Home / Case study – Industrial Vacuum System for the collection of polyethylene filaments

Case study – Industrial Vacuum System for the collection of polyethylene filaments

To continuously vacuum up large amounts of material

Companies in the textile industry need to collect production offcuts and scraps. In this case, the need is to vacuum significant quantities of polyethylene filaments, a versatile and durable material often used in the textile industry in the form of fibers and filaments, continuously and without interrupting the production cycle.

 

Customer’s need and our proposal

The polyethylene filaments the customer needs to manage are a type of residual waste that, if not properly removed, can accumulate, clogging machinery and causing malfunctions and production slowdowns.

We have developed a large, customized suction system with two pre-separators to efficiently handle the simultaneous vacuuming and disposal of large quantities of polyethylene filaments. To ensure a safe working environment and protect operators during routine maintenance, the system includes an alarm that signals when it’s necessary to step away from the machinery.

 

Customized Vacuum Solutions

Polyethylene filaments that the customer needs to manage are a type of residual waste that, if not properly removed, can accumulate and clog machinery, leading to malfunctions and production slowdowns.

We have designed a customized suction system with two pre-separators that efficiently vacuum and dispose of large quantities of polyethylene filaments simultaneously.

To ensure a safe working environment, the system is equipped with an alarm function that alerts operators if they have to move away from machinery.

Pagina Polietilene

How does the system work?

The vacuum system we designed includes a powerful suction unit, our three-phase Puma 18 industrial vacuum cleaner, and two pre-separators that work alternately to avoid downtime in production.

The strength of this suction system lies in its two pre-separators, which enable simultaneous and alternating suction and discharge: while separator 1 vacuums, separator 2 discharges, and vice versa.

The switching time between pre-separators can be adjusted based on the workload, for example, every 10 minutes.

This system ensures a continuous and uninterrupted work cycle. Due to the high volumes of material handled, unloading is carried out in large Big-Bags.

Disegno Impianto Eng

Safety system overview

To ensure operator safety, the discharge areas of the pre-separators are protected by two cages with gates. When a pre-separator is discharging or in operation, the gate locks, preventing entry for routine maintenance tasks. This status is visually indicated by a system of 4 flashing lights, with 2 above the separators and 2 in the discharge area.

The Area Is Safe To Access 3
  • Pre-separator lights: red when the pre-separators are in operation, otherwise green.
  • Discharge area lights: red when the pre-separators are operating, green when the pre-separators are neither operating nor discharging. When the light is green, the area is safe to access.
  • When the light turns from green to orange, only 5 minutes remain before access is restricted, requiring personnel to vacate the area.
  • If someone attempts to access the separators by opening the gates while the system is operating and the lights are red, a siren immediately sounds, and the entire system shuts down.
 

Through the control panel, it’s possible to set the operating time for each separator before they switch, e.g. 10 minutes. However, two electronic level sensors trigger an early switch, if one separator fills up too soon.

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Pneumatic discharge

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Pre-separator and discharge area lights

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Pre-separators and discharge area lights

Quadro Nero

Control panel

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Level sensor

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Level sensor

 

Control panel 4.0

The plant is set up for remote management 4.0, which enables the transmission of operational data to the company’s ERP.

With this setup, you can track key performance metrics, optimize processes, and make data-driven decisions to enhance productivity.

The control panel further simplifies operation, offering an intuitive interface that provides quick access to essential information and adjustments.

Schermo Reduced
 

Explore our installation

Puma Ridotto

Vacuum Unit Puma 18

The suction unit selected for this installation is the Puma 18, a medium-to-high-power vacuum cleaner equipped with a robust side-channel turbine, capable of delivering an impressive airflow of up to 1120 m³/h.

  • Power: 12,5 kW
  • Filtering surface: 45.000 cm2
  • Capacity: 175 liters

Thanks to its specifications, the vacuum cleaner guarantees excellent performance for continuous, uninterrupted operation.

Pagina Polietilene (3)

Side channel blower

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Antistatic star filer M Class

9

Completely grounded

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Tangential inlet

Progetto Senza Titolo (99)

Pre-separator 570 mm with pneumatic discharge

In this installation, the two separators are aligned and interconnected to ensure continuous and uninterrupted discharge. Each separator is designed to unload the collected material into one-cubic-meter Big-Bags, providing high storage capacity and reducing handling time. The system is fully grounded, ensuring maximum safety.

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Level sensor

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Big bag

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Completely grounded

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Pneumatic discharge

If you would like to learn more about our central vacuum systems or would like a customized solution to meet your industrial vacuum needs, please contact us for a free inspection!

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