Complete solution aluminium

  • 1 Chopper fan with wall platform and noise protection hood
  • 2 Chopper fan in pit                                              
  • 3 Chopper fan
  • 4 Foil cutter
  • 5 Material separation with two waste fractions for sorting
  • 6 Filter system                                                                                 
  • 7 Baling press
  • 8 Filter fan
  • 9 Foil separator machine
  • 10 Foil doubler
  • 11 Rolling mill for binder and foils
  • 12 Cutting machine for foil
  • 13 Cutting machine for binder

Deltoid develops cost-efficient, energy saving and environmentally friendly turnkey solutions fort the pneumatic waste disposal management – Made in Germany.

This guarantees the minimisation of interface problems and ensures a smooth overall procedure.

 

Economic efficiency through maximum flexibility and reliability

In the aluminium industry today, a wide variety of band and foil alloys need to be produced in a broad range of thicknesses and edge strip widths with a high degree of flexibility and low setup time.

Continuously increasing levels of environmental and quality checks in the aluminium recycling process require waste sorting also in production facilities.  The development shows that sorted production waste recycling is a perfect example for resource efficiency and economic productivity.

The packaging industry especially has a high sorting recycling potential, particularly in the area of aluminium foils. In recent years, the average machine speed of rolling mill facilities, foil cutter systems and winding machines has increased considerably. At the same time, the amount of trimmings resulting from the production process have also been increasing. The mass consideration of the total waste at all roll stands, cutting and winding machines play a decisive role here.

 

Scope of performance

The performance scope of Deltoid extraction systems
currently ranges from 6 µm to 900 µm.

Example 1

Foil cutter facility Old
Machine speed 800 m/min
Aluminium foil 6 µ bis 80 µ, double (160 µ)
Edge strip (Amount x Width) 2 x 30 mm, max.
Sections (Amount x Width) 6 x 10 mm, max.
Edge strip waste 1.244 kg/h
Foil cutter facility Modernised
Machine speed 1500 m/min
Aluminium foil 6 µ bis 80 µ, double (160 µ)
Edge strip (amount x width) 2 x 30 mm, max.
Sections (amount x width) 6 x 10 mm, max.
Edge strip waste 2.333 kg/h
Extra waste 1.089 kg/h

 

Example 2

Edge-trimming cutter Old
Machine speed 500 m/min
Aluminium foil 900 µ
Edge strip (amount x width) 2 x 30 mm, max.
Edge strip waste 4.374 kg/h
Edge-trimming cutter Modernised
Machine speed 900 m/min
Aluminium foil 900 µ
Edge strip (amount x Width) 2 x 30 mm, max.
Edge strip waste 7.873 kg/h
Extra waste 3.499 kg/h

 

These additional waste amounts must not only be pneumatically gathered and transported, but also be further processed in the recycling process, e.g. in the baling press, in the waste container or in the filter system.

To minimise the risk of a potential loss of production, parts of the edge strip disposal system need to be modernised or redrafted.

Here, an analysis of the whole extraction system is extremely important. When doing so, the demand for maximum availability, production flexibility and economic efficiency places the highest demands on the optimal dimensioning and layout of the total system, from the suction nozzle right up to the filter system with a heat recovery system.

 

A task that Deltoid has successfully been devoting itself to for decades.

Energy cost savings

Deltoid waste disposal systems offer a broad range of advantages – modular, safe, flexible

The modular and redundant designed deltoid complete systems can be integrated into machine data logging system (e.g. Hydra-Manufacturing-Execution-System (MES)). Hereby, the performance of the suction system is automatically adjusted to the respective production process using modern control technology.

In case of an alloy change, at the end the feed pipe built-in diverter valves automatically switch to the respective waste fraction.

This not only reduces setup time, but also ensures unmixed production scrap while at the same time reducing energy costs.

 

The producer therefore receives high prices for his sorted aluminium while at the same time significantly improving the quality in the further recycling process.

The simple and cost-efficient way to separate a wide variety of band- and foil alloys stands for higher energy efficiency, cost efficiency and short amortisation times for modernisations or new investments. The ROI (Return On Invest) is thereby achieved much sooner.

Operating costs

Lowering operating costs through intelligent heat recovery

Generally, the transport air volume in the pneumatic extraction systems is not further used. The transport energy / process warmth released through the pneumatic waste transport is usually directed into the air, unused.

 

In order to secure a balanced air quality in the production rooms, it can be important for the extracted air to be directed back in. This can occur for instance using a cross-flow heat exchanger. In this manner, up to 80% of the outgoing energy in the air can be retrieved.

The annual operating costs / investment costs for external be- and ventilation systems can hereby be reduced significantly.

Quality

Cleanly cut, visible quality

For fully wound coils, the quality of the cut is directly connected to the cutting and extraction processes.

A careful and thorough mechanical and electrical adjustment of the extraction system to the cutter is the prerequisite for optimal pneumatic gathering of the edge strips / trimmings.

This means that the early project planning plays a significant role in maintaining the highest production quality of the completely wound coil. At the same time, the facility operator profits from maximum flexibility for the production of a wide variety of tape and foil types at differing winding speeds. The perfectly set up extraction system rules out the need for an after-treatment of the coil.

Pictures