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Process Waste Extraction Systems

waste extraction

Process waste extraction covers the extraction and reduction in size of production waste from machines in the packaging industries by chopper fan, transported to centralised separation and reclamation for subsequent recycling or disposal in industries such as paper, tissue, corrugated, carton, can and flexible packaging applications.

Capturing the Waste

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 or waste collection conveyor, a sweep-up hood from a floor sweep-up point or direct extraction from a in-built cutting process, typical in printing machinery. 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.

Chopper Fan

At the heart of many 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 a slitting process is chopped into short lengths and bulky collections of waste, from collection conveyors or sweep-up points, is broken up enabling conveying.

Ductwork System

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.

Waste Separation

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 equipment below. The conveying air then simply passes through the screen to be exhausted or, if dusty, filtered.

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:

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

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.

In certain industries or applications, a wet filtration system is more appropriate. The Aqualine unit has been designed for applications where a wet recovery system lends itself to recycling in a paper pulping process.

Energy Management

In addition to the filtration and recycling described above, a significant step for has been made with the introduction of the Separojet unit. In applications where the waste is extracted from a process in a small cut size, it is often unnecessary to use a chopper fan, other than for its conveying characteristics. Unfortunately, the design of the impeller is not the most energy efficient.

In the Separojet, the separation and filtering process are combined into one single, neat unit. The design enables a more conventional Uniline extractionfan to be used, which will be significantly more efficient, often meaning the energy requirement may be reduced by one third of that on a chopper fan.

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AMSP Separator




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