Custom Solutions

Tailored Solutions for Unique Manufacturing Challenges
Leading expert for customized blower and air knife solutions
Dominate the manufacturing landscape with Sonic's 35+ years of experience in blower and air knife systems. Sonic's team of experts specializes in creating customized equipment that meets or exceeds your specific requirements. Featuring an engineering team to provide CAD drafting, mechanical designs, and application engineering, our experienced engineers develop turnkey systems, including electrical control integration for applications where no other solution exists. With your best interest in mind, Sonic guarantees a full refund and will take the equipment back if we fail to deliver the results that you expect. Our priority is your confidence, and we're committed to providing systems and equipment that meet or exceed standards.

We Build Reliable, High-Performance Solutions for Every Industry
Sonic Air Systems specializes in designing custom air blower and air knife systems for various industries with specific needs. These solutions are developed to improve efficiency, increase productivity, and ensure precision in applications where airflow control is crucial. Whether it's drying, heating, cooling, cleaning, coating control, or material handling, Sonic's custom systems are engineered to meet the unique challenges each industry faces.
The process begins with a detailed consultation to understand the unique operational requirements and environmental factors that impact the system’s performance. Sonic Air Systems collaborates with clients to create an air blower or air knife system that integrates seamlessly into their existing infrastructure. These systems are built using high-quality components that ensure reliability and long-term durability while precise airflow control optimizes overall performance and reduces operational costs.
Applications
Sonic’s custom solutions are applicable across numerous industries, such as:
How Custom Solutions Enhance Your Operations and Drive Results
FEATURES
- Tailored Engineering: Custom systems are designed based on specific operational needs, making adjustments to airflow control to suit particular processes. This allows businesses to optimize performance and gain maximum efficiency from their air systems.
- Premium Components: Sonic Air uses durable, high-quality components that extend the lifespan of the system. The choice of reliable materials minimizes downtime and the need for frequent replacements, ensuring long-term value.
- Advanced Technology: Utilizing cutting-edge, patented technology allows our team to create solutions that address modern industrial challenges. Our innovative designs ensure the system remains effective and efficient, even as technologies continue to evolve.
- Scalable Solutions: Custom systems are designed with future growth in mind, allowing businesses to scale up as needed. Whether expanding production capacity or upgrading to meet new demands, these systems can be easily adapted.
BENEFITS
- Cost Efficiency: Custom solutions help reduce energy consumption, lower maintenance costs, and eliminate frequent repairs. Over time, businesses save significantly, making these systems an investment with a high return.
- Reliable Operations: They help avoid disruptions caused by system failures, offering consistent and dependable performance. This reliability supports smooth operations without unnecessary interruptions.
- Maximized Space: We take into account available space, ensuring the system fits perfectly within the existing facility. Efficient use of space allows businesses to optimize their workspace and avoid the clutter of bulky equipment.
- Enhanced Efficiency: The tailored designs improve overall system efficiency by minimizing waste and streamlining workflows. This creates more productive and optimized operations that result in cost savings.
View Case Studies

Frequently Asked Questions
There is an almost endless number of application considerations for determining whether Sonic XE air knives or Sonic air nozzles produce the most effective and efficient blower-driven results. Generally, air knives deliver laminar airflow over a wide surface area, while air nozzles are better suited to narrow targeted surfaces. Whichever combination of blower power and impact air force you choose, just remember to request a Sonic blow-off performance guarantee.
If Sonic doesn’t already have a suitable design out of the hundreds of standard and customized air knife and nozzle models we have to choose from, contact us and we will be happy to design one to meet your needs.
