Introduction
Heavy machines are not easy to move in factories. Forklifts and cranes need ample space and can damage floors. This is overcome by using an air-film mover, in which compressed air is blown beneath heavy loads to lift them slightly off the ground. This thin layer of air enables workers to move large equipment with a small force.
These are also sometimes referred to as air casters, air bearings, air skates, or air skids. They can carry a weight ranging from a few tons to more than 1000 tons. They can transport aircraft parts, factory machinery, transformers, and other heavy equipment. This article lists 10 popular air-film mover brands and their key attributes.
How Do Air Film Movers Work?
The principle behind air film movers is very simple.
Firstly, workers install the air caster modules under the load. These modules are connected to a compressed-air supply via hoses.
A rubber or polyurethane bladder inflates when air is introduced into the module. This bladder is in contact with the floor surface. The air pressure in the chamber increases until the air load is slightly off the ground.
Then, a thin layer of air is released evenly around the bladder’s edge. This forms a cushion of air between the load and the floor. The load is then floated easily.
Most systems carry the load of about 0.003-0.1 inches. The floor and load come into little contact, so the friction is very low. Large machines are easily and manually conveyed by workers with significantly lower effort.
Air film movers are suitable for smooth, sealed, and flat floors. Cracks, holes, rough concrete, and rough surfaces can let air out. This reduces lift and increases drag.
Top 10 Air Film Movers Brands
Finer (Shandong Finer Lifting Tools)
In 1998, Finer began to manufacture air casters in Shandong, China.
The company has exported to more than 70 countries and regions.
Finer manufactures air skates, air trailers, air load-moving systems, and air-bearing kits.
They are typically configured for 10- to 48-ton loads, but can be customized to larger sizes if required. Each load module has a capacity of 2.5 to 8 tons.
Finer focuses on simple, low-profile designs. Many modules are just 50 mm high, and workers will not have to lift machinery up high before moving it.
The company also offers battery-powered machinery, skates, and gap-crossing air bearing systems. Finer claims that some air skates last over eight years without any significant issues.
AeroGo
AeroGo is a well-established name in the air caster industry. The company was founded in the U.S. in 1967 and is known for large industrial air bearing systems.
AeroGo manufactures standard air casters, air planks, air pallets, and automated transport systems. According to AeroGo, their air casters have been designed to comply with ASME B30.1 safety requirements.
AeroGo offers several caster types:
- Heavy-duty urethane air casters
- Neoprene air casters for factory floors are available
- Gapmaster casters for crossing joints and gaps
- High-lift casters for increased clearance
- Slide-mount casters for easy replacement
Aerofilm Systems
Aerofilm Systems is a Netherlands-based company that has over 40 years of experience in air caster technology.
The company specializes in designing modular air caster systems, transport skids, air jacks, support plates, and control units. They can transport large items effortlessly without damaging the floor surface.
Aerofilm breaks down the lifting process into four easy steps:
- Place and connect the caster
- Inflate the membrane
- Make the air layer
- Provide airflow for floating movement
They typically run at 1-4 bar pressure.
Aerofilm also offers both neoprene and polyurethane air casters. Polyurethane varieties are wear-resistant for repeated motion. Neoprene models are able to withstand greater loads.
Airfloat
Airfloat is based in Illinois, USA, and has operated for more than 50 years.
The company builds air-powered systems for moving heavy and difficult loads. Their products replace cranes, forklifts, and wheeled systems in many factories.
Airfloat systems create a thin air layer under the load, allowing movement in all directions. The company focuses on low-friction handling and accurate positioning.
Their product range includes:
- Air bearings
- Air caster platforms
- Turntables
- Assembly line handling systems
Hovair Systems
Hovair Systems was formed in the 1970s and became known for pneumatic load-moving equipment.
The company produces air-bearing kits, air skates, industrial turntables, and transport systems made of steel or aluminum.
Hovair systems have also been used in aircraft engine handling and large industrial manufacturing projects. The company later became part of Movetech UK.
Solving
Solving is a Finnish company known for extremely heavy transport systems.
Their air-film movers handle loads of 1,000 tons or more. Solving builds both manual systems and automated guided vehicles that float on air casters.
The company separates products into two groups:
- Air Bearing Modules for occasional movement
- Air Film Movers for regular heavy-duty operation
Air Caster Solutions
Air Caster Solutions focuses on ergonomic heavy-load handling equipment.
The company works with factories that move loads above 150 tons. Their products are often used in aerospace, automotive, and defense industries.
Their systems include:
- Low-profile air casters
- Lift tables
- Container positioning systems
- Custom transport platforms
Innoairvation
Innoairvation began operating in the United States in 1995.
The company produces extended-wear air casters and replacement parts for other brands. Their systems use 90-durometer urethane molded bladders designed to resist abrasion.
Innovation products focus on:
- Lower air consumption
- Longer bladder life
- Easier maintenance
- Replacement compatibility
Hover Transport Systems
Hover Transport Systems is a Dutch manufacturer that produces modular air caster systems for industrial transport.
The company traces its air caster history back to the early Sakko systems from 1906.
Hover Transport Systems builds:
- Modular air caster kits
- Cleanroom transport systems
- Replacement air casters
- Cross-compatible parts
ASE Systems
ASE Systems provides load-handling equipment and custom material-handling systems.
The company has more than 25 years of experience with air caster technology. Their products include air caster modules, cranes, vacuum lifters, and custom transport systems.
ASE Systems also works as a partner of Aerofilm Systems in the southern United States.
Practical Tips for Purchasing Air Film Movers
The condition of the floor is the key consideration when choosing an air film mover. The floor must be smooth, flat, sealed, and airtight. Cracks and rough concrete result in air leakage and reduced lifting capacity.
Always verify the actual weight distribution of the load. Most of the weight of some machines is on one side only. In those cases, the system requires equalizing the air pressure in the casters.
The supply of compressed air is also of importance. Most systems have a range of 15-90 psi, depending on load size. The compressor must deliver sufficient airflow at all times while in motion.
Choose the bladder material based on the work environment:
- Polyurethane is suitable for frequent motion and moving production lines.
- Neoprene rubber can withstand higher point loads and harsher environments.
Check service support prior to purchase. Over time, air hoses, membranes, and seals deteriorate. Having a manufacturer that can supply replacement parts and repair support helps minimize downtime.
Last but not least, consider future use. Some modular systems can be expanded with additional air casters. This enhances the load capacity without requiring changes to the entire system.
These tips help you buy the tight air film mover.