient and reliable solution for drying applications. They provide:
- A faster and more effective drying process
- Less energy consumption than conventional drying
- Lower failure rate and higher product quality
- Broad applicability in various industries.
Want to know how a similar solution can optimize your production process? Feel free to contact us and discover the possibilities!