Sonic Air Systems was born out of the 1980s Montreal Protocol, which was necessitated by Earth’s sustainability crisis. The over-use of industrial fluorocarbons, CFCs & HCFCs specifically, was severely damaging our planet’s radiation-blocking stratospheric ozone layer. The nearly total worldwide ban on these chemicals resulted in many products and industries quickly switching to water-based chemistries for coatings, lubricants, and cleaning agents. Sonic air knives became the go-to solution for the blow-off of these new chemistries. Sonic was on the sustainability forefront again for both potable water conservation and electric energy reduction before our ecological contribution expanded further into more areas of CO2 emissions reduction, a variety of recycling enhancements, and other industry best practices.
The majority of Sonic air knives and air nozzles have no moving parts and therefore, require little or no regular maintenance. For those industries that specify Sonic Sanitary or E-Z Clean Air Knives for food, pharma, medical devices, and other critical cleanliness blow-off air, these Sonic designs facilitate industry compliance. There are also Sonic air knives with static ionizing bars, self-propelled rotary air knives, and other specialty designs that require some annual or bi-annual maintenance.
Sonic air knives are available in a variety of materials suitable for standard duty, medium duty, heavy-duty, and extra heavy duty based on whatever is most suitable for the industry and application they will be operating in. The life expectancy for most customers is indefinite, but if the duty rating turns out to be shorter than required, usually because of the environment, Sonic can construct the next replacement to better suit whatever the current conditions are.
Prior to the creation of the non-contact high air velocity blower powered air knife industry product surface processes such as drying, coating control, heating, cooling, and debris removal were all performed using either mechanical contact methods (scrapers, rollers, or towels) and other types of non-contact options (high pressure compressed air, radiant heaters or just very long conveyor runs), all of which require significantly high energy, substantially higher acquisition costs, additional factory floor space and more costly recurring maintenance. Not only do Sonic air knives operate at 95% exit air efficiency, but our wide range of non-contact air knife and air nozzle technology is second to none for the fastest drying times, highest energy efficiency, smallest production line space allocation, and the most uniform coverage, Sonic also provides a written performance guarantee for virtually every system that we quote.
Although we specialize in optimizing effectiveness and efficiency when we pair Sonic air knives and nozzles with the appropriately sized Sonic blower, we also have a wide range of end-user and OEM customers who specify the type, profile size, length of the Sonic XE air knives which they prefer above all others for use with their existing non-Sonic blowers.
Sonic’s air engineering team consists of specialists in all aspects of the successful integration, installation, and operation of our centrifugal blowers and air knife systems on any existing production line or within any new open or totally enclosed conveying system. Ensuring the success of a Sonic installation requires our collaboration with and understanding of a customer’s products and their production line dynamics (mechanicals, electricals, air flows, liquids, temperatures, and material handling) to deliver the most effective and efficient system.
There is an almost endless number of application considerations for determining whether Sonic XE air knives or Sonic air nozzles produce the most effective and efficient blower-driven results. Generally, air knives deliver laminar airflow over a wide surface area, while air nozzles are better suited to narrow targeted surfaces. Whichever combination of blower power and impact air force you choose, just remember to request a Sonic blow-off performance guarantee.
If Sonic doesn’t already have a suitable design out of the hundreds of standard and customized air knife and nozzle models we have to choose from, contact us and we will be happy to design one to meet your needs.
Sonic Air Systems was born out of the 1980s Montreal Protocol, which was necessitated by Earth’s sustainability crisis. The over-use of industrial fluorocarbons, CFCs & HCFCs specifically, was severely damaging our planet’s radiation-blocking stratospheric ozone layer. The nearly total worldwide ban on these chemicals resulted in many products and industries quickly switching to water-based chemistries for coatings, lubricants, and cleaning agents. Sonic air knives became the go-to solution for the blow-off of these new chemistries. Sonic was on the sustainability forefront again for both potable water conservation and electric energy reduction before our ecological contribution expanded further into more areas of CO2 emissions reduction, a variety of recycling enhancements, and other industry best practices.
