Blog / scrap and filtration system
18 September 2023
integratedAIR was approached by an overseas client in the
Southern Hemisphere to design and install a dual-purpose system for collecting
and extracting aluminium scrap from multiple trimmers and an oil mist extractor
to evacuate oil fumes and improve the atmosphere at the plant. The project
aimed to efficiently manage aluminium scrap from can production while ensuring
compliance with environmental and safety standards. It was designed to
integrate with the existing infrastructure and minimise downtime through a
robust, continuously operating system.
Two separate systems were installed to collect bright
aluminium scrap from bodymakers and cupping presses. Both systems convey the
scrap to a new Austropressen DS700 baler, each configured with bypass options
to an existing baler to ensure operational redundancy.
The first air system collects trimmed aluminium scrap from
12 trimmers and one cupper, utilising rerouted existing ducting to connect to a
new baler room location. The material is then conveyed to the front-end scrap
separator, which feeds Baler 1 via a weigh hopper divert valve, with an option
to bypass to Baler 2.
The second air system effectively collects trimmed aluminium scrap from seven trimmers and one cupper, featuring newly installed ductwork
adaptable for various can sizes. Similar to the first system, the material is
conveyed to the front-end scrap separator, feeding Baler 1 through a weigh
hopper divert valve, with the option to bypass to Baler 2.
The system collects whole cans from seven positions in the
plant and two washer belts. The washer bins, constructed from stainless steel,
activate automatically upon detecting high levels. Whole cans are processed
through a chopper fan and then conveyed to a separator before baling, ensuring
a consistent output.
The fans, air separators, and divert valves were arranged on
top of a mezzanine platform, pre-assembled by integratedAIR in the UK to ensure
a proven design before shipment to the Southern Hemisphere. The baling presses
were positioned on the floor beneath the platform to maximise operating space.
The fully compliant mezzanine access platform supports the
balers while enabling conveying fans and exhaust filters to be supported on the
floor so the space has been used to maximum capacity. In addition, the exhaust
stacks were extended to three meters above the roofline, effectively minimising
environmental pollution.
The newly integrated system boosted efficiency for the
client through continuous scrap handling, which reduced downtime at the plant.
In addition, the advanced filtration solutions have created a cleaner
atmosphere and ensure environmental compliance. Furthermore, the improved air
quality has enhanced the working environment and promoted operational safety
for employees.
The efficient design displayed in this overseas-based
project leverages the expertise integratedAIR has gained from installations at
numerous leading plants, offering reliable performance and reduced emissions to
support high-speed operations. integratedAIR Systems’ tailored scrap and air
filtration solution reinforced productivity at the client’s plant and improved
their working environment.
This project in the Southern Hemisphere highlights
integratedAIR's ability to deliver innovative systems on a global scale. From
pre-assembly in the UK to successful implementation overseas, integratedAIR
continues to demonstrate its expertise in providing high-quality solutions for
clients worldwide. Whatever challenges your operations face, and no matter
where your facility is located, integratedAIR can tailor-make a solution for
all your scrap extraction and air filtration needs. Contact
our team for a detailed quote.
