CONTINUOUSLY REMOVE LARGE QUANTITIES OF MATERIAL

CASE STUDY - Centralized vacuum system for polyethylene filaments

Textile industry businesses must manage production waste such as offcuts and scraps. In this scenario, it’s crucial to continuously vacuum large amounts of polyethylene filaments — a strong and flexible material frequently used in textile manufacturing as fibers and threads — without causing interruptions in the production process.

customer's need

Polyethylene filaments are a form of residual waste that, if not properly removed, can build up, block machinery, and lead to breakdowns and production delays. The customer needs to vacuum and collect large amounts of polyethylene quickly and without interruptions, ensuring the production cycle runs continuously.

our customized centralized vacuum system

To address this challenge, we designed a high-capacity custom suction system featuring two pre-separators. This setup enables the simultaneous collection and discharge of large amounts of polyethylene filaments, ensuring uninterrupted operation.

For maximum workplace safety and operator protection during routine maintenance, the system is equipped with an alarm that alerts operators when they need to move away from the machinery.

How does it work?

The suction system we developed features a high-performance suction unit, our three-phase Puma 18 industrial vacuum cleaner, and two pre-separators that operate alternately to ensure continuous production without downtime.

Efficient and Continuous Scrap Management

The core advantage of this suction system lies in its 2 pre-separators, which enable simultaneous suction and discharge: while one separator vacuums, the other discharges, ensuring seamless operation.

The switching interval between the pre-separators can be adjusted according to workload requirements, such as every 10 minutes.

This configuration guarantees a continuous, interruption-free work cycle. Given the large volumes of material processed, discharge is directed into spacious Big-Bags.

Overview of the Safety Features

To guarantee operator safety, the pre-separator discharge zones are secured with two gated cages. If a pre-separator is in operation or discharging, the gates lock automatically, restricting access during routine maintenance procedures. This condition is visually signaled by a system of four flashing lights — two positioned above the separators and two in the discharge area.

Pre-separator indicators: The lights turn red when the pre-separators are active and green when they are idle.

Discharge area indicators: The lights are red when the pre-separators are running and green when neither operation nor discharge is taking place. A green light indicates that the area is safe to enter.

When the light changes from green to orange, only 5 minutes remain before access is restricted, requiring personnel to leave the area.

If anyone tries to access the pre-separators by opening the gates while the system is running and the lights are red, a siren is triggered, and the entire system shuts down immediately.

The control panel allows configuring the operating time for each separator before switching, for example, every 10 minutes. However, if one separator reaches its maximum capacity earlier, two electronic level sensors automatically trigger an early switch.

pneumatic discharge

pre-separation and discharge area lights

level sensor

control panel 4.0

The system is designed for 4.0 remote management, enabling the transfer of operational data directly to the company’s ERP system.

This configuration allows monitoring of key performance indicators, process optimization, and data-driven decision-making to boost productivity.

The control panel streamlines operations with an intuitive interface, ensuring fast access to critical information and system adjustments.

discover our installation

vacuum unit puma 18

The suction unit chosen for this installation is the Puma 18, a powerful industrial vacuum cleaner with a durable side-channel turbine, capable of generating a maximum airflow of 520 CFM.

POWER 16.9 HP
FILTERING SURFACE: 7.000 IN2
CAPACITY: 46 gal

Due to its advanced features, the vacuum cleaner ensures high performance for continuous and uninterrupted operation.

Class M antistatic filter

completely grounded

side channel blower

tangential inlet

PRE SEPARATOR WITH PNEUMATIC DISCHARGE

In this setup, the two separators are aligned and connected to enable continuous and uninterrupted discharge. Each separator unloads the collected material into one-cubic-meter Big-Bags, offering high storage capacity and minimizing handling time. The entire system is fully grounded for maximum safety.

For more information about our central vacuum systems or to request a customized solution tailored to your industrial vacuuming needs, feel free to contact us for a free inspection!