Dust/Chip Extraction – Cleaning – Material Transportation
To size systems you need to consider a few things:
- How many operators/machines
- what type of operation/ what kind of material is being picked up
- how many are working and using the system at the same time
- what distance does the material have to travel
- do you need to recover the collected material – pre-separator
- how often would you like to empty the waste – container/bag/bucket
- maintenance needs
- sound sensitivity – placement of central unit
- do you want one big system or many smaller ones
An example of a stationary unitÂ
Custom solutions to meet your needs
In addition to standard solutions Dustcontrol recognizes that there isn’t one single fix that applies to every application. That is why we provide fully customized options that can be suited to each customers individual needs. Having such extensive experience in designing and constructing innovative customized solutions, we can provide a high level of system integration and customer value.
Health & Environment
Dust has been proven to contribute to many negative health effects throughout the years. A significant benefit of installing a Dustcontrol system is that by reducing the amount of airborne particles, you are reducing the exposure to workers. In addition to this reducing dust can have the following benefits:
- Cleaner safer working environment
- Meet demands of Health and Safety legislation
- Motivated and healthy employees
- Improved organisational culture
- Easier to recruit and retain staff
- Automated recycling
Operational Efficiency
- Vacuum transport as a part of the manufacturing process
- Shorter maintenance breaks
- Lower repair expenses
- Fewer breaks in the manufacturing process
- More efficient waste management/ recycling
- Lower house keeping costs
Quality
- Increased product quality by elimination of dust, liquid or smoke at the source
- Clean products ready for delivery or the next stage in the manufacturing process sooner
For a dust extraction system to deliver the desired benefits, it must be complete from suction casing to vacuum producer. For this reason Dustcontrol supplies quality equipment for all aspects of the system installation. You can have the piece of mind knowing that genuine Dustcontrol equipment has 40 years of experience tackling the toughest dust related tasks.
Vacuum Producers – Turbo pumps or Radial Blowers
The vacuum producer is at the heart of the installation, where the negative pressure is created that drives the system. In Dustcontrol extraction systems, the vacuum level is generally from 6-40 kPa.
Our normal stationary source extraction and vacuum cleaning systems use turbo pumps. Turbo pumps have the ideal characteristics and capacity for a source extraction system ie low volume high vacuum. Vacuum level increases as more resistance is presented, an important quality in minimizing the possibility of blockages in the tubing system.
For applications involving fume and light dust, such as paper, radial blowers are used. These have a larger air-flows and operate at a lower relatively constant, vacuum level.
Both our turbo pumps and radial blowers have very low operating noise, giving you more flexibility on central equipment placement.
Tubing System
Tubing systems transport the material from the point of collection to the central unit. Dust is generally abrasive, some more than others, therefore our standard material thickness of the tubing system is 1.5 mm. Applications with fume and light dust use reinforced spiral duct. Stainless tubing systems and extra abrasion resistant fittings are available.
Dustcontrol has a very comprehensive assortment of tubing fittings and installation hardware. This gives greater flexibility in design and installation of our tubing systems. Our mechanical jointing system makes alterations and additions a breeze.
Work Place Equipment
Source extraction systems are sized only for outlets that are to be used simultaneously. This is in order to maximize efficiency and minimize the size of the central unit. All outlets must have some type of closure, either a valve or shutter. These can be manually actuated, such as flap valves or manual shutter valves, or automatically controlled for actuation only when extraction is required.
Flexpipe can be used for fume extraction, high flexibility and small diameter allow it to be placed very close to the fume source.
Overhead suspension arrangements such as swing-arms and hose reels can increase the usefulness of the system, increase ergonomics and minimize potential trip hazards from hose left on the floor.
When large volumes of material are to be introduced into the system, stainless floor funnels can be used from which the material is then extracted.
Accessories
Our accessories from hose to suction casings have been designed and manufactured to withstand the toughest dust without sacrificing flexibility and operators use. At Dustcontrol we aim to have our products easily integrate into the customers existing process, and have the maximum working life possible.
Dustcontrol hose is tasked with the job of transporting the extracted materials away from the process, because of this it is designed with numerous qualities in mind. Flexibility is very important for functionality at the users end, this is why our range of standard hose’s all integrate a high level of flexibility. Also it has to be tough to handle the most abrasive material transport. Hose selection should include consideration of abrasion, chemical and heat resistance as well as conductive to static electricity. Dustcontrol has a comprehensive assortment of hose types, diameters and hose connections.
Cleaning tools, suction casings and special nozzles are the components that are actually used to capture the contaminant. The design and effectiveness of these will determine the efficiency and acceptance of the entire system. This demands a complete assortment of specially designed products. Dustcontrol has that. If a standard product does not exist, we have the capacity to design and manufacture it.
Control Systems
Motor starters and System Control Panels control the operation of the system, both operation of the vacuum producers and cleaning of the filter. A variety of other control functions can be installed as required.
Even with a rather basic control system, intelligent features can be included to clear coarse material in the main tubing runs or control vacuum production and therefore energy consumption according to actual requirement.