Industrial dust extraction systems: the challenge in the converting sector

Industrial dust extraction is an important component in production and processing processes in many industries.

Industrial dedusting systems, in fact, guarantee high standards of cleanliness, health and safety in the workplace. They also make it possible to comply with the strict environmental regulations in force and, last but not least, contribute to the quality of the final product, especially in certain areas.

In this article, we will offer a general overview of the industrial dust extraction industry. We will then focus on the converting sector in which Sorgato operates, presenting the challenges that companies have to face and the answers that our company offers.

Industrial dust extraction: what it is

As we have anticipated, the dust extraction sector provides solutions that are efficient in terms of results and ensures safety and regulatory compliance in the workplace. The systems, in fact, are designed to capture and remove airborne particles that are generated during industrial production processes, offering a series of advantages and responding to different needs of companies. These include:

• Increased operational efficiency. The presence of dust can impair the efficiency of machines and plants, causing malfunctions and unplanned and sometimes significant downtime. Dust extraction systems help keep production systems clean, reducing maintenance costs and improving overall productivity.
• Protection of workers’ health. Industrial dust extraction systems reduce operators’ exposure to potentially harmful substances in the work environment, preventing respiratory problems and other health risks. Over time, this reduces the incidence of acute or chronic illnesses, improving the well-being of workers and reducing related costs for the company.
• Compliance. Companies must comply with strict environmental and workplace safety regulations. Dust extraction systems allow companies to comply with these regulations, not only to avoid penalties, but also to make the environment safe for operators and the company. This is the case, for example, of the ATEX standard: all Sorgato industrial dust extraction systems are manufactured in compliance with this standard, to prevent the risk of explosion or mitigate its effects.
• Improved product quality. The presence of dust in the working environment can contaminate finished products. Dust extraction systems help to maintain high quality standards, guaranteeing final products that comply with the required specifications. We talked about it by presenting one of the projects we have carried out: thanks to Sorgato plants, the customer has recorded a decrease in the amount of powder present and a consequent improvement in the quality of the finished product.

Industrial dust collection systems, as can also be seen from the wide variety of Sorgato products and solutions, combine various elements. Among the most important are the different filtering systems: drum filters, water scrubber filters, bag filters, cyclone filters, based on the specifications of the system and the needs of the company and processes.

Companies in the converting sector mainly process paper fiber: due to its characteristics, this material generates a significant amount of dust during the various processing phases. The presence of a well-designed and functioning dust extraction system, therefore, is essential: not only to improve the working conditions and health of workers, but also to optimize the efficiency of production processes and reduce costs.

These elements offer companies a competitive advantage that is not negligible: and it is precisely on the issues of competitiveness and efficiency that Sorgato intervenes, in response to the requests of companies in the sector.

The challenges of the converting sector and Sorgato’s answers

Our company works with the declared goal of satisfying the needs of customers more and more effectively, offering tailor-made systems: from this goal come the innovations in Sorgato’s products and solutions. Recurring challenges faced  by tissue and converting companies include:

• Search for a balance between cost sustainability and plant performance. Many companies consider dust extraction systems to be a less priority investment compared to more strategic expenses. Sorgato responds by studying technical solutions that allow effective dedusting, in line with the required standards, at a reasonable cost.
• Request to install dust extraction systems not only along the line where the paper is processed but also in the corridor. Sorgato wins over the competition by offering solutions that make it easier for line operators to carry out cleaning and maintenance activities, reducing time and costs.
• Need to contain electricity consumption. In this case, we offer systems with fans sized in order to reduce the amount of energy needed to operate the dedusting system. At the same time, we introduce technical measures to maintain high performance, even with a lower air flow.
• Difficulty in correctly interpreting the working conditions of a converting line that is not yet in operation. If the line is already operational, the preliminary survey of the plant by our technicians is easier: critical issues are examined, identifying the points where more dust is generated and understanding how and where to intervene in a targeted manner. On new lines, where the plant has yet to be installed, the Sorgato team is in most cases able to predict where the dust emission will be concentrated and, with a good level of approximation, also how much dust will be generated.

Let’s take a closer look at this last aspect: thanks to the extensive experience gained in the field, our technicians can count on an excellent knowledge of the mechanisms of development and operation of processing lines. These skills also come into play when they are looking at new processing lines on which the plants have yet to be installed.

Based on the assumption of the amount of dust generated by the line, the proposed design will include an adequate number of dust hoods and a filter with a fan and motor sized suitably for the needs. These choices will make the cost/benefit ratio more sustainable: an important element, as we have seen, for companies in the sector.

Do you want to know the Sorgato solutions that help improve the operational efficiency of your company? Contact our offices.