Hot Air Knife Systems (Patented)
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Sonic’s Patented Heater-less Hot Air Knife Technology
Patented hot air blower technology for industrial applications requires no electric heater or live flame element.
Sonic Air Systems understands that every industry and application has unique needs. That's why our industrial hot air blowers are engineered to meet each customer's specific objectives, delivering precise heated (variable temperature/fixed temperature) technology for forced convective drying. Eco-friendly and energy-efficient Sonic air flow ranging from 125°F to 275°F (50°C to 135°C) with our innovative VT (variable temperature's) heater-less hot air blower systems eliminate the need for any inline heaters.
A Smart Solution for Efficient, Targeted Heating
A hot air knife system is an industrial device that uses a high-velocity stream of heated air to perform tasks like drying, curing, heating, or removing moisture from surfaces. It consists of a blower, air knives, and a heating element that precisely controls the temperature of the air. Unlike traditional methods that rely on inefficient heat sources, a hot air knife system delivers targeted, uniform airflow, making it ideal for applications that require consistent heating across a production line. Industries such as automotive, food processing, textiles, and packaging commonly use heated air blowers to accelerate drying times, enhance product quality, and reduce energy consumption.
Performance-Driven Features for Industrial Excellence
- Patented technology available ONLY at Sonic Air Systems
- Environmentally responsible design eliminates the burning of carbon fuel sources.
- Six Sonic FT/VT blower models from 7.5 to 50 HP (5.5 to 37 kW) sized for maximum efficiency
- Reduce energy by up to 75% by eliminating the inefficiencies and parasitic energy losses of electric, gas, and steam heaters.
- Fire and safety hazard prevention, as a Sonic VT/FT does not require a heater element or fuel
- Eliminates duct heaters, which reduces size, cost, and utilities
- Replaces infrared heated dryers with Sonic Hot Air XE Air Knives, delivering precise high-velocity air
- Avoids the cost, size, and energy usage of high kW 3-phase heater control panels
- Engineered by Sonic for each customer's application
- Sonic Hot Air Knives dry water-based coatings, paints, and inks on continuous conveyor lines
- Web coating dryer with heated high-velocity Sonic XE Air Knives or Nozzles
- Sonic Hot Air Batch Drying with forced convection for parts and bulk materials
- Hot air tunnel dryer for coating drying on a wide range of product sizes, shapes, and conveyor speeds
- Sonic Hot Air Knives for cold-filled bottles prior to labeling
- Low-temperature shrink film applications
How to Select the Right Industrial Diverter Valve
Determining the best valve for your system depends on balancing air volume, pressure, and material characteristics. When these factors align, you achieve smoother performance, higher efficiency, and long-term reliability. The ideal configuration not only maintains consistent airflow and minimizes pressure loss but also enhances energy efficiency across continuous production cycles.
Common Types of Diverter Valves
- Flap Type Diverter: Simple, cost-effective valve ideal for low- to medium-pressure systems handling powders, pellets, or airflows requiring gentle redirection.
- Plug (Rotor) Diverter: Designed for continuous-duty applications, offering smooth switching between lines with minimal leakage.
Slide or Slideflex Diverter: Provides fast, tight-sealing transitions for high-pressure or high-temperature processes where precision airflow management is essential.
Key Technical Considerations
When specifying an industrial air diverter valve, consider the following engineering factors to ensure long-term reliability:
- Material Compatibility: Choose materials suited to your process—aluminum for lightweight efficiency, stainless steel for hygienic or corrosive environments, or coated alloys for chemical resistance.
- Actuation & Automation: Sonic offers manual, pneumatic, or automated actuation to integrate with PLC or sensor-driven systems for instant airflow control.
Sealing & Maintenance: Valves are designed with precision-fit components and replaceable seals to maintain efficiency and reduce downtime during maintenance intervals.
Frequently Asked Questions
Yes. Sonic butterfly valves can operate in conjunction with a VFD for blower speed control; however, they can also function as the sole airflow control device. As a low-cost alternative to a VFD, the butterfly valve allows operators to manually fine-tune air velocity and pressure, setting the optimum airflow level during the initial system setup without relying on expensive electronic controls.
The Sonic Y-Verter™ is a mechanical alternative to Variable Frequency Drive motor controllers traditionally used in blower and air knife systems. It allows rapid, reliable airflow redirection between system branches without changing motor speed, reducing complexity and maintenance requirements compared to VFD-based systems.
A Y-Verter™ is particularly effective when using standard 3,600 RPM, 60 Hz motors where air control needs can be met through mechanical redirection rather than motor speed modulation. While certain high-speed blower motors (up to 20,000 RPM) may require VFDs with output frequencies up to 330 Hz, many air knife applications can achieve equal or better airflow management with the simpler, more durable Y-Verter™ system.
Yes. They can be integrated with most industrial blowers or pneumatic systems, and custom configurations are available for unique operating conditions.
Specification Sheets
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Hot Air Knife Systems (Patented)
Sonic’s Patented Heater-less Hot Air Knife Technology
Patented hot air blower technology for industrial applications requires no electric heater or live flame element.
Sonic Air Systems understands that every industry and application has unique needs. That's why our industrial hot air blowers are engineered to meet each customer's specific objectives, delivering precise heated (variable temperature/fixed temperature) technology for forced convective drying. Eco-friendly and energy-efficient Sonic air flow ranging from 125°F to 275°F (50°C to 135°C) with our innovative VT (variable temperature's) heater-less hot air blower systems eliminate the need for any inline heaters.
A Smart Solution for Efficient, Targeted Heating
A hot air knife system is an industrial device that uses a high-velocity stream of heated air to perform tasks like drying, curing, heating, or removing moisture from surfaces. It consists of a blower, air knives, and a heating element that precisely controls the temperature of the air. Unlike traditional methods that rely on inefficient heat sources, a hot air knife system delivers targeted, uniform airflow, making it ideal for applications that require consistent heating across a production line. Industries such as automotive, food processing, textiles, and packaging commonly use heated air blowers to accelerate drying times, enhance product quality, and reduce energy consumption.