Siderise Insulation Case Study
Improved Performance and Reliability for Siderise Insulation
A Total Solution from Air Plants Dust Extraction Ltd, providing years of trouble free reliability and financial benefits
Siderise Insulation in Maesteg South Wales, one of the country’s leading processors of insulation materials
Problems with Previous Plant
- A more effective, efficient and reliable dust and waste extraction solution to reduce power consumption and fit within a limited footprint.
- Problem free extraction of dust and waste from machining operations that will not block.
- Regular blockages.
- Handling of a highly abrasive material, results in a fine irritant dust. When machined, the very lightweight material bulks up to around 10 times its compressed volume.
- The bulk of the waste means it has to be discharged into portable containers and loaded into a compactor prior to disposal.
- Not all parts of the plant operate at the same time. Demand is at its peak when the main line is running.
- Fan on the clean side of the filter means that the main motor is quite large. Power consumption is high, even when the extraction demand is low.
- Air Plants Transair Filter.
- This Baghouse Dust Collector of robust construction, with extra large filter sleeves, fits comfortably within the available space.
- The risk of system blockages are minimised by the main fan being situated on the clean side of the system, 500mm diameter filter sleeves and a control panel that sequences start up and shut down procedures, purging the filter of waste material at the end of a shift.
- A drop out chamber takes 60-70% of the waste from the airflow before transferring the air into a filter. The filter removes the remaining material before returning the clean air to the factory, reducing winter heating bills. The inclusion of a summer heat dump means heat can be released to the atmosphere during warm weather.
- Four collection bins sit below the main filter, each is served by large rotary valves. Interlocked gates protect the operator and each section. The system is programmed to allow the operators 3 minutes to change a bin while the rotary valve in that section stops. Should a problem occur, once the 3 minutes have elapsed the entire plant will shut down to prevent blockages.
- Introducing an Ecogate system into the scheme has helped to reduce power consumption. Each branch has a motorised blast gate fitted, which is connected to the machine. When the machine starts the blast gate opens, sending a signal to the controller. The controller then increases or decreases the volume of air required by means of an inverter, linked to the main fan.
- Siderise Insulation can expect a 20% net saving in fan speed, a power saving of approximately 50% and a payback period of around 18 months.