Wood & Panel

Energy efficient high-volume dust collection system for US market

 Wednesday, January 15, 2020

Alvic USA along with partner Nederman introduced high-volume energy efficient dust collection system for the American market. The Florida plant has 320,000 square feet of floor space with capacity to add machinery to the existing production lines. Currently there is one Wemhoener short cycle press line, one Superfici lacquering line, one automated storage system, one Heesemann sanding line and several Schelling saws. There are also three IMA edgebanders.


“When selecting Nederman as a partner the goal was to acquire a dust collection system which is known to be very reliable while finding the best ratio between price and performance, capable to be easily expanded in the future and (operated) separately for different production departments,” Lebovics said. “Lead time was an extremely important part of the decision-making process as well and Nederman performed exactly what they promised. The dust collection system came with blast gates for each machine which allowed (us) to shut off dust collection by machine and in the meanwhile we even further developed the energy consumption reduction by automatically dialing down fan speeds when parts of the machines are not running or no parts are running through the machine for a specified period of time.”


The advanced dust collector came with a Flamex system, connected to the facility’s sprinkler system is now able to automatically shuts off the air flow in the extraction pipe and fights fire with the connected sprinkler system in case of a fire. “The size of the system was chosen to cover the required CFM of the machines in the facility during the first stage of the production, and knowing it easily can be expanded was a significant advantage to minimize energy cost during day-by-day operation,” Lebovics said. “The system therefore did not need to be oversized for future needs and consume unnecessarily energy in the meantime. The Nederman process to clean bags during operation was imperative, especially since we have to deal with many different kinds of extractable waste, ranging from sanding dust to melamine paper chips to typical chip and dust particles. To date the dust collection system did not show any signs of problems dealing with this variety of materials.”



Modern machinery requires higher capture speeds and hood vacuum pressures due to the cutting and feed speeds, Williamson said. Without providing the correct air flow and pressure, the function and quality of the process would be comprised.  Also, Alvic provides complex and high-quality finishes on their decorative process. The sanding and cleaning process generates extremely fine particles. The system was dimensioned to filter the dust-laden air at high efficiency rates and be able to regenerate the media within a defined pressure range so to not affect the extraction volume.


“The system is set up for phased installation of the equipment and can be expanded to handle future capacity.  This was the installation site for our first CARZ-N Explosion Isolation Valve. We just released this new product series to meet the more stringent ATEX test protocols. We rented a quarry in Sweden to test these large diameter valves because many test companies could not handle the impact areas of the test explosions.”


According to Williamson, maximum extraction volume of the dust collection system is 70,000 SCFM. The system features a reverse air cleaning system, NRS-10 ATEX compliant rotary valve discharge, and central control panel with PLC controller. Cleaned air is exhausted to the atmosphere.


There are three extraction zones. All zones can run independently or operate together. Also, variable frequency drives can dynamically change the airflow in each line.  Zone 1 has extraction capacity of 15,500 SCFM, Zone 2 has extraction capacity of 27,000 SCFM, and Zone 3 has extraction capacity of 17,200 SCFM. A Quickfit piping “clamp together” system connects wood processing machinery to system. Discharge arrangement consists of a closed loop pneumatic system to load a 40-yard container.  Safety components include a spark detection and extinguishment systems on the three extraction lines, explosion isolation flaps on three extraction lines.



News source: woodworkingnetwork



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