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Custom Conveyor Extraction System
18 December 2024
integratedAIR was approached by a longstanding client in
need of an efficient, cost-effective, and noise-controlled extraction system.
The client’s request centred around collecting and processing trim waste from a
conveyor belt with a system capable of merging two collection points and
processing the media with minimal energy costs. To achieve the client’s goals
within budget and facility constraints, integratedAIR’s design incorporated
high-end equipment, a redesign of the ductwork layout, and insulation
strategies.
The project involved implementing two conveyor-based
extraction points with collection hoods at the end of a conveyor belt. These
two lines would converge into a single main header Ø450 duct running at roof
level, which would be connected to a high-performance air separator and baler
system. The goal was to improve collection and conveyance, boost energy
efficiency, reduce noise, and save costs. integratedAIR recommended upgrading
the system’s motor to 18.5kW, which would strike a balance between performance
and energy savings.
integratedAIR
designed a heavy-duty ductwork system to enable smooth airflow. A Ø450
galvanised steel main header was connected uniformly to the air separator to
improve the conveyance of media through the system. Additionally, long-radius
bends, and flanged connections were integrated to minimise blockages, while
Ø300 trim ducting was added to give flexible adaptation for changes in the
future.
Essential equipment included an 18.5kW Chopper Fan, which
pulled material efficiently through the system, coupled with an air separator
and baler setup for better separation and collection of trim media. integratedAIR
also designed a control panel for integrating and managing system components.
This control panel was fitted with a VSD and an isolator, among other
components from ABB, Schneider, Siemens, and other reputable brands.
The VSD-controlled 18.5kW motor improved the fan's energy
draw, which reduced power usage without compromising system performance.
integratedAIR’s energy-conscious design resulted in long-term cost savings for
the client, with the motor and control setup tailored to serve variable
operating requirements.
Several adjustments were made during installation to
meet on-site requirements. The extraction system was configured to pull from a
single hood at the conveyor's end, with an additional branch featuring a manual
slide damper and mesh to allow for easy future expansion. A 77/55 Chopper Fan
was chosen to maximise airflow and efficiency within the updated layout. The full
duct insulation thoroughly addressed the noise control concerns. This meant we
could remove a silencer from the initial design plans. Additionally, the
existing sensor in the baler was used to streamline the system operations, which
removed the need for an extra level sensor on the baler chute as was originally
planned.
integratedAIR’s customised extraction solution met the
client’s precise requirements by combining technical innovation with practical
modifications, such as insulation and energy efficiency. The system provided
cost savings and noise control while allowing operational flexibility and positioning
the client for future expansion. This project exemplifies integratedAIR’s capacity
to execute tailored, efficient waste extraction and
filtration solutions to improve productivity and reduce operational
costs across numerous industrial industries. Contact us to learn more
about how integratedAIR can upgrade your business operations.
