Scrap System Upgrade in Tight Shutdown Window

The Challenges Behind The Upgrade

This project involved a number of technical and logistical challenges. The installation of the new system, as well as the removal of the old one, had to be finished within a set 14-day shutdown period. Due to the baler room's minimal capacity, there were few possible layouts, and precise engineering was needed. The age of the existing infrastructure meant that commissioning also required the careful integration and rebalancing of older fans and ductwork.

Structural constraints also had to be addressed, with the existing roof and mezzanine removed and modified to accommodate the new equipment. In parallel, operational continuity was maintained through extensive pre-shutdown works, enabling the factory to remain fully operational until shutdown commenced.

Planning & Pre-Shutdown

The team was on site two weeks before the factory shutdown. During this phase, the team made extensive preparations so that once the shutdown began, all activities could be carried out swiftly.

The team carried out detailed site surveys and finalised the installation sequence at an early stage. Opportunities were identified to fabricate, assemble, and prepare essential elements in advance, including exhaust fans, silencers, and control panel components. Wherever possible, sections of the system were built off-site, with crane lifts planned in detail to minimise on-site installation time. This meticulous preparation meant that once the shutdown began, all activities could progress without delay.

Shutdown & Installation (14 Days)

Once the factory entered shutdown, integratedAIR mobilised immediately. The baler area's roof was temporarily removed. During the shutdown period, integratedAIR carried out the full strip-out of the existing scrap system, excluding the balers, and installed a new mezzanine platform supported by a complete structural design. The works included installing two air separators, one with provision for a future whole can, along with new ductwork, exhaust air ducting, and associated supports.

New roof-mounted silencers were installed, supported by structural upgrades to accommodate the additional load. All associated controls for the weigh hopper, new exhaust fans, and trimmer fan were wired and commissioned as part of the shutdown works.

The design engineers effort was particularly noteworthy, ensuring that all equipment fit together within the confined baler room while still allowing for future expansion.

Baler Installation & System Integration

An external specialist contractor carried out the physical installation. Due to their position at the base of the scrap handling process, the balers and all associated equipment had to be fully installed before integratedAIR could complete the final scrap system works.

This sequencing was critical, as the scrap extraction system needed to be designed and configured around the balers to ensure correct alignment, airflow, and material flow. Once the balers and related equipment were in place, integratedAIR completed the integration and commissioning process, ensuring the balers operated correctly in line with the upgraded scrap system and performed as intended within the modified installation.

Primary System Improvements

The scrap management system saw several notable improvements as a result of the modification. A contemporary, high-efficiency solution, created to meet current operational demands, replaced an installation that was more than 30 years old. To accommodate future expansion, two new air separators with additional capacity were added. The installation of new control panels enhanced problem diagnosis and overall system control and existing fans were rebalanced during commissioning to guarantee peak performance with the new system.

Despite the project’s complexity, the confined space in the baler room and the tight shutdown window, integratedAIR completed all work well within the 14-day deadline. As a result, the factory restarted production on schedule, with a fully upgraded scrap extraction system in place.  If you have a project that requires expertise in large-scale industrial scrap and air-handling systems,  today to find out how we can support your operations.