MODERNIZATION OF DUST EXTRACTION SYSTEM AND MATERIAL TRANSPORT FOR SIGNIFICANT ENERGY SAVINGS

We have completed a large modernization project for a major furniture manufacturer in Poland, upgrading an existing dust extraction and material transport system to improve energy efficiency, operational flexibility and safety.

The project involved replacing the customer’s existing pneumatic material conveying systems and extraction system equipment with new, high-efficiency and explosion-safe mechanical transport systems, baghouse filter, fans, rotary valves and cyclones.

Significant Energy Savings Through Mechanical Transport

In total, 370 m chain conveyors were installed for energy-efficient mechanical transport of the collected material. This includes a 130 m reversible conveyor from five existing large filters at the factory with the possibility to control with storage solution to transport to.

A key objective of the modernization was to reduce the energy required to transport collected material to the three silos at the facility. The previous pneumatic transport system relied on large fans and high volumes of air to move collected material over considerable distances, resulting in a high installed motor power.

By replacing energy-intensive pneumatic transport with chain conveyors, the new material transport solution has reduced the installed motor power required for material transport was reduced with 161.2 kW – from 170.7 kW to 9.5 kW.

And the benefits are also being seen in daily operation. According to feedback received after commissioning, the customer is experiencing energy savings that are even greater than initially expected.

Complete System Upgrade

The modernization project was engineered and supplied by Moldow Polska and includes:

• 1  Moldow MHL EXP Ex-certified baghouse filter with explosion relief panels
• 3 ExPSR Moldow JHM cyclones with explosion relief panels
• 4 Ex extraction fans
• 6 Ex chain conveyors with explosion relief panels
• 7 Ex-certified rotary valves
• 2 control panels for operation and advanced control of the complete system.

The result is a modernized system that has significantly reduced the power required for material transport while providing greater operational flexibility, updated safety measures and comprehensive equipment documentation.

Modernizing an Existing Production Facility

Modernization projects come with different challenges than installations in new production facilities. New equipment must be integrated with existing processes and infrastructure, often while production continues around the installation.

For this project, careful planning of the dismantling and installation sequence was therefore an important part of the solution. The existing systems were replaced in stages, allowing the customer to keep as much of the production running as possible throughout the modernization and minimizing interruptions to daily operations.

Updated Explosion Safety and Documentation

Energy efficiency was not the only reason for modernizing the existing installation.

Replacing the older filters, fans and cyclones also provided an opportunity to bring the dust extraction system up to current requirements with new, documented equipment designed for applications involving combustible wood dust.

The upgrade gives the customer a modern extraction and material handling solution with documented equipment and appropriate explosion-safety measures, providing a safer and more future-proof installation.

Proven Solutions for the Woodworking Industry

With decades of experience in dust extraction and material handling for the woodworking and furniture industries, Moldow develops both new installations and modernization solutions for existing production facilities.

This project demonstrates how upgrading older extraction and pneumatic transport technology can provide benefits beyond replacing ageing equipment. By evaluating how the material is transported throughout the system, it was possible to introduce a solution that combines reliable dust handling with substantially lower energy requirements.