The Client: The Animal Manufacturer
A well-established and UK-based animal nutrition brand that have three sites in the UK for R&D (research and development) and the manufacturing of sustainable animal foods approached Auto Extract Systems to help them assist providing them with an animal food dust-free workplace for their manufacturing plant. After receiving a large investment from an overseas company, the client was able to triple the manufacturing volumes in one of their three sites.
The Challenge: Removing Animal Food Dust
After previously contracting Auto Extract Systems at their other two sites, we were tasked with proposing and installing a comprehensive LEV (local exhaust ventilation) system in the production facilitates to safely capture and remove the animal food dust that was being emitted into the workplace’s environment air during the business’s operations. The LEV system was installed as part of a project to ensure the site meets stringent operational requirements and to work strictly in accordance with HSE’s ‘HSG258: Controlling Airborne Contaminants at Work – A Guide to Local Exhaust Ventilation (LEV)’ guidance.
The Solution
A meticulous LEV proposal was put together, which included a filtered nine-point extraction system, which consisted of six direct-connections and three 1.5-metre self-supporting hose extraction arms and connected to a 2.2-meter high steel stand. The 9-points ran to a common duct and ran through to a centrifugal extraction fan via a reverse-pulse dust extraction filtration unit, which has the capacity for eight filter cartridges.
The hose extraction arms specified featured metallic fume capture hoods, gas-powered support struts and four-way knuckle joints. The arm’s design means they are fully flexible and can be turned virtually 360° to be operated above and below their mounting height, which allows the user to position the hood at-source with a simple operation. This extraction arm also provides the workshop with 25% increased airflow over a traditional-styled internal knuckle extraction arm, as they feature an externally mounted supports, which reduce static pressure airdrops. An ergonomically designed hood which is ideal for the collection of hot welding fumes, gases and grinding. The capture hood features a flat base to take benefit from the Coanda effect; the phenomenon is known to Science when a jet of air clings to a flat surface over a longer length than it would over towards an open collection area, enabling a greater collection of fumes over a longer length than any traditional type all round hood.
Dust Filtration
Whilst the filtration unit specified for this LEV system was a modular dust bank collector filter that could accommodate eight cartridge filters and gives a total filter surface area of 156m2 (19.5m2 per sleeve). The filtration unit featured the latest innovative technology and is capable of self-monitoring, self-cleaning and filtering up to 99.9% efficiency. A high level of filtration is achieved in this filter by a reverse-pulse process, whereby compressed air is manually released down the inner side of the filter cartridge over internal ‘torpedo’ shaped filter carrier. This process allows for the pneumatic air to be used more effectively down the full length of the filter (compared to conventional cage carried or shaker type filters). It also prolongs the life of the filters and reduces maintenance costs replacing them more frequently. Dust collects in a metal waste bin below and has a 95-litre capacity.
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