The majority of Sonic air knives and air nozzles have no moving parts and therefore, require little or no regular maintenance. For those industries that specify Sonic Sanitary or E-Z Clean Air Knives for food, pharma, medical devices, and other critical cleanliness blow-off air, these Sonic designs facilitate industry compliance. There are also Sonic air knives with static ionizing bars, self-propelled rotary air knives, and other specialty designs that require some annual or bi-annual maintenance.
Sonic air knives are available in a variety of materials suitable for standard duty, medium duty, heavy-duty, and extra heavy duty based on whatever is most suitable for the industry and application they will be operating in. The life expectancy for most customers is indefinite, but if the duty rating turns out to be shorter than required, usually because of the environment, Sonic can construct the next replacement to better suit whatever the current conditions are.
Prior to the creation of the non-contact high air velocity blower powered air knife industry product surface processes such as drying, coating control, heating, cooling, and debris removal were all performed using either mechanical contact methods (scrapers, rollers, or towels) and other types of non-contact options (high pressure compressed air, radiant heaters or just very long conveyor runs), all of which require significantly high energy, substantially higher acquisition costs, additional factory floor space and more costly recurring maintenance. Not only do Sonic air knives operate at 95% exit air efficiency, but our wide range of non-contact air knife and air nozzle technology is second to none for the fastest drying times, highest energy efficiency, smallest production line space allocation, and the most uniform coverage, Sonic also provides a written performance guarantee for virtually every system that we quote.
Although we specialize in optimizing effectiveness and efficiency when we pair Sonic air knives and nozzles with the appropriately sized Sonic blower, we also have a wide range of end-user and OEM customers who specify the type, profile size, length of the Sonic XE air knives which they prefer above all others for use with their existing non-Sonic blowers.
Sonic’s air engineering team consists of specialists in all aspects of the successful integration, installation, and operation of our centrifugal blowers and air knife systems on any existing production line or within any new open or totally enclosed conveying system. Ensuring the success of a Sonic installation requires our collaboration with and understanding of a customer’s products and their production line dynamics (mechanicals, electricals, air flows, liquids, temperatures, and material handling) to deliver the most effective and efficient system.
There is an almost endless number of application considerations for determining whether Sonic XE air knives or Sonic air nozzles produce the most effective and efficient blower-driven results. Generally, air knives deliver laminar airflow over a wide surface area, while air nozzles are better suited to narrow targeted surfaces. Whichever combination of blower power and impact air force you choose, just remember to request a Sonic blow-off performance guarantee.
If Sonic doesn’t already have a suitable design out of the hundreds of standard and customized air knife and nozzle models we have to choose from, contact us and we will be happy to design one to meet your needs.
Sonic Air Systems was born out of the 1980s Montreal Protocol, which was necessitated by Earth’s sustainability crisis. The over-use of industrial fluorocarbons, CFCs & HCFCs specifically, was severely damaging our planet’s radiation-blocking stratospheric ozone layer. The nearly total worldwide ban on these chemicals resulted in many products and industries quickly switching to water-based chemistries for coatings, lubricants, and cleaning agents. Sonic air knives became the go-to solution for the blow-off of these new chemistries. Sonic was on the sustainability forefront again for both potable water conservation and electric energy reduction before our ecological contribution expanded further into more areas of CO2 emissions reduction, a variety of recycling enhancements, and other industry best practices.
The majority of Sonic air knives and air nozzles have no moving parts and therefore, require little or no regular maintenance. For those industries that specify Sonic Sanitary or E-Z Clean Air Knives for food, pharma, medical devices, and other critical cleanliness blow-off air, these Sonic designs facilitate industry compliance. There are also Sonic air knives with static ionizing bars, self-propelled rotary air knives, and other specialty designs that require some annual or bi-annual maintenance.
Sonic air knives are available in a variety of materials suitable for standard duty, medium duty, heavy-duty, and extra heavy duty based on whatever is most suitable for the industry and application they will be operating in. The life expectancy for most customers is indefinite, but if the duty rating turns out to be shorter than required, usually because of the environment, Sonic can construct the next replacement to better suit whatever the current conditions are.
