Blog / Scrap, Oil and Mist Systems
22 November 2024
A major beverage producer planned to build a new can-making
facility in Mexico and turned to integratedAIR for their expertise in the
two-piece beverage can manufacturing sector. integratedAIR delivered a
comprehensive solution to improve recycling and reduce emissions across the
facility.
The client's facility required several complex air and waste
management systems to support a high-capacity, two-piece D&I can-making
plant. integratedAIR was commissioned because of our extensive experience in
designing and installing state-of-the-art systems to manage scrap material,
mitigate airborne pollutants, and ensure safe operations.
A multi-stage scrap system was implemented to manage bright
aluminium trim, and the whole can scrap. This system collects and
separates bright aluminium scrap from 14 trimmers and a cupping press, which consolidates
the material for baling and recycling.
The scrap system includes adjustable sweep-up points that
can handle varying can sizes so adjustments can be made swiftly as production
requirements change.
Scrap is directed to two balers, with built-in redundancy to
ensure continuous operation. In case one baler is offline, the system diverts
materials to the second baler, ensuring production continuity.
Each system has automated controls so each can run only when
necessary, which reduces energy usage. Redundant systems, like the baling
bypass and emergency valves, maintain efficiency even in cases of mechanical
failure.
integratedAIR coordinated the positioning of fans, air
separators, and diverter valves on a customised mezzanine platform to increase floor
space in the plant and streamline the airflow and scrap handling processes.
A standalone oil mist extraction system was installed to
control oil emissions from the bodymaker units. This system filters
the air in multiple stages and removes 98% of contaminants larger than 20
microns.
The system uses an automatic wash-down to prevent
buildup and flush accumulated oil and aluminium particles, creating
long-lasting efficiency and reducing maintenance requirements.
integratedAIR installed an ink mist and OV extraction system with dedicated exhaust points for high-speed processing to reduce emissions in the plant. The system has two-stage primary and secondary filters and high-capacity fans, which capture and filter ink mist to enhance air quality and maintain a safe production environment.
To capture dust generated during spray coating, a custom
dust extraction system was designed for 16 spray machines, including additional
extraction points along the conveyor to handle potential buildup.
Given the explosive nature of spray dust, the system
incorporates a dust filter, which is positioned outside the plant to prevent
hazards and comply with safety protocols.
By installing this unified solution, integratedAIR helped
the facility to operate efficiently and capture scrap for recycling while
maintaining a safe production environment. The systems create a productive
workflow, from aluminium trim collection to ink mist extraction.
This case study is another example of integratedAIR's expertise
in designing and delivering adaptable systems in complex manufacturing plants. Our
ability to tailor solutions to complicated manufacturing processes allows us to
transform manufacturing plants by creating systems that address immediate
production needs and add sustainable systems that give long-term value. Contact us regarding
turnkey scrap oil and mist systems for your business.
