CENTRALISED DUST EXTRACTION SYSTEM FROM DUSTCHECK HELPS NORCROS ADHESIVES MEET THEIR TARGETS
The Customer: Stoke-on-Trent based Norcros Adhesives, a leading UK manufacturer and supplier of adhesives, grouts, surface preparation and tile aftercare products, is part of the Norcros Group of companies. Their state of the art fully automated, PLC controlled facility in Stoke-on-Trent was installed in 2005.
Dustcheck were approached when it became apparent that whilst Norcros” manufacturing processes had improved and changed, their existing dust extraction and filtration equipment was no longer world class.
Opportunities were identified to:
- Improve working conditions
- Maximise product yield
- Reduce the cost of disposal and maintenance
Installed Solution :
Three new systems were recommended and installed by Dustcheck:
- General dust extraction system within production area – including improved cleaning system
- External extraction for bulk silos with independent vent filters.
- Independent vent filter for internal bulk storage silo
System Detail:
Central Dust Extraction System
A new centralised dust extraction system serving an existing production facility was required to include dust collection from mixers, weigh hoppers and filling machines and also contains additional capacity for future expansion up to 1,286m3/hr.
Extraction from: The system has 24 individual extraction points which collectively generate an airflow of approximately 14,975m3/hr.
The new dust extraction system replaces a number of systems currently using “mechanical shake” cleaning technology – a method that utilises offline cleaning more suited to applications handling coarse dusts and intermittent production lines that are not permanently in use. In the past this has meant that production has had to be essentially shut down before cleaning can take place.
The new system uses an on-line ‘rotating wing’ reverse jet cleaning technology, whereby a quick burst of compressed air is used to close a damper plate effectively taking the cartridge off-line during cleaning. The residual air drives a rotating ‘wing’ which forces air uniformly through the filter in the opposite direction to the dusty air stream. The cleaning air breaks up dust build up on the filter, taking place while the system is still running, thereby maintaining steady differential pressures across the filter and ensuring that extraction rates are maintained at all times. This leads to longer filter life, lower maintenance and system downtime and lower ‘whole of life’ running costs.
Also, as the filters are kept cleaner the risk of nuisance dust egress such as silica etc., is also significantly reduced.
Another key replacement was the duct pipework providing more efficient extraction.
The new system offers:
- Reduced running costs
- Cleaner environment
- Safer environment
- Reduced cleaning hours
External extraction for bulk silos with independent vent filters
The site also has individual silos – each for storing of different raw materials. The existing silo vents had common ductwork and were jointly connected to a floor mounted dust extractor.
This had associated problems such as:
- The whole system had to be shut down for maintenance
- Potential for cross contamination between products
- The waste had to be emptied and disposed of regularly, adding to cost and impacting environmentally
The new Dustcheck system has individual spot filters for each silo. Although more costly in terms of initial outlay longer term benefits include:
- Uncontaminated material can be reused, improving product yield
- As product is being reused the waste is eliminated so the cost of disposal disappears and maintenance is also significantly reduced
Independent vent filter for internal bulk storage silo
The third system installed is for an internal silo which was previously connected to the outdoor common system.
It is now separate from the outdoor silos with its own floor mounted system with benefits such as:
- Uncontaminated material can be reused – improving product yield
- As product is being reused the waste is eliminated so the cost of disposal and maintenance is also reduced
The Result :
Norcros’ Environmental Policy states that over 90% of their raw materials by volume are sourced within a 30 mile radius of the manufacturing plant and over 95% of the Quality Controlled quarantined product is recycled in the manufacturing process. The new system fully ensures those targets are met.
Dustcheck also offered a performance guarantee that no more than 25% of the acceptable level of dust would be left in the atmosphere once the Dustcheck system was operational.
Performance checks confirmed dust levels reduced to less than 20% of the WEL and respirable quartz to 10%.
The Future:
Dustcheck”s approach is to look at the long term usage for any systeminstalled. Future proofing is the norm with all Dustcheck”s designs and Norcros” future requirements have been accounted for including expansion in mixing and packaging.
For more information contact: Dustcheck Ltd, Stoke – on – Trent, Staffordshire.
Tel: 01782 5999454 Fax: 01782 599478 E-mail: sales@dustcheck.co.uk
Web: www.dustcheck.co.uk