Prior to the creation of the non-contact high air velocity blower powered air knife industry product surface processes such as drying, coating control, heating, cooling, and debris removal were all performed using either mechanical contact methods (scrapers, rollers, or towels) and other types of non-contact options (high pressure compressed air, radiant heaters or just very long conveyor runs), all of which require significantly high energy, substantially higher acquisition costs, additional factory floor space and more costly recurring maintenance. Not only do Sonic air knives operate at 95% exit air efficiency, but our wide range of non-contact air knife and air nozzle technology is second to none for the fastest drying times, highest energy efficiency, smallest production line space allocation, and the most uniform coverage, Sonic also provides a written performance guarantee for virtually every system that we quote.
Although we specialize in optimizing effectiveness and efficiency when we pair Sonic air knives and nozzles with the appropriately sized Sonic blower, we also have a wide range of end-user and OEM customers who specify the type, profile size, length of the Sonic XE air knives which they prefer above all others for use with their existing non-Sonic blowers.
Sonic’s air engineering team consists of specialists in all aspects of the successful integration, installation, and operation of our centrifugal blowers and air knife systems on any existing production line or within any new open or totally enclosed conveying system. Ensuring the success of a Sonic installation requires our collaboration with and understanding of a customer’s products and their production line dynamics (mechanicals, electricals, air flows, liquids, temperatures, and material handling) to deliver the most effective and efficient system.
There is an almost endless number of application considerations for determining whether Sonic XE air knives or Sonic air nozzles produce the most effective and efficient blower-driven results. Generally, air knives deliver laminar airflow over a wide surface area, while air nozzles are better suited to narrow targeted surfaces. Whichever combination of blower power and impact air force you choose, just remember to request a Sonic blow-off performance guarantee.
If Sonic doesn’t already have a suitable design out of the hundreds of standard and customized air knife and nozzle models we have to choose from, contact us and we will be happy to design one to meet your needs.
Sonic Air Systems was born out of the 1980s Montreal Protocol, which was necessitated by Earth’s sustainability crisis. The over-use of industrial fluorocarbons, CFCs & HCFCs specifically, was severely damaging our planet’s radiation-blocking stratospheric ozone layer. The nearly total worldwide ban on these chemicals resulted in many products and industries quickly switching to water-based chemistries for coatings, lubricants, and cleaning agents. Sonic air knives became the go-to solution for the blow-off of these new chemistries. Sonic was on the sustainability forefront again for both potable water conservation and electric energy reduction before our ecological contribution expanded further into more areas of CO2 emissions reduction, a variety of recycling enhancements, and other industry best practices.
The majority of Sonic air knives and air nozzles have no moving parts and therefore, require little or no regular maintenance. For those industries that specify Sonic Sanitary or E-Z Clean Air Knives for food, pharma, medical devices, and other critical cleanliness blow-off air, these Sonic designs facilitate industry compliance. There are also Sonic air knives with static ionizing bars, self-propelled rotary air knives, and other specialty designs that require some annual or bi-annual maintenance.
Sonic air knives are available in a variety of materials suitable for standard duty, medium duty, heavy-duty, and extra heavy duty based on whatever is most suitable for the industry and application they will be operating in. The life expectancy for most customers is indefinite, but if the duty rating turns out to be shorter than required, usually because of the environment, Sonic can construct the next replacement to better suit whatever the current conditions are.
Prior to the creation of the non-contact high air velocity blower powered air knife industry product surface processes such as drying, coating control, heating, cooling, and debris removal were all performed using either mechanical contact methods (scrapers, rollers, or towels) and other types of non-contact options (high pressure compressed air, radiant heaters or just very long conveyor runs), all of which require significantly high energy, substantially higher acquisition costs, additional factory floor space and more costly recurring maintenance. Not only do Sonic air knives operate at 95% exit air efficiency, but our wide range of non-contact air knife and air nozzle technology is second to none for the fastest drying times, highest energy efficiency, smallest production line space allocation, and the most uniform coverage, Sonic also provides a written performance guarantee for virtually every system that we quote.
