Polyplas’s order called for profiled sections made from Santoprene™ brand thermoplastic vulcanizates (TPV), which comprises  of high-performance elastomers, combining the desirable characteristics of vulcanized rubber, such as flexibility and low compression set, with the processing ease and re-cyclability of thermoplastics.  Polyplas found, when extruded over extended periods, this material produced fumes in the production area to such an extent that fume extraction equipment was required.

Polyplas is a manufacturer of custom made thermoplastic profile extrusions with a new 18,500m² factory operating six extrusion lines, two of which are coupled with jockey extruders to produce co-extruded profiles, as well as ancillary equipment for additional processing.  Established 20 years ago, they supply both UK and Export markets with products for building &construction, bathroom & shower manufacturers, transport & marine, medical as well as mechanical / industrial engineering.

Although not all the lines are being used on this particular contract, a strategic decision was made to provide fume extraction on all six lines as this would cover all future eventualities.  Flextraction was chosen to supply 6 x 1.5m long, 150mm diameter ‘Flextractor’ articulated arms each with an epoxy black painted flared hood, all connected to a Sodeca 3 phase 230/240V 50Kz 2.2kW centrifugal fan running at 2,600rpm with a maximum airflow of 7,800m/hr, more than enough to handle the 5,100m³/hr air volume required to cover all six lines.

The spiral galvanised steel ducting system to take the fumes away from the work place to an outside discharge flue and cowl, was designed by Flextraction to provide the correct conveying velocity throughout its length with the necessary access and inspection doors for easy maintenance.

Clive Chappel, Works Manager at Polyplas commented: “Although current environmental legislation played little part in our decision to purchase this equipment, we were fully aware that the installation of fume extraction equipment would help the working environment for our line operators.  Using the internet and my own knowledge of fume extraction we sought out suppliers.  Flextraction was chosen because their equipment was right for the job.  Although the installation is still new, we have found that it meets our requirements, with our line operators finding the articulated arms easy to use.  We decided to undertake the installation during our shut down period, but to meet orders we had to operate all the lines.  This, however, caused no problems and the installation proceeded without a hitch.”

There are three coolers in the range, PROCOOL 9000, PROCOOL 17000 and PROCOOL 24000. They are designed as portable air conditioning systems delivering cool, dry air to an area or areas, where a reduction in temperature is called for. They are ideal for use in industry to improve the working conditions in working areas that do not have air conditioning, on NC controlled machine tools and electronic control systems that require cool air as well as in automotive workshops where mechanics often work inside cars and trucks, places where PROCOOL’s flexible delivery tubes can reach.

They can also be used by the rental market for hire to the Food and Events industries in serving areas, kitchens as well as corporate and social event marquees.

PROCOOL 9000 delivers 300m³/hr of cool air, cooling an area between 20-30m² at an operating noise level 63db(A) at >35°C, using one flexible directional delivery tube, whilst the PROCOOL 17000 delivers 850m³/hr, cooling an area between 40-60m² at an operating noise level 68db(A) at >35°C, using dual flexible delivery tubes that allow the airflow to be directed to two distinct areas and the PROCOOL 24000 delivers 1000m³/hr, cooling an area 70-100m² at an operating noise level 69db(A) using 3 delivery tubes. A feature of the PROCOOL 24000 is that it also has the option of replacing the 3 delivery tubes with a single inflatable tube to supply cool air to large areas such as Marquees and complete workshops.

All PROCOOL spot coolers feature a digital display on the function control, with the user being able to set ambient temperature or the air delivery temperature at the vents. The flexible extensible delivery tubes can be positioned where required. The PROCOOL 9000 has a 10-litre capacity condensation tank whilst the PROCOOL 17000 and 24000 have 20-litre condensation recovery tanks for extended operating times.

Optional accessories include 3m flexible extension tubes and a vent for exterior discharge of hot air.

The APS aluminium rail system mounted on telescopic ceiling and wall brackets is a flexible solution for the extraction of exhaust fumes from moving vehicles that can be connected to a separate fan or a central exhaust system. Features of this system include the aluminium rail also acting as the suction duct with only one rubber seal placed on top of the duct, whilst the design of the trolley produces one of the lowest pressure drops for this type of system, thereby producing low running costs.

The APS system can be supplied with an automatic trolley return control and other devices for automatic control and when used alongside a production line to extract welding fumes, the rail can be supplied with one or more trolleys equipped with Fumex R or RX extraction arms equipped with a 360° swivel.

Heat resistant rubberised fabric EPDM/Polyester hoses are supplied in standard lengths of 5m in diameters of 75, 100, 125 and 150mm. Additional sections are also available are in 2.5 m lengths. The hoses are supported by a balance.

The AFS Hose rail is a simpler system with a tiltable supporting steel rail to achieve automatic return of the trolley and it has a 160mm diameter hose suspended underneath connected to a separate fan or a central exhaust system. The vertical suction hose is available in 100, 125 and 150mm diameters and in the same lengths as the APS System.

