Custom Conveyor Extraction System

Project Requirements

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.

System Design and Custom Ductwork Layout

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.

Advanced Equipment Integration

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.

Post-Installation Adjustments

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.

Outcome

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.