Although we specialize in optimizing effectiveness and efficiency when we pair Sonic air knives and nozzles with the appropriately sized Sonic blower, we also have a wide range of end-user and OEM customers who specify the type, profile size, length of the Sonic XE air knives which they prefer above all others for use with their existing non-Sonic blowers.
Sonic’s air engineering team consists of specialists in all aspects of the successful integration, installation, and operation of our centrifugal blowers and air knife systems on any existing production line or within any new open or totally enclosed conveying system. Ensuring the success of a Sonic installation requires our collaboration with and understanding of a customer’s products and their production line dynamics (mechanicals, electricals, air flows, liquids, temperatures, and material handling) to deliver the most effective and efficient system.
There is an almost endless number of application considerations for determining whether Sonic XE air knives or Sonic air nozzles produce the most effective and efficient blower-driven results. Generally, air knives deliver laminar airflow over a wide surface area, while air nozzles are better suited to narrow targeted surfaces. Whichever combination of blower power and impact air force you choose, just remember to request a Sonic blow-off performance guarantee.
If Sonic doesn’t already have a suitable design out of the hundreds of standard and customized air knife and nozzle models we have to choose from, contact us and we will be happy to design one to meet your needs.
Sonic Air Systems was born out of the 1980s Montreal Protocol, which was necessitated by Earth’s sustainability crisis. The over-use of industrial fluorocarbons, CFCs & HCFCs specifically, was severely damaging our planet’s radiation-blocking stratospheric ozone layer. The nearly total worldwide ban on these chemicals resulted in many products and industries quickly switching to water-based chemistries for coatings, lubricants, and cleaning agents. Sonic air knives became the go-to solution for the blow-off of these new chemistries. Sonic was on the sustainability forefront again for both potable water conservation and electric energy reduction before our ecological contribution expanded further into more areas of CO2 emissions reduction, a variety of recycling enhancements, and other industry best practices.
The majority of Sonic air knives and air nozzles have no moving parts and therefore, require little or no regular maintenance. For those industries that specify Sonic Sanitary or E-Z Clean Air Knives for food, pharma, medical devices, and other critical cleanliness blow-off air, these Sonic designs facilitate industry compliance. There are also Sonic air knives with static ionizing bars, self-propelled rotary air knives, and other specialty designs that require some annual or bi-annual maintenance.
Sonic air knives are available in a variety of materials suitable for standard duty, medium duty, heavy-duty, and extra heavy duty based on whatever is most suitable for the industry and application they will be operating in. The life expectancy for most customers is indefinite, but if the duty rating turns out to be shorter than required, usually because of the environment, Sonic can construct the next replacement to better suit whatever the current conditions are.
Prior to the creation of the non-contact high air velocity blower powered air knife industry product surface processes such as drying, coating control, heating, cooling, and debris removal were all performed using either mechanical contact methods (scrapers, rollers, or towels) and other types of non-contact options (high pressure compressed air, radiant heaters or just very long conveyor runs), all of which require significantly high energy, substantially higher acquisition costs, additional factory floor space and more costly recurring maintenance. Not only do Sonic air knives operate at 95% exit air efficiency, but our wide range of non-contact air knife and air nozzle technology is second to none for the fastest drying times, highest energy efficiency, smallest production line space allocation, and the most uniform coverage, Sonic also provides a written performance guarantee for virtually every system that we quote.
Although we specialize in optimizing effectiveness and efficiency when we pair Sonic air knives and nozzles with the appropriately sized Sonic blower, we also have a wide range of end-user and OEM customers who specify the type, profile size, length of the Sonic XE air knives which they prefer above all others for use with their existing non-Sonic blowers.
