Case Study - Fume Extraction
Merlin Diesel Systems
Merlin Diesel Systems are manufacturers of diesel fuel injection test equipment and repairers of diesel fuel pumps.
Problem
Merlin Diesel Systems were experiencing fume build-up issues within their two Bosch testing rooms which house performance rigs for bench testing repaired pumps. The rig is used to check pump performance on different speeds, right up to the maximum speed of the pump. This test creates hot, vaporous diesel fumes which are unpleasant and potentially harmful if inhaled.
Solution
JJ Ventilation designed and installed a ducted extraction system incorporating an axial flow fan and numerous extraction grilles. The grilles are positioned to draw fumes out of the test rooms before a build-up can occur. Ductwork then conveys the harmful fume to atmosphere via an axial flow fan and exhaust stack for rapid dispersal.
Replacement air enters the rooms via grilles in the factory partition wall.
An inverter is included to give flexibility in winter when the extract rate is reduced to prevent high heat losses. During the summer months, the system can be used on a higher speed to provide the required extraction capacity with additional background ventilation.
Testimonial
We wish to express our thanks for a superb job that works well. I think it would be impossible to criticise the standard of your work and except for those in the know, you would not know it was there.
Jonathan Chaytor
Merlin Diesel Systems
Rexam
Rexam are one of the world’s leading consumer packaging groups serving the beverage, personal care, healthcare and food markets.
Rexham Plastic Containers form plastic tubs and similar containers for the food industry at their large site at Deeside.
Problem
Significant fume emissions are produced from the high volume manufacture of rigid plastic containers across a number of process lines. The process is known as rotary thermoforming and combines plastic sheet extrusion and thermoforming in a single operation. Existing machine-based extraction systems proved inadequate and allowed the fume to spread and accumulate throughout the factory, creating a visible haze.
This fume build-up resulted in health and safety concerns and an oily, sticky residue on machine parts and fixtures and fittings.
Solution
Local exhaust ventilation is preferable for solving problems of this kind. Fume and contaminants are captured at or near the source and are thus prevented from passing into the working environment. Dilution ventilation systems, very often in the form of roof extract fans, are normally only used for fume control when local exhaust is impractical.
For effective fume capture at the Rexam process lines, a lightweight aluminium extract canopy is located above each machine structure. Exhaust ductwork runs to outside via individual roof-mounted extract fans. Canopy positioning and distance from the fume source is constrained by the machine platform; however, excellent extract performance is assured by bespoke canopy design and air flow and strip curtaining for additional containment as necessary.
The result is a much safer, brighter and more pleasant building environment for employees and visitors alike. The fume build-up has been almost eliminated, with a corresponding improvement in factory cleanliness.
Real Crisps
When The Real Crisp Company outgrew their building due to rapid growth in sales and production requirements, they opted to relocate to a new factory and entrusted
JJ Ventilation to handle a turnkey package for all their extraction and ventilation requirements for the new premises.
Problem
The Real Crisp Company had to relocate their factory whilst continuing production, which forced a staged installation of the main extraction systems. In addition, there were general ventilation and steam extraction issues at the new factory which needed to be addressed, and also flue duct requirements for the gas burner stacks for each fryer.
Solution
JJ Ventilation manufactured and installed individual extraction systems which were fitted above each of the crisp fryers to remove steam, grease and odour generated during the production process. Individual flue stacks were also installed at each fryer location to ensure the combustion gasses were exhausted safely to atmosphere. In addition to the fryer specific extraction systems, JJ Ventilation also installed general extraction systems to remove overspill steam and odours from the main production and wash-down areas. The extraction systems were complemented with the installation of several strategically positioned JJ Roof Inblo Units used to supply general ventilation and filtered make-up air back into the production area to offset the extraction volumes.
Key Requirements
- Specific fryer extraction.
- General factory extraction.
- Filtered fresh air inlet ventilation.
- Flue stacks from fryer gas burners.
- Steam extraction for tray-wash area.
Further Expansion
Following our initial successful installation, The Real Crisp Company expanded their production facility further leading to the purchase of additional fryers which consequently required extraction canopies and extraction systems. The management at The Real Crisp Company immediately instructed JJ Ventilation (International) Ltd to proceed with the works involved.
Testimonial
JJ Ventilation acted in a professional manner from handling the initial design concepts, through the site planning meetings, installation and final handover. The system was installed in a safe manner, on budget, & to the agreed timescales. The professionalism exhibited during this initial project was a major deciding factor in Real Crisps selecting JJ Ventilation once more to carry out the additional works for our recent expansion. I am very satisfied with the standard of work undertaken by JJ and will certainly consider them again for our continuing expansion plans.
Peter Menzies
Operations Manager
Real Crisps