A range of different nozzles are available for both welding and for vehicle exhaust fumes including oval connections for both single and double exhausts, pneumatic rubber nozzles and high mounted exhaust pipes.

To view a video demonstration of the extraction system, please click on the link below and see for yourself this excellent product in operation:

View demo video of the Fumex APS (42Mb MPG file)

Flextraction welcomes the opportunity to introduce a new extensive range of their CMA(ATEX), CMP(ATEX) and CMR(ATEX) centrifugal exhaust fans, which are certified for use in ATEX explosive atmospheres. This covers a wide variety of applications including food processing and pharmaceutical manufacturing, wood and ceramic dryers, painting and bulk product packaging and handling booths, as well as grain and other agricultural product storage.

These fans meet European Directive 94/9/CE for installation in explosive atmospheres. The materials used and the minimum distances of moving parts have been designed to avoid sparks during operation meeting EN14986:2005 standards.The centrifugal single inlet medium pressure CMA(ATEX) fans are made from cast aluminium. 11 models offer the user a range of operating speeds from 2,765 – 2,880 rpm (revs per minute), maximum airflow from 440 – 3550 m³hr and sound pressure levels from 70 – 88 dB(A).

The CMP(ATEX) fans fitted with multi-blade impellers have steel casing and impellers with a spark-proof inlet ring in either copper or aluminium depending on the model. 32 models offer speeds from 1,350 - 2,900 rpm, maximum airflow from 830 – 16,500 m³hr and sound pressure levels from 61 – 89 dB(A).

The robust CMR(ATEX) fans are fitted with backward curved impellers. 14 models in the range offer speeds from 935 – 2,915 rpm, maximum airflow from 5,800 – 48,000 m³hr and sound pressure levels from 64 – 89 dB(A).

All these fans are available with either EEx-e (explosion proof) or EEx-d (flame resistant) certification and are supplied with either 3 phase 230/400V 50Hz or 400/690V 50Hz motors and have a working temperature range from -20°C to +80°C.

This reinforced pre-separator has been designed for use with cyclone operations for high vacuum dust extraction installations, industrial vacuum cleaners and Kiekens plate filter type ‘Dustmaster’ fine dust systems. It has a manual operated tipping mechanism for unloading and is fitted with forklift truck profiles. It is supplied with either a 60mm, 80mm or 100mm diameter 325mm high cyclone pre-separator cover and safety chain to keep the unit from moving, the cover has a hinged partition for easy access and it is supplied with either wheel and swivel casters with brakes.

Options available include a sieve, drain cock and a water and wear resistant PV hose.

Other Kiekens pre-separators are available from Flextraction for high vacuum and low vacuum applications.

TEKA’s new plasma tables are supplied as modular assemblies so that additional lengths can be retrofitted to existing cutting tables at a later date. They have sectional suction chambers every 500mm and are suitable for both portal and boom cutting machines. For larger air movements, such as found in shipyards and other heavy duty fabrication shops, they are usually supplied with either TEKA’s new integrated ZPF 9N or 9H central suction and de-dusting cartridge filter system which takes polluted air from the suction point using specially designed pipework into the filtering units. (On the stand a 2m x 1m plasma table with a FILTERCUBE 9 central suction and filter unit will demonstrate how the system operates) The ZPF 9 is equipped with 9 long life BGIA M standard filter cartridges with a dust collecting efficiency of >99% . Included in the filtering units is a de-dusting system.

A feature of this system is the micro-processor controlled PULSE-CONTROL, which programmes and controls the operation of the suction and filtering devices. With easy to read digital display, it calculates and automatically adjusts the specific compressed air requirements of the de-dusting operation. A GSM capable version of the programme is also available providing a remote control facility.

Other features of the ZPF 9 central suction and filter units are their modular design to suit customers’ requirements, use of standard filter cartridges, dust collected efficiency > 99%, de-dusting of the filter cartridges using the POWER-SPRAY system, re-circulation of cleaned air into the work area.

For smaller air movements the FILTERCUBE ZPF 3 and ZPF 4 are available with fully automatic de-dusting and BGIA M filter cartridges.

The ZPF 3 is supplied with 3 suction arms and the ZPF 4 with 4 suction arms. These arms are 150mm in diameter, 3m in length and are supplied with exhaust ventilation hoods with throttle valve.

The HNW1500 Wet Dust Separator is one of a series with airflows ranging from 1,500m3/hr to 10,000m3/hr. The engine sizes range from 1,5kW 400V 50Hz up to 15,0kW 400V 50Hz. With its high dust collection capacity it is designed for a wide range of industrial applications.

The air is cleaned by swirling the dust with water, with the air being centrifuged in the W-swirl, which was originally designed for the separation of explosive dusts and adopted for use with this Wet Dust Separator. Dust particles in the air flow are enclosed in the water due to the strong turbulence in the swirl.

Water in this separator can be used again and again and pumps or nozzles are not used. A robust high performance is utilised providing continuous operation of the separator. Through the arrangement of the impeller, the fan achieves a high negative pressure.