Sonic’s air engineering team consists of specialists in all aspects of the successful integration, installation, and operation of our centrifugal blowers and air knife systems on any existing production line or within any new open or totally enclosed conveying system. Ensuring the success of a Sonic installation requires our collaboration with and understanding of a customer’s products and their production line dynamics (mechanicals, electricals, air flows, liquids, temperatures, and material handling) to deliver the most effective and efficient system.
There is an almost endless number of application considerations for determining whether Sonic XE air knives or Sonic air nozzles produce the most effective and efficient blower-driven results. Generally, air knives deliver laminar airflow over a wide surface area, while air nozzles are better suited to narrow targeted surfaces. Whichever combination of blower power and impact air force you choose, just remember to request a Sonic blow-off performance guarantee.
If Sonic doesn’t already have a suitable design out of the hundreds of standard and customized air knife and nozzle models we have to choose from, contact us and we will be happy to design one to meet your needs.
Sonic Air Systems was born out of the 1980s Montreal Protocol, which was necessitated by Earth’s sustainability crisis. The over-use of industrial fluorocarbons, CFCs & HCFCs specifically, was severely damaging our planet’s radiation-blocking stratospheric ozone layer. The nearly total worldwide ban on these chemicals resulted in many products and industries quickly switching to water-based chemistries for coatings, lubricants, and cleaning agents. Sonic air knives became the go-to solution for the blow-off of these new chemistries. Sonic was on the sustainability forefront again for both potable water conservation and electric energy reduction before our ecological contribution expanded further into more areas of CO2 emissions reduction, a variety of recycling enhancements, and other industry best practices.
The majority of Sonic air knives and air nozzles have no moving parts and therefore, require little or no regular maintenance. For those industries that specify Sonic Sanitary or E-Z Clean Air Knives for food, pharma, medical devices, and other critical cleanliness blow-off air, these Sonic designs facilitate industry compliance. There are also Sonic air knives with static ionizing bars, self-propelled rotary air knives, and other specialty designs that require some annual or bi-annual maintenance.
Sonic air knives are available in a variety of materials suitable for standard duty, medium duty, heavy-duty, and extra heavy duty based on whatever is most suitable for the industry and application they will be operating in. The life expectancy for most customers is indefinite, but if the duty rating turns out to be shorter than required, usually because of the environment, Sonic can construct the next replacement to better suit whatever the current conditions are.
Prior to the creation of the non-contact high air velocity blower powered air knife industry product surface processes such as drying, coating control, heating, cooling, and debris removal were all performed using either mechanical contact methods (scrapers, rollers, or towels) and other types of non-contact options (high pressure compressed air, radiant heaters or just very long conveyor runs), all of which require significantly high energy, substantially higher acquisition costs, additional factory floor space and more costly recurring maintenance. Not only do Sonic air knives operate at 95% exit air efficiency, but our wide range of non-contact air knife and air nozzle technology is second to none for the fastest drying times, highest energy efficiency, smallest production line space allocation, and the most uniform coverage, Sonic also provides a written performance guarantee for virtually every system that we quote.
Although we specialize in optimizing effectiveness and efficiency when we pair Sonic air knives and nozzles with the appropriately sized Sonic blower, we also have a wide range of end-user and OEM customers who specify the type, profile size, length of the Sonic XE air knives which they prefer above all others for use with their existing non-Sonic blowers.
Sonic’s air engineering team consists of specialists in all aspects of the successful integration, installation, and operation of our centrifugal blowers and air knife systems on any existing production line or within any new open or totally enclosed conveying system. Ensuring the success of a Sonic installation requires our collaboration with and understanding of a customer’s products and their production line dynamics (mechanicals, electricals, air flows, liquids, temperatures, and material handling) to deliver the most effective and efficient system.
Applications
Sonic’s custom solutions are applicable across numerous industries, such as: