Riley Product Handling Ltd in Derby is a manufacturer of bakery systems used predominantly in biscuit and cracker production. Their equipment links the exit of an oven with wrapping machines, sorting products into the right numbers of lanes and presenting the products at the correct angle and pressure.
When Riley Product Handling, which exports up to 80% of its products, took the strategic decision to dispense with out sourcing their MIG, TIG and MMA welding fabrication, they needed the appropriate equipment to undertake such work. Initially they used a portable fume extraction system with two extraction arms, before they decided to go for a fixed system with flexible extraction arms extracting fumes externally via a filter unit to save on space with no clutter and a much reduced noise level.
Tim Wilding, Engineering Manager at Riley Product Handling contacted Simon Plaister at Foster Industrial, his local welding equipment distributor in nearby Nottingham for advice. Foster Industrial is a distributor for flextraction Ltd, supplier and manufacturer of local Exhaust Ventilation (LEV) products and was asked as one of three bidders to submit a quotation.
The flextraction system was selected on the basis of design, price and communications. It comprised 5 x extended HPDs (Hood Positioning Devices) and 2 x 2m standard HPDs. Each extended HPD consisted of a 3m standard extraction arm and a 3m extension. All seven HPDs were equipped with epoxy painted black 150mm diameter flared hoods and assembled complete with wall mounting, control damper and with no internal components.
A TEKA 400V/50Hz ‘Filtercube 4H-4000’ centralised filter unit with a dust extraction efficiency of >99% to meet BGIA certification DIN EN ISO 15012-1 (Health and Safety in welding and allied processes) was used. Dedusting of the filter cartridges is done using a fully automated microprocessor Pulse Control. The ducting used in the project was manufactured from spiral galvanised sheet steel and was installed with inspection doors, flexible hose connections and supporting brackets.
The extended HPDs are used for welding, whilst the standard HPDs which are linked to a wet pre-separator system before joining the main ductwork, are used for grinding operations.
Tim Wilding said: “We fabricate our products using 1mm – 6mm mild steel and stainless steel, occasionally up to 10mm. Typical components are frames for conveyors and machines, tracks for vibratory conveyors, guides and guards. The main welding process we use is TIG welding, however MMA welding is used for high strength welds in vibratory troughs, whilst MIG welding is used on frameworks where large fillet welds are required.
We decided on the flextraction system because with ever increasing Health and Safety legislation, we thought it prudent to install a system that did not just meet legalisation but would be future proof. As it was, the installation was completed in a week, which was to the timescale quoted and compared to our existing portable units the fabricators’ working environments are significantly improved with reduced noise levels. The length and type of HPD are light in weight and are quick and easy to locate for the point of extraction where ever it is needed, which is exactly what we wanted.”
Lee Darton General Manager Products at Flextraction said: “Our fume extraction system is equipped with gate valves so it can be balanced. During commissioning, the system was tuned to achieve the legislative face velocities at each point of extraction, which was easily achieved as the system is capable of 8,000m3/h over 6 extraction points. In fact we were able to reduce the velocities to meet current legislative levels to reduce noise.”
Tim Wilding continued; “The system is inspected every week by the shop floor person responsible and there have been no issues. We encourage individuals to look after their equipment and report any faults, all of which are logged in a book, which is used as part of a safe contractor qualification.”
Overall the system was installed successfully and on time, meets all the extraction requirements of Riley Product Handling and the workshop environment has greatly improved.
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