to be overcome was the limited factory space which had been allocated for the new machinery . Plastratum designed a water spray cross transfer from leg one to leg two which enabled the installation to be fully installed with ease .
Each leg has a load / unload station enabling multiple , integrated programming of cleaning and chemical processing simultaneously , realising the benefit of increased productive output efficiency utilising our random-access software . Combined with SCADA and management data acquisition which is , linked to the company ’ s production server , this provides a powerful management and production tool .
Water discharge saving of 80 %
Water treatment is integral to the successful operation of this equipment . All rinse water must be less than 20 µ Scm-1 and sufficient to provide excellent rinse efficiency . Although space limitations ruled out double or triple counterflow rinses , there was an opportunity to provide rinse water recirculation .
This would enhance rinse water at the correct conductivity , with reduced discharge to foul sewer , thus dramatically reducing risk to the environment along with reducing treatment and discharge cost to the business .
A detailed evaluation of the parts and chemistry was undertaken to calculate the volumes of water required and suitability for recirculation , utilising ion exchange deionisation . This extensive evaluation showed conclusively in favour of water recirculation and provided a water discharge saving of over 80 % of the volume to drain . Therefore , there were consequential savings in effluent costs , both plant and on-going foul sewer costs .
The customer , unusually , had very limited additional electrical power within the factory where the installation of the new plant was to take place . Electrical heating would have exceeded the electrical capacity and a new cable supply would have to have been installed . This installation would have increased the project costs and seriously delayed the project , along with increasing the plant running costs using electrical heating .
Full in-depth feasibility study
Plastratum again undertook an in-depth feasibility study and was able to show the customer that a gas fired thermal fluid boiler and distribution system was a beneficial and cost-effective option which was advantageous to the installation and ideal for the customers ’ needs . It was shown that the payback on capital investment would be as little as one and a half years , comparing the electrical costs against the cost of gas , the quantity of which was more than an adequate supply within the factory .
The major benefits of Thermal Fluid heating systems are :
The system only needs once a year servicing .
It is non-corrosive unlike steam and medium temperature hot water .
It does not require water treatment or boiler blow-down .
There is no additional expense of chemical additions .
The fume extraction is a centralised common installation from both legs of the plant and supports the differential volumetric tank lid technology . The use of lids is instrumental in reducing the fume extraction volume using a turn down of 70 %. Therefore , it is not only a much-reduced plant sizing and factory footprint allocation when compared to open tank fume extraction , it also reduces the quantity of expensive heated factory air to atmosphere . Once again this is of great financial benefit for the customer as it reduces operating costs .
The company is headed by Mike Taylor , Managing Director , a specialist in Effluent Treatment and Rinse Water Recirculation systems , Roger Speck with over 40 years ’ experience in Chemical Engineering and Electroplating Equipment and Glenn Williams for fume extraction and odour control products .
Due to our continuous product development and in house design , coupled with a commitment to high quality and technical standards , we are able to secure total turnkey projects . We have demonstrated that we are able to design , manufacture install and commission complete plant , equipment and associated products which are providing major financial benefits for our customers .
Please call us if you have a project that might benefit from our expertise .
Mike Taylor - Managing Director .
Telephone : 0121 314 1191 Email : mike @ plastratum . com Visit : www . plastratum . com
Please visit us at Stand E13 , Surface World Live , March 2nd – 3rd 2022 . twitter : @ surfaceworldmag NOVEMBER 2021
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