Complete solution Press screen

  • 1 Chopper fan
  • 2 Chopper fan with wall platform und noise protection hood
  • 3 Filter fan
  • 4 Can-end shredder
  • 5 Material separation with two waste fractions for sorting
  • 6 Press screen scrap chute                                                             
  • 7 Baling press/crusher
  • 8 Centrifugal separator
  • 9 Rotational drum filter
  • 10 Shell press screen
  • 11 Die cutting press screen

Deltoid develops cost-efficient, energy saving and environmentally friendly turnkey solutions for pneumatic waster management – Made in Germany

This guarantees the minimisation of interface problems as well as a smooth total process.

 

Cost efficiency through maximum flexibility and reliability

Nowadays a wide variety of materials and material thicknesses must be produced with maximum flexibility and with minimal setup times. The punch waste amounts that hereby occur can no longer be rationally handled. With the installation of a modern press screen-extraction system the complete manual handling of the press screen disposal is removed. A completely crushed waste package falls out of the baling press in the waste container. This increases productivity and operational safety, and lowers risk of accident.

 

Ever increasing environmental and quality requirements in the recycling process requires unmixed waste sorting even in production facilities. This development shows that sorted production waste recycling is a perfect example of resource efficiency and economic value.

 

In the last years, the average punching speed has increased significantly. Similarly, the amount of punch waste resulting from the production process has increased in the same time / period. A complete overview of the total punching waste at all punching machines plays a decisive role here.

 

Scope of performance

Example 1 – Can industry

Shell press screen Old
Machine speed 250 Takte/min
Aluminium-Press screen 224 µ
Press screen width 130 mm
Press screen length 1.200 mm
Edge strip waste 282 kg/h
Shell press screen Modernised
Machine speed 450 Takte/min
Aluminium-Press screen 224 µ
Press screen width 130 mm
Press screen length 1.200 mm
Edge strip waste 596 kg/h
Extra waste 314 kg/h

 

Example 2 – Foil and paper industry

Die cutting press screen Old
Machine speed 180 Takte/min
Aluminium-Press screen 30 µ
Feed 100 mm
Press screen width 300 mm
Press screen waste suitable for production ca. 18%-25%
Die cutting press screen Modernised
Machine speed 380 Takte/min
Aluminium-Press screen 30 µ
Feed 200 mm
Press screen width 500 mm
Press screen waste suitable for production ca. 16%-24%
Extra waste suitable for production ca. 446 kg/h

 

The hereby resulting punch waste must not only be pneumatically gathered and transported, but also further processed, for instance in the baling press, in the press containers, in the waste containers or in the filter system.

To minimise the risk of a possible loss of production, parts of the press screen-disposal system must be modernised or re-designed.
It is immensely important to look at the whole extraction system here. The demand of maximum availability, production flexibility and economic efficiency places the highest demands on the optimal dimensioning and design of the total system, right from the scrap chute / suction nozzle 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 disposal systems offer multiple advantages here – modular, safe, flexible.

The modular and redundantly designed Deltoid complete systems can be integrated into a machine data logging system (e.g. Hydra-Manufacturing-Execution-System (MES)). This way, the performance of the extraction system is automatically set up for the respective production process with the use of state-of-the-art technology.

In case of production grade change, the diverter valve at the end of the feed pipe automatically switches to the required waste fraction.

This not only reduces setup times, but also ensures unmixed punch waste sorting while simultaneously reducing energy costs.

 

The producer therefore achieves high prices for his sorted scrap, while ensuring a significant increase in quality in the further recycling process.

The simple and cost-effective method of separating a wide variety of production waste stands for higher energy efficiency, cost-efficiency and short amortisation times for modernisations or new investments. The ROI (Return On Invest) is thus achieved much sooner.

 

Operating costs

Lowering operating costs through intelligent heat recovery

Generally, the transported air from the pneumatic extraction system is not further used. The released transport energy/ process warmth from the waste transport is usually directed out into the air, unused.

In order to ensure a balanced air quality in the production rooms, it can be important for the extracted air amount to be re-directed into the system. This can for instance take place using a cross-flow heat exchanger, enabling up to 80% of the energy in the outgoing air to be regained.

The yearly operating costs / investment costs for external ventilation systems can thus be significantly reduced.

 

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