Corrugated Cartons

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Corrugated Cartons

DELTA NEU Limited (formerly part of the NEU Engineering) is a member of the European DELTA NEU Group, and has over 30 years of experience in air technologies in Corrugated Carton manufacturing in the UK, Europe and Middle East including waste extraction, dust extraction and filtration and industrial ventilation. This includes corrugated board manufacturing and carton conversion.

About Corrugated Board Waste Extraction

Corrugated board process waste extraction covers the extraction and reduction in size of production waste from machines in the corrugated packaging industries by chopper fan, transported to centralised separation and reclamation for subsequent recycling.

The effectiveness of the waste extraction system depends greatly on the capture of the waste. Depending upon the application this may be a capture hood, from a trimming process on the corrugator slitter, waste collection from conveyor or rotary feeder on the conversion operations, a sweep-up hood from a floor sweep-up point or direct extraction a core or sheet board shredder. Correct and effective design at this point affects not just the performance but also the size of the waste extraction system due to the air volume selected.

At the heart of many corrugated board waste extraction systems is the Chopper Fan. The basic design has been in use for over 40 years and has changed little! In many applications, the waste needs to be reduced in size to be conveyed from the entrainment point to the reclamation area. The chopper fan is designed with cutting blades on the radial impeller to break the waste up for this purpose. Continuous trimmed waste from the corrugator slitting process is chopped into short lengths and bulky collections of waste, from collection conveyors or sweep-up points, is broken up enabling conveying.

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In the design of the ductwork system, it is necessary to consider the dynamic laws of airflow, adequate conveying velocities, distribution and balance, abrasion and wear, energy running costs, sizes and materials available. The dynamic designs are applied in all cases however the construction and material requirements for waste extraction applications are more rigorous than in most other ductwork systems. The design of the ductwork system will have a significant bearing on the fan selection and motor size and the Chopperline range offers a broad spectrum to choose from.

In most applications, the waste from various areas or machines is conveyed to a central collection area where the waste is removed from the airflow and prepared for recycling or disposal. From each source, the ducting systems will connect to an AMSP Separator. This unit comprises of a static screen which causes the waste product to simply drop out of the air stream into the collection and recycling equipment below. The conveying air then simply passes through the screen to be exhausted or, if dusty, filtered.

About Dust Filtration and Recycling

In many applications, the process creating the waste will often also release some dust from the product into the airflow. Dust may also be created by any shredding or even the chopper fan actions. For both environmental and energy saving reasons this dust is filtered from the air using dust extraction techniques.

With a large range of dust filters available, we can meet most applications and requirements. The Jetline range of fabric filters is both extensive and the most versatile and offers:

A wide range of sizes and filtration areas to suit airflow and space availability

Automatic filter cleaning with energy saving pressure monitoring available

Where large quantities of dust are involved, for example in a printing and binding process, the collected dust can be made into briquettes and then added to the recycled waste rather than landfill disposal of loose dust.

About Ventilation Systems

Ventilation systems are used wherever there is a presence of heat, fumes or humidity and also where there is a need for air make-up to compensate for extraction systems themselves. Ventilation design techniques are based on two principal processes; extraction and input. Each of these is governed by good design principles, covering performance, effectiveness, energy consumption and treatment. Extracting air using Extractair roof extraction units takes away the warm air from a production area like the corrugator bay to the outside but it is important to remember that for air to be extracted, it must be possible to enable replacement air into the area. Ignoring this means the area will operate under a negative condition and draw air in through any opening, doorway or gap in the building fabric which may cause the ingress of airborne pollution and insects. The heat and humidity in areas of the corrugated board plant can be significant and even with a significant amount of ventilation may result in a temperature rise or condensation problems.

Many waste extraction applications lend themselves to recirculation of the factory air after the filter process and making a significant contribution to heat recovery and energy management plans. The benefit of recirculation is two-fold. Firstly, the recycled air means that cold ambient air is not drawn in as make-up air due to the negative pressure created by the initial extraction. Secondly, the heat energy from the fan motor is added to the air as it is re-circulated.

The simplest way to offset an area of high temperature is to provide an air input at a reduced temperature. Air conditioning is very often impracticable in manufacturing environments due to the large air volumes involved and hence high capital and operating costs. The alternative is evaporative cooling, the name given to the adiabatic process which, by evaporating a small amount of water into the air causes, under most conditions, a reduction in the temperature. Even in UK summer weather this reduction can be as much as 10oC at times, which can have a significant impact on the performance of the ventilation system. By inputting cooled air, the internal conditions can be maintained at temperatures at or below the outside ambient, even taking account of the heat gain inside. The evaporative cooling technique is employed in the Econoclim product range and operates with very low running costs, using a small amount of water from a direct supply. The inherent design has added features making it a totally safe and reliable process ideally suited to manufacturing production areas in corrugated board plants and assists in meeting hygiene standards.

Corrugated

Roof mounted Evaporative Cooling unit

 

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