CASE STUDY
Industrial Dust Collector for Aluminum Swarf on CNC Cutting Machines
Aluminum cutting operations—especially for profiles, frames, and fixtures—generate a continuous stream of swarf and residues. If this waste is not collected at the source, it accumulates around the cutting area, causes machine malfunctions, and slows down production.
For machines like cutting saws and CNCs, relying on manual cleanup or occasional vacuuming is no longer enough. The most effective way to keep the cutting process under control is to connect a dedicated industrial dust collector that continuously extracts aluminum chips during cutting.
This case study shows how Depureco helped an aluminum profile cutting company manage a large volume of aluminum swarf with a customized dust collector, improving productivity and minimizing downtime.
Customer Profile & Application
Application: Collection of Aluminum Swarf
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Application: Collection of aluminum swarf generated by aluminum cutting processes.
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Process: Cutting aluminum profiles on a large CNC cutting machine.
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Material: Aluminum chips and fine swarf created during cutting.
The company needed to extract chips continuously from the machine to avoid buildup on the cutting table, along the saw area, and inside the machine structure.
The Challenge: Large Amounts of Aluminum Swarf
The main challenge was collecting a large amount of aluminum swarf directly from the CNC cutting machine without interrupting production.
Key issues included:
Waste buildup around the machine
Without continuous extraction, aluminum chips accumulated in the cutting area, increasing the risk of jams, tool wear, and malfunction.Maintenance and downtime
Frequent stops were needed to manually clean the machine, leading to:Higher maintenance costs.
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Lost production time.
Product quality
Chips and swarf around the cut zone could affect:Cut precision.
Surface finish of the profiles.
Overall quality of the final product.
Workplace cleanliness and safety
Loose chips on the floor and around the equipment created a messy, less safe working environment.
The goal was clear: collect a large quantity of aluminum swarf, improve productivity, and minimize downtime by installing a dedicated extraction system on the cutting machine.
Depureco Solution: Customized Dust Collector for Aluminum Swarf
To solve this problem, Depureco developed a customized industrial vacuum solution designed specifically for aluminum cutting on a large CNC machine.
The solution is based on a dust collector with a powerful electric fan and pneumatic discharge hopper, engineered to:
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Continuously extract aluminum swarf directly from the cutting area.
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Handle a significant volume of chips.
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System Configuration & Operating Principle
Customer Need vs Depureco Solution
Customer’s Need:
Vacuum a significant amount of aluminum chips generated by a large CNC cutting machine, continuously and directly from the machine.
Depureco’s Customized Solution:
A dust collector system including:
A powerful electric fan.
A pneumatic discharge hopper.
Double discharge with electropneumatic butterfly dampers.
M-class star filter with large surface area.
This configuration is designed to handle heavy chip loads while maintaining stable airflow and easy discharge.
Key Technical Features
From the case study, the main technical features of the customized dust collector are:
- Power: 4 kW.
- Provides the negative pressure and airflow needed to capture swarf at the cutting point and transport it through the ductwork to the hopper.
- Filter surface: approximately 110,000 cm².
- Filter type: M-class star filter, suitable for fine aluminum dust and swarf.
- Large surface area ensures low pressure drop and consistent performance, even with heavy loading.
- Handles the collected aluminum chips and discharges them automatically.
- Reduces the need for manual emptying and supports continuous operation.
- Two discharge points controlled by electro-pneumatic butterfly valves.
- Allows flexible discharge strategies (for example, into containers, conveyors, or chip trolleys).
This combination of strong suction, large filtration surface, and automatic discharge makes the system ideal for intensive aluminum cutting operations on CNC lines.
Integration with Aluminum Cutting Systems
Direct, On-Board Extraction
The dust collector is integrated directly with the CNC cutting machine:
Suction points are placed close to the blade or cutting zone.
Chips and swarf are captured at the source, before they spread around the machine.
The system runs continuously during cutting operations, preventing waste buildup.
Compatibility with Different Cutting Machines
Beyond this specific CNC installation, Depureco’s vacuum solutions for aluminum swarf can be installed on:
Single-head cutting machines.
CNC machining centers for aluminum profiles.
Automatic saw machines.
Large double-head cutting machines.
This makes the approach scalable across different cutting lines and plant layouts.
Results & Benefits
For the Aluminum Profile Cutting Company
With the customized dust collector in place, the company achieved several important results:
Reduced Maintenance Costs and Downtime
Continuous extraction of aluminum swarf greatly reduced manual cleaning around the machine, leading to:
Fewer stoppages for cleanup.
Lower maintenance hours and associated costs.
Improved Productivity
The cutting line can run for longer without interruptions, as chips are evacuated in real time during operation.
Better Product Quality
Cleaner cutting areas mean:
- More stable cutting conditions.
More consistent cut quality and surface finish.
Less risk of swarf damaging or scratching profiles.
Clean and safe work environment
Less swarf on and around the machine contributes to:
A tidier workspace.
Reduced slip or trip hazards.
Improved operator comfort and safety.
Overall, the solution helped the company collect all aluminum swarf and avoid machine downtime, exactly as required.
Why This Matters for Aluminum Profile & Frame Manufacturers
Manufacturers of aluminum profiles, windows, doors, and frames face similar issues:
High volumes of chips and swarf during cutting.
Pressure to maintain tight tolerances and high-quality finishes.
The need to reduce unplanned downtime and maintenance costs.
A dedicated industrial vacuum solution for aluminum cutting helps you:
Keep cutting machines cleaner and more reliable.
Reduce manual cleaning and maintenance interventions.
Improve final product quality and consistency.
Maintain a cleaner, safer work environment for operators.
Whether you use single-head saws, double-head cutting machines, or large CNC lines, a properly sized dust collector can make a measurable difference in your productivity.
Talk to Depureco USA About Aluminum Cutting Solutions
If you operate aluminum cutting lines or CNC machines for profiles and frames, Depureco USA can help you design the right industrial vacuum system for aluminum swarf.
Get in touch with Depureco USA to discuss your aluminum cutting application and build a cleaner, more efficient cutting process.
Evaluate your cutting machines and chip volume.
Recommend the most suitable dust collector or high-vacuum solution.
Design custom discharge systems and integrations for continuous, on-board extraction.