Some of the extraction systems at Oldbury were relatively new and others were in good condition, so Unistrut decided not to buy complete new systems, but to utilise their existing system. Following a number of meetings with Flextraction, they contracted them to carry out the dismantling, undertake any needed refurbishment, install new equipment where required and re-locate it all to West Bromwich. Flextraction were happy to work to a timetable decided upon by Unistrut Maintenance Engineers, although these timetables were often revised at short notice, the re-location took just 4 weeks to complete.

Eric Shropshall, Unistrut’s Production Engineer said: “The complete fabrication shop was moved including a robot welding cell, continuous MIG seam welding machine, MIG welding benches plus 2 cable ladder MIG welding benches all of which required fume and dust extraction systems. All this equipment is used to weld carbon and stainless steel bracket assemblies for our Metal Framing Systems including cantilever brackets. We also weld cable ladders in widths from 150mm to 900mm and depths from 100mm to 150mm, with all their necessary accessories to provide safe and effective management of heavy duty electrical cabling.”

Lee Darton, Flextraction’s Sales Manager said: “Our distributor in the West Midlands, Central Welding Supplies Ltd was fully involved in obtaining this contract, but overall we were responsible for carrying out the project. In addition to the re-location we manufactured and supplied a new extraction system for 2 cable ladder welding jigs using lip extraction, which uses long extraction manifolds mounted under the welding area to extract the welding fumes downwards away from the welder’s face. This was a new concept for Unistrut and has resulted in a cleaner working atmosphere.”

Eric Shropshall continued: “In addition to the ladder jig extraction and refurbishment of some of our equipment, Flextraction installed new more efficient fans to aid extraction. We currently discharge our welding fumes into the outside atmosphere, but we are currently working to use filtered units, which will allow us to re-circulate clean air back into the workshop and reduce our heating costs. The only problems we encountered were difficulties supporting the 8 ductwork stacks on the side of our building, fortunately Flextraction came up with a solution using some of our own products to construct framework to support the structures and spread the loads. We have been impressed by the service from Flextraction and their ability to react quickly to our requirements and find solutions to any problems we incurred. The result is that our fabrication shop has a better working environment.”

New products include a brand new TEKA plasma cutting table with integrated fume extraction, TEKA’s new ‘ZPF9’ central de-dusting cartridge filter system with 9 long life BGIA M filter cartridges and a dust collection efficiency of > 99%, with the filtering device being equipped with PULSE-CONTROL for easy use and programming.

TEKA’s new high performance ‘Wet Dust Separator’ with a high dust collection efficiency for a wide range of applications, including difficult dust conditions will be demonstrated.

Other new products on show include a new grinding bench from TEKA for simple disposal of grinding dust, where dust is extracted through to the back and to the bottom of the table. 90% of the particles collected are separated immediately by an integrated pre-separator.
Other dust and fume equipment on show will include TEKA’s ‘Caremaster SF-W’ Stationary welding fume filter for almost every type of industrial fume extraction problem. It is equipped with a durable filter cassette, pre-filter unit, filter monitor, sealing face lifter, hour-meter, wall bracket and protective motor switch for wall mounting. Alongside it will be TEKA’s BGIA: 200520840/1140 approved ‘Cleanmaster’ mobile, high-performance welding fume filter for industrial fume extraction. It has a visual and acoustic filter monitor, sealing face lifter, hour-meter, cable reel and castors with brakes as standard.

TEKA’s BGIA: 200520840/1140 approved ‘Strongmaster’ mobile cartridge filter for industrial fume extraction comes equipped with a separator, durable, de-dustable, large-surface filter cartridge and PTFE laminate will be shown. The filter cartridge stays in the unit during de-dusting preventing dust from entering the workroom.

Other equipment on show will include Kiekens ‘Mistmaster’ centrifugal mist separator for the filtration of oil mist at turning lathes, milling and other production machines and iekens centralised vacuum system for on welding gun fume extraction and a TEKA ‘Handycart’ mobile portable high-vacuum extraction unit with manual de-duster or fully-automatic pneumatic de-duster and infinitely adjustable speed control as well as a downflow extraction bench and extraction equipment for print processing equipment.

Industrial cleaning equipment will be highlighted by Kiekens ‘W192 / Wet & Swarf’ cleaner for the suction of slightly contaminated liquids, swarfs and accompanying coolants, lubricants and wet industrial waste. Characterized by a strong suction power with a low noise level, it contributes to dust free and safer working conditions.

 The company’s products are divided principally into 6 groups comprising extraction arms, filter systems, vacuum systems, extraction fans, downflow booths and other products, along with accessories. There is also a section on Services and Support that the Company offers as well as a Latest News section with all the company’s press information and images, including application stories.

 Lee Darton, Sales Manager at Flextraction said: “This new website replaced our old site at the beginning of January.  It has taken a considerable amount of painstaking work to complete, but in the end the information that is now available to visitors to the site far exceeds anything we were able to do with our former website.”