PROCESS AUTOMATION
KEEPING UP TO SPEED
Joshua Evans MEng (Hons) IChemE, Applications Engineer and Head of BOFA Academy, explains the value of optimising fume extraction in an automated
manufacturing environment
s the march of automation continues across industry, all the enabling elements that contribute to the overarching productivity strategy need to align.
A
Laser technology is a case in point. Lasers play a key role in multiple processes, whether that’s the labelling and coding of fast-moving consumer goods, marking electronics components, cutting materials for packaging, or for powder bed fusion in 3D printing. Innovation in lasering continues apace, with
fibre lasers capable of very fast speeds, meaning that the rate of production of goods in, say, the food and drink industry, can be significantly increased.
It’s a technology evolution that makes the role of fume and dust filtration even more important, because with faster processing comes a requirement for particle extraction system and filter innovation to help keep production lines working at optimum speed and quality.
Depending on the process, canning line coding for example, lasers are known to generate airborne particles with the potential to be harmful to human health. The emissions caused by ablation can also settle on laser lenses if not appropriately controlled, which can in time lead to the distortion of the beam and a degrading of the mark being made. This can lead to product rejection and costly downtime.
Keep production lines moving This is why companies invest in fume and dust extraction technology, such as that developed by Donaldson BOFA, to help keep production lines moving and workplace environments safe for people by contributing to effective workplace atmosphere management. As a result, there is an increased reliance on automation and the role that operational data can play in enhancing productivity.
Automation enables the integration of lots of complementary systems to create one holistic solution – and fume extraction
18 NOVEMBER 2024 | PROCESS & CONTROL
technology is one important part of that architecture. In the case of lasering, this means designing filtration systems capable of capturing particulate at the point of emission, even on the fastest moving FMCG line.
It also makes the availability of performance data critical for each part of the manufacturing process which, in the case of fume extraction, means a particular
focus on system performance monitoring and reporting, smart airflow management and filter design and capacity.
This data is made available through Donaldson BOFA’s Intelligent Operating System (iQ), which responds dynamically as filters begin to fill to maintain the airflow needed to deliver the specified extraction performance. iQ provides a visual system condition read-out, along with independent filter status monitoring to enable operators both to order replacement filters and exchange them in a timely fashion, usually in step with maintenance schedules, to avoid the risk of unplanned downtime.
For example, Donaldson BOFA’s portable AD Oracle iQ is a global product – one system that caters for the world over. It offers clear and simple access to extended onboard data logs and real-time system condition visualisation for ease of use. Users can quickly review, for example, filter status, which can help head-off potential issues before they have an impact on production. This combination of downloadable data and visual read-outs makes diagnostics smarter and quicker and no longer relies on operator interpretation of data alone, thereby providing manufacturers with better information on real-time filtration performance.
Specifying the correct extraction system needs to take account of lots of factors. It’s not just about process speed.
At a basic level, manufacturers need to make reference to Safety Data Sheets to
The AD Oracle iQ is a global product - one system that caters for the world over
understand the workplace exposure levels and potential risks associated with the materials being worked in any given process. However, materials science is constantly evolving and certainly in the 3D printing space, new functional materials are regularly developed to exhibit specific characteristics, for example scratch resistance or tensile strength. And often there’s also a correlation between process temperature and the volume and type of airborne contaminant being emitted, so specifying the appropriate system geometry, airflow management and capacity and capability of multi-stage filtration is vital.
Assessing risk A well-designed filtration system starts with assessing risk and understanding the factors which may compromise performance, for example ensuring that particulate does not gather around the laser head, in hoses/ ducting or in filters. Any such build-up could contaminate components such as rollers or bearings, and impact on the quality of the mark or finished product.
A well-designed fume and dust extraction system will help companies achieve a compliant working environment while enhancing productivity. This requirement will only grow in importance as manufacturers seek to leverage the inherent business benefits associated with automation. BOFA
donaldsonbofa.com
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