Ready-to-install air technology system solutions

Solutions by Elektror

Solutions:
Air technology
conceived
as a system.

Modern production processes place the highest demands on air technology and process integration. That is why Elektror's Solutions division combines air technology expertise with system know-how.

We develop ready-to-install modules and inline solutions that optimise your processes, save energy and reduce your air technology engineering effort. From development and dimensioning to design engineering and commissioning: you get everything from a single source.

Services:

Air technology consulting and process support

Prototype construction and feasibility analyses

Calculation, dimensioning & simulation

Delivery of a plug-and-play system

Engineering
and design of the
air solution system

Support of installation and commissioning

Areas of application for Solutions:

Temperature control modules

After heat-intensive processing steps, metal parts usually need to be cooled quickly. Elektror Solutions develops customised cooling solutions tailored to the workpiece, system geometry, target temperature and specified cycle time.

Use Cases

Blow-off stations

In many industrial processes, products or components have to be dried or freed of dust. Targeted blowing with air delivers efficient results. Elektror Solutions blow-off stations are individually adapted to the cycle time, the installation situation and the object to be blown off.

Use Cases:

Air cabinets for central air/vacuum supply

Installing many individual units can make the air supply in larger systems confusing and complicate maintenance. Elektror Solutions brings the air/vacuum supply together in individually tailored air cabinets.

Use Cases:

Solutions Use Cases:

Two modules for an existing system:
A smart concept – for a cool result.

Challenge

After welding and painting, the rigid axles cooled down on two racks at ambient temperature. This took too long for efficient series production. A space-saving cooling solution was needed to speed up the process.

Solution

Elektror Solutions added cooling towers with slot and round nozzles to the existing racks. The cooling capacity was matched to both process steps to significantly accelerate cooling after welding and painting.

Added value

  • Shorter cooling times after welding and painting
  • Space-saving integration by using the existing racks
  • Matched cooling capacity for two different process steps
  • On-schedule series production of the axles in a very confined space
[Translate to English:] Kühlturm von Elektror Solutions zur lufttechnischen Kühlung von Werkstücken.​
[Translate to English:] Kühltunnel von Elektror Solutions zur Kühlung geschweißter Werkstücke.​

Modular extension of a system:
Compact cooling tunnel with built-in added value.

Challenge

Welded workpieces had to be cooled to a defined temperature on an existing conveyor belt within the specified cycle time.

Solution

A compact cooling tunnel cools the welded workpieces within the specified cycle time. Sensitivity studies and a 3D flow simulation were used to precisely design and validate the cooling process.

Added value

  • Process-reliable cooling to the required temperature within the specified cycle time
  • Lower noise levels thanks to the sound-insulating box
  • Protection of the blower against small parts being drawn in
  • No heat build-up in the box thanks to self-cooling of the blower by the intake air

Does your process need the right cooling?

Whether individual workpieces or complete production processes: discuss your requirements with us. Together, we will find the right air-based cooling solution for your system.

We will be happy to advise you on your individual solution

Discuss your cooling solution now

Complete system:
Razor-sharp air technology – so that everything ends up dry.

Challenge

Plastic pouches filled with milk had to be dried completely before printing. Residual water collects in the recesses of the flexible pouches and can only be removed with high air velocities.

Solution

A newly developed blow-off system is precisely matched to the geometry and properties of the pouches. Air velocity and volume flow were already dimensioned during prototype construction so that drying performance and process speed work together perfectly.

Added value

  • Complete drying, even in the recesses of the pouches
  • Fast and gentle processing without damaging the pouches
  • Demand-based energy use for the required drying performance
[Translate to English:] Abblasstation von Elektror Solutions zur Trocknung von Kunststoffbeuteln.​
[Translate to English:] Abblasstation von Elektror Solutions zur Trocknung von Eimern.​

Module for an existing system:
Retrofit in the tightest of spaces – for a perfect result.

Challenge

An existing production line was to be extended with a blow-off station for drying buckets. Only limited installation space was available, and the conveyor speed was to remain unchanged.

Solution

A precisely dimensioned blow-off station with three air knives was integrated into the existing line in a space-saving way. An easy-to-open cover provides simple access for cleaning.

Added value

  • Complete drying of the buckets for subsequent processing
  • Unchanged conveyor speed during blow-off
  • Space-saving retrofit of the existing line
  • Easy cleaning thanks to easily accessible air knives

Ready for the next processing step?

Do you want to remove water from packaging or components in a targeted way?
Talk to us about your application. We will support you in finding the right blow-off solution for your production process.

We will be happy to advise you on your individual solution

Request a blow-off solution

Air cabinet:
All in one – a system that makes everything simple.

Challenge

Individually installed units along a can printing line were to be replaced by a central air supply. To achieve this, the components and the piping system had to be dimensioned to meet demand.

Solution

A compact, separate air cabinet centralises the air supply and features ready-to-install air and electrical connections. The self-contained design supports safe operation while keeping all components easily accessible.

Added value

  • Reduced heat generation and noise exposure around the system
  • Easy maintenance and quick replacement thanks to easily accessible components
  • Ready-to-install connection to the existing system
  • High process reliability thanks to a self-contained air supply
[Translate to English:] Vakuumschrank von Elektror Solutions für die zentrale Luftversorgung einer Produktionsanlage mit mehreren Seitenkanalverdichtern.​
[Translate to English:] Innenansicht einer Zentralvakuum-Lösung von Elektror Solutions mit zwei HRD-Ventilatoren.​

Central vacuum:
From 7 to 1 – central vacuum instead of many individual units.

Challenge

A system with seven side channel blowers was to become more efficient. To this end, the pressure losses were analysed and a central supply concept with just one high-pressure blower was developed.

Solution

One high-pressure blower maintains a stable, uniform vacuum at all stations. A second blower is on standby as a reserve and can be switched to at any time.

Added value

  • Significantly lower energy consumption compared with the previous concept
  • Lower noise levels for improved working conditions
  • Greater process reliability thanks to a second, switchable blower
  • Simpler maintenance thanks to the central supply solution

How efficient is your vacuum supply?

Would you like to replace individual units with a central solution or optimise your existing vacuum supply?
Discuss your system and your requirements with us.

We will be happy to advise you on your individual solution

Discuss your vacuum supply