Wienerberger Clay Brick Production​

Case Study

Project Overview

Wienerberger Ltd, the UK and Ireland arm of the world's largest brick manufacturer, is a leading supplier of building products, including bricks, roof tiles, pavers and blocks. One of their production facilities in East Manchester approached integratedAIR to conduct a survey to replace a worn-out dust extraction system for their high-speed roller in the Clay Preparation Plant. The current filter unit had been poorly designed, particularly on the filtered roof, and was badly corroded, allowing water to leak inside the filter casing making the filter unit unusable.

Dust Control Solution

integratedAIR entered into discussions with Wienerberger Ltd to look at producing a filter unit incorporating features to avoid the same potential problems. Our BlueClean® VT Tubular Bag filters have a specially designed robust roof which does not distort when personnel stand on the roof panels, eliminating the collection of standing water that leads to corrosion. Our BlueClean® RJ Tubular Bag filters also have a superior powder-coated external finish giving extended life.

Solution Benefits

Post discussions led integratedAIR to propose additional benefits that were important to the customer:

  • The compressed air header tank, diaphragm and solenoid valves were fitted inside the clean air section of the filter unit, reducing the noise created by the exhaust of the valves.
  • The pulse sequence controller was positioned at a low level for ease of access.
  • The filter bags have a hydrophobic treatment providing more efficient cleaning.
  • A manna valve was fitted for the dust discharge from the hopper in place of a conventional rotary valve, eliminating any moving parts.

Our BlueClean® TV units are ideally suited to this application. There are many other applications that this filter can be applied. Don't hesitate to contact the integratedAIR Filtration Sales Team if you are looking for a stand-alone filter unit or a complete turnkey LEV system for any dust or fume extraction needs.

"It has always been our strength to listen to our customer’s needs and incorporate these needs within our design. Our aim is to provide a solution that our customer is happy with and one that will continue to work effectively for many years."
Sales Manager, Gary Lockwood
"It has been a pleasure working with Weinberger to ensure their exposure to clay dust is reduced as much as possible. We look forward to working with them in the future as they continue to invest in productions health and safety."
Project Manager, Chris Tayor
"It was a great pleasure to work with integratedAIR on this project. From the initial meeting to the commissioning of the unit, the project went seamlessly and the communication was to an excellent standard. I am extremely happy with the outcome from the install, and I will be using integratedAIR, for further upcoming projects"
Client Maintenance Manager, Paul