Scrap Extraction and Air Filtration System

Scrap Collection 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.

Oil Mist Extraction for Bodymakers

The system captures oil mist from bodymakers, utilising high-efficiency coalescer filters with 98% efficiency for 20-micron particles. Exhaust air is purified and safely vented outside the facility, ensuring clean indoor air quality.

The system's advanced mist elimination begins at the screen plate section at the front of the unit. This section removes the majority of incoming liquid, deflecting air towards the downstream coalescer section. Large droplets and liquids are trapped in a dead zone beneath the screen and are drained away. The coalescer section captures larger droplets while combining smaller ones into larger droplets as they pass through its main body. These are then directed to the droplet separator for final removal.

In the droplet separator, the airflow undergoes a series of sharp turns that throw the remaining oil particles onto the surfaces of vanes. These particles are collected in vertical drainage channels that lead to the sump below, ensuring effective separation of oil mist.

To maintain optimal performance, the unit includes an automatic water wash-down system. Spray bars, strategically arranged in front of the coalescer section, operate once daily to remove oil film and aluminium particle build-up from internal surfaces. Exhaust air is vented above the roof through a stack package, which keeps the working environment clean and safe.

Whole Can Scrap System

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.

Extracting Decorator Ink Mist and Overvarnish

The decorator ink and OV mist extraction system is an integral part of the tailor-made solution for this project, modelled on proven designs from successful beverage packaging installations. This system efficiently extracts ink mist from eight points on the decorator and OV mist from two points, ensuring cleaner air and higher operational efficiency.

Ink mist extraction is managed through flexible connectors attached to the eight inker box exhaust points on the decorator. These connectors converge into a central header duct positioned alongside the machine, which channels the airflow to a two-stage filter and exhaust fan assembly. This unit is mounted on the mezzanine with anti-vibration supports, effectively captures emissions, and maintains system stability.

Two 100 mm diameter flexible connectors are attached to the decorator’s OV mist exhaust points for OV mist extraction. These lead to a floor-mounted pre-separation drum beside the machine, designed to collect liquid draining into the system. From the drum, the air passes through ducting to a second two-stage filter and exhaust fan assembly on the mezzanine. This parallel arrangement ensures smooth operation and minimal disruption. Both decorator and oil mist systems exhaust air to the exterior via a dedicated stack package, maintaining a clean and compliant workspace.

Supportive Infrastructure

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.

Impactful Results

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.

Outcome

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.