Faster Press Speeds
Depending on the process and the type of drying equipment that is being replaced, converters have experienced 40 to 150% increase in line speed after they upgraded to Compressed Air Drying Technology.
The rate at which heat is transferred from the air to the substrate is proportional to the velocity of the air as it strikes the substrate. Since compressed air systems have velocities that are roughly 15 times greater than that of traditional force air dryer systems, the substrate can be raised more rapidly to an equivalent temperature even with lower temperature air.
- Lower Operating Costs
The cost of heating the air accounts for over half of the total energy required to operate traditional dryer systems. It is the reduction in this cost alone that will more than offset the cost of using compressed air. An example is provided to clarify the cost savings:See Operating Cost Comparison Worksheet
- Reduced Heat Load to the Plant – Compressed air dryer systems operate at much lower temperatures, which radiate less heat into the plant environment.
Constant Web Temperatures
FlexAir’s patent pending technology uses a heater cartridge that runs the entire length of the air bar. This unique feature is critical in maintaining an even temperature profile across the web as well as eliminating hot spots inside the dryer.
Controlling the Temperature of the Web
FlexAir’s patent pending technology has a unique feature to monitor and control the temperature of the web as it passes through the dryer. This allows converters to competitively run temperature sensitive films on film presses that are not equipped with chill drums.
- Lower Retained Solvents –The increased evaporation rates of compressed air drying technology reduces retained solvent levels.
- Cost Savings – A combination of the low air volumes and increased evaporation rates results in a richer mixture of air that is exhausted from the dryer. Incinerators are rated in terms of air volumes; therefore more dryers can now be dedicated to each incinerator. In addition, the air that is exhausting from the dryer is rich enough that burning within the incinerator is self-sustaining.
FlexAir Dryers can be powered up and maintain operating temperature without consuming compressed air, while the press is in standby mode.
Low Noise Operation
At 15 psi and 5 feet away, a typical dryer will operate at 50 decibels.