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AIR CLEANING
he increase in automation in manufacturing and processing industries has heightened the productivity gains associated with effective maintenance regimes. In many markets, such as FMCG (fast-moving consumer goods), manufacturing is a 24/7 environment, so for sure prevention is better than cure when unplanned downtime can be extremely costly, financially and in terms of customer relationships. And, when it comes to extraction systems that filter the fumes and dust emitted by certain processes, there is also operator health and wellbeing to consider should a blocked filter reduce airflow and filtration efficiency resulting in increased airborne contaminants being emitted. Filtration technology plays an important role in both keeping the wheels of industry turning and helping employers implement their workplace environmental health strategies. There are strict occupational limits in place covering a wide range of airborne emissions with the potential to be harmful to human health, whether from ink printing, lasering, additive manufacturing and electronics manufacture.
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So, fume and dust extraction systems, such as those manufactured by Donaldson BOFA, need to be maintained to a schedule that meets local production conditions, notably on how the emissions resulting from a given process and the materials being worked, impact on the saturation period – and therefore exchange frequency - of filters. At the same time, such systems can also be subject to statutory test and performance certification regimes. However, there are some easy, routine actions that manufacturers can employ to help keep systems working optimally. These include:
A daily visual inspection to flag up any equipment alerts or alarms that need to be investigated, linked for example to filter saturation levels.
A weekly supervisor-led inspection to look at the physical condition of extraction devices/nozzles/enclosures/hoses and check the system for damage, changes to configuration and correct operation.
A monthly check involving disconnecting hoses and checking for blockages, signs of dust or vapour/gas/odour carry over (remember to wear appropriate PPE).
An annual service by a competent engineer to include these regular checks plus inspection of filter condition, extractor motor and electrics. Replace any filters not exchanged during preceding 12 months.
Maintaining a log of actions and findings to help inform future preventative maintenance.
To help keep production flowing, Donaldson
BOFA’s Intelligent Operating System (iQ) is incorporated into many of its filtration systems.
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WELL-MAINTAINED MACHINERY MAKES FOR A SAFER, EFFICIENT AND PRODUCTIVE WORKING ENVIRONMENT
This sophisticated control platform will monitor system performance and filter condition, with an option to download data logs that can be shared remotely with Donaldson BOFA engineers for expert analysis and rapid response.
THE 1-2-3 OF FILTRATION Donaldson BOFA systems typically include a three-stage filtration set-up and not monitoring the rate at which these filters are filling up can have a detrimental effect on extraction performance. For example, if the activated carbon filter become saturated, gases will bypass this stage, with the potential to return into the working environment.
A tell-tale sign that the extractor needs attention would be when fume and dust is seen to ‘dwell’ within an enclosure rather than clearing through the extraction unit. In the UK, companies have a legally-binding duty to safeguard their employees by complying with HSG258 guidance for controlling airborne contaminants, which includes a 14-month local exhaust ventilation (LEV) recertification process for extraction technology. However, Donaldson BOFA advises scheduling this for 12 month periods to help avoid any unplanned downtime
By Joshua Evans MEng (Hons) IChemE, applications engineer and head of BOFA Academy
should an issue arise during the service. The guidelines state that a service should be carried out and tested by a competent engineer (often British Occupational Hygiene Society P601 certified). The process includes a professional assessment, system service and re- certification for compliance.
The precise service process will depend on the configuration and complexity of the system, but generally will include:
Full initial airflow and pressure measurement at appropriate capture/duct points to ensure compliance with HSG258 guidelines.
System checks to ensure everything is running to optimal performance.
A full LEV report detailing the test results and any remedial actions taken in the context of the workplace exposure levels that need to be met.
Guidance notes and advice on ways filtration performance might be improved.
Donaldson BOFA’s technical team is on hand to provide advice and information to help keep extraction systems in tip-top condition and mitigate the risk of unplanned downtime.
BOFA International
www.bofainternational.com
Summer 2024 UKManufacturing
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