CASE STUDY
Centralized Vacuum System for Polyethylene Filaments in the Textile Industry
Textile manufacturers deal with a constant flow of production offcuts and scraps. In this case, the customer needed to manage large volumes of polyethylene filaments—a strong, versatile material commonly used as fibers and threads in textile processes.
If these filaments are not removed continuously, they accumulate around the machines, clog equipment, and cause malfunctions and production slowdowns.
This case study explains how Depureco designed a customized centralized vacuum system with a PUMA 18 industrial vacuum cleaner and two alternating pre-separators to continuously collect polyethylene filaments without interrupting the production cycle, while keeping operators safe during maintenance.
Customer Profile & Application
Application: Continuous Collection of Polyethylene Filaments
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Sector: Textile manufacturing.
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Material: Polyethylene filaments, generated as offcuts and scraps during production.
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Requirement: Continuously vacuum and collect large amounts of filaments without stopping the line.
The filaments are considered a residual waste that must be removed promptly to avoid clogging machinery and impacting productivity.
The Challenge: Scrap Build-Up and Production Slowdowns
Polyethylene filaments present several challenges on the production line:
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Accumulation and blockages
If not removed regularly, filaments build up inside and around machinery, clogging moving parts, guides, and conveyors. -
Malfunctions and breakdowns
Clogged machines can malfunction or stop completely, leading to unexpected downtime and lost output. -
Need for continuous operation
The production line is designed to run continuously. Stopping frequently to empty containers or clear clogs is not acceptable. -
Safe maintenance operations
Operators must be able to access the discharge area safely when changing Big-Bags or performing routine maintenance.
The customer needed a vacuum system designed for continuous suction and discharge, capable of managing large quantities of filaments with minimal manual intervention and maximum safety.
Depureco Solution: Customized Centralized Vacuum System
To address these needs, Depureco developed a customized centralized vacuum system built around:
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A high-performance three-phase PUMA 18 industrial vacuum cleaner.
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Two pre-separators operating alternately for continuous suction and discharge.
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A safety system with cages and warning lights to protect operators in the discharge area.
This configuration allows the plant to vacuum large amounts of polyethylene filaments continuously, while automatically discharging them into Big-Bags without stopping production.
System Configuration & Operating Principle
Core Components
The centralized vacuum system for polyethylene filaments includes:
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PUMA 18 three-phase industrial vacuum unit
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Provides the suction power needed for continuous, heavy-duty operation.
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Serves as the main vacuum source for the entire system.
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Two pre-separators
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Installed upstream of the PUMA 18.
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Designed to collect large quantities of polyethylene filaments.
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Work in alternating mode to ensure uninterrupted suction.
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Big-Bag discharge system
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Collected filaments are discharged into large Big-Bags, ideal for handling big volumes of lightweight material.
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How the System Works
The operation of the system is based on the alternate use of the two pre-separators:
Continuous suction with alternating pre-separators
While pre-separator 1 is in suction mode, collecting polyethylene filaments, pre-separator 2 is in discharge mode, emptying into a Big-Bag.
After a set time, the roles are reversed: separator 2 starts suction, while separator 1 discharges.
Adjustable switching time
The switching time between the two pre-separators can be adjusted according to workload and production needs (for example, every 10 minutes).
This flexibility ensures that suction capacity and discharge cycles are optimized for the actual volume of filaments generated.
Continuous and uninterrupted work cycle
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Because suction and discharge alternate between the two pre-separators, the system provides a continuous and uninterrupted work cycle.
Even at high volumes, there is always one separator available for suction while the other is being emptied.
Final collection in Big-Bags
Due to the large amount of material, unloading is carried out in Big-Bags, which are ideal for collecting and transporting high volumes of light, bulky filaments.
This setup ensures efficient scrap management with no need to stop the production line to empty containers or clear clogs.
Safety System Overview
Protected Discharge Area
- The discharge zones of the two pre-separators are enclosed by cages with gates.
- When a pre-separator is in operation or in discharge mode, the gate automatically locks, preventing access to the discharge area.
This prevents operators from entering the area while filaments are being discharged into the Big-Bags, reducing the risk of accidents.
Status Lights and Access Management
A system of four flashing lights visually indicates the status of the pre-separators and discharge area:
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Pre-separator lights (2 lights above the separators)
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Red: the pre-separators are in operation.
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Green: the pre-separators are not operating.
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Discharge area lights (2 lights in the discharge zone)
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Red: the pre-separators are operating or discharging, and access is not allowed.
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Green: the pre-separators are not operating or discharging, and the area is safe to access.
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In addition, when the light changes from green to orange, only a short time (for example, five minutes) remains before access will be restricted. This warns personnel to leave the area before the system resumes operation.
This combination of physical barriers and visual indicators ensures that operators can perform routine maintenance and Big-Bag changes safely, with clear, intuitive feedback on system status.
Results & Benefits for the Textile Manufacturer
By adopting this centralized vacuum system for polyethylene filaments, the textile manufacturer achieved several key benefits:
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Continuous collection without production stops
Alternating pre-separators allow suction and discharge to happen in parallel, keeping the production line running without interruption. -
Efficient management of large quantities of filaments
The system is sized to handle high volumes of polyethylene filaments and discharge them into Big-Bags with minimal manual handling. -
Reduced clogs and machine downtime
Continuous removal of filaments helps prevent clogging and malfunctions, reducing unexpected stops and maintenance interventions. -
Safer operating environment
Caged discharge areas, automatic gate locking, and a clear light-signaling system protect operators during maintenance and bag changes. -
Cleaner, more organized work areas
Filaments are collected and contained efficiently, improving housekeeping around the machines and overall plant organization.
Why This Matters for Textile & Fiber Producers
For textile and fiber producers, production waste like trims, scraps, and filaments is a constant challenge. Without a proper vacuum system:
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Waste accumulates quickly around the machines.
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Clogs and malfunctions become more frequent.
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Production has to stop for manual removal and cleaning.
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Operator safety can be compromised during handling.
A centralized vacuum system with alternating pre-separators is ideal when:
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You need to collect large quantities of light, bulky material (like filaments and trims).
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You want to avoid interrupting the production process for discharge.
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You need to guarantee safe access during maintenance through barriers and clear signaling.
Talk to Depureco USA About Polyethylene Filament & Scrap Solutions
If you operate in the textile industry and need to manage polyethylene filaments, trims, or other production scraps, Depureco USA can help you design a centralized vacuum system tailored to your line.
We can:
Evaluate your production layout and waste streams.
Size the suction unit and pre-separators for continuous operation.
Integrate safety systems, Big-Bag discharge, and control logic according to your standards.
Get in touch with Depureco USA to discuss your application and build a safe, efficient solution for managing polyethylene filaments and textile scraps.