Air Planks for Flexible Manufacturing

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Why Air Planks are the preferred, cost-effective alternative to wheels, rollers, & forklifts

Air Planks, an excellent choice for flexible manufacturing, allow faster product transfer while enhancing product flow to increase productivity. Predominantly used on loads with minor changes in width, and varying lengths, Air Planks require a simple air connection to permit nearly frictionless movement allowing a single person to move up to 15,000-pounds strategically through the production process.

By eliminating forklifts, wheels and rollers, products can move effortlessly through flexible work cells to minimize labor, production floor space, and maximize production output. Popular moving applications for air planks include electrical control panels, switch gear, commercial refrigeration, air compressors, narrow modular structures and rack mounted equipment. Once Air Planks are deflated, the loads rest firmly on your floor without concerns of movement typical of wheels and roller to aid in assembly operations.

Budget-friendly Air Planks offer a unique, nearly frictionless, easy-moving solution for work cells & assembly lines

Besides their nearly frictionless properties, Air Planks offer ergonomic, omni-directional movement, allowing precision maneuverability of heavy loads while floating on a thin film of compressed air. Compared to wheels and rollers heavy loads can be moved with a fraction of the pushing force minimizing labor and eliminating employee injury claims.

Their low-profile design provides low working height maintaining a comfortable working elevation for employee task. In most cases, Air Planks can be sized to fit entirely beneath the load allowing full perimeter access during assembly operations. Omni-directional travel, distinctive to air casters, allow variable path movement to facilitate non-linear production flow not available with wheels or rail systems. Air planks offer maximum flexibility while conserving expensive manufacturing floor space.

Features of Air Planks

A typical light-weight air plank system has two or more air casters per plank with two or more planks per system, one regulator, one ball valve, and an interconnect hose to connect the planks in series. Air Planks are available with top (LM) or side (LE) manifolds to customize your load moving experience. Options include: guide wheels, U-shaped handles, cross bars to permanently fix the plank spacing, special tooling plates, and dead-man throttle control

Allows easy transfer station to station eliminating forklifts
Easily contained underneath the load for perimeter access in assembly
When casters deflate the load rest firmly on floor eliminating movement
Products manufactured on air planks include: Electrical Switchgear, Variable Speed Drive cabinets, Electronic Enclosures, Refrigeration Equipment, and many other cabinet or base frame mounted products.

Can operate with single regulation with internal automatic flow controls
Low cost Flexible Options including handle, manifolds, cross bars, risers, guide wheels, no load wheels and tooling plates
Regulators can attach directly to LM series manifolds

Air Plank Models & Specifications

# Planks in System	Plank Destination	Manifold (LM or LE)	Caster Type	Plank Length (in.)	Capacity (lb.)	Height (in.)	Max Length (in.)
2	PK	LM	12GHD	XXX	8,000	2.38	144
2	PK	LM	15GHD	XXX	14,000	2.38	144
2	PK	LM	18GHD	XXX	20,000	2.38	144
2	PK	LM	21GHD	XXX	32,000	2.38	144
2	PK	LM	24GHD	XXX	40,000	2.50	144

Innoairvation LM series air caster air plank manifold

LM Series Plank Manifold Option

Most durable air connection to planks, top mounted, have two ¾ Inch NPT through air connection points allowing for series connection. Each LM manifold includes integral automatic flow controls to compensate for 60 / 40 offset loading distribution using one single regulator to operate several casters connected in Loop series. Regulators can be attached directly to LM manifolds if individual regulation is required.

Innoairvation LE series air caster air plank manifold

LE Series Plank Manifold Option

Low profile air connection to planks, side mounted, have two ¾ Inch NPT through air connection points allowing for series connection. Each LE manifold includes integral automatic flow controls to compensate for 60 / 40 offset loading distribution using one single regulator to operate several casters connected in Loop series.

Frequently Asked Questions

What is the minimum number of Air Casters to move a load?

3 Air Casters is the minimum required, with the casters arranged in a triangular pattern.

How much pushing force is required to move a load on Air Casters?

On a smooth sealed concrete floor, the coefficient of friction is approximately .002 to .003, requiring 2 to 3 pounds of pushing force for each 1000 pounds of load on a flat level floor.

Is there a minimum load allowed on a specific Air Caster size?

Yes, each caster has a minimum load rating between 5- 10% of its maximum capacity. In many cases the regulation is the issue trying to operate at low pressure ranges down to 2 to 3 psi. Often this can be circumvented by ganging several Air Casters on a single regulator to provide higher adjustment ranges for equally loaded casters.

Will my floors work for Air Casters?

This is the single most important question presented by most end users. Air Casters require smooth machine trialed finished concrete with a high-quality sealer to ensure the concrete is not porous. Painted and epoxy coated floors work exceptionally well. Air Casters will protect your floor finish over conventional rollers and wheels.

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