“The compressors with the refrigeration units weren’t doing a good enough job.” – Mick Abbott, Maintenance Manager, Wienerberger
Ready to Stop Equipment Failure and Save Thousands?
Project Background:
“When we tapped the pipe, we’d hear the ice rattling up the pipe, but nothing got through the Expel system, and the conveyors were fine.” – Mick Abbott, Maintenance Manager, Wienerberger
The Bishop Auckland site was experiencing prominent issues with liquid water in the compressed air system. The solenoid valves and conveyors were getting damaged, causing significant problems in the transfer area. This damage caused faulty operation, production downtime, and part replacement costs. Maintenance Manager Mick Abbott reported that the site is particularly prone to problems in the winter months. The liquid water in the lines would freeze, causing pneumatic equipment in the area to freeze and not function correctly.
Summary:
Previous attempts to deal with the problems caused by moisture included purchasing a compressor with a built-in refrigerant dryer. These built-in dryers provided pressure dew points of 3⁰C, creating severe limitations for the site. When the ambient air temperature dropped below 3⁰C, more water vapour condensed, meaning significant volumes of water would pass through to the airlines. Pneumatic equipment was then left vulnerable to extensive damage.
When the air reached the site’s transfer area, water vapour in the lines had already condensed to liquid water. Installing Expel filters at the point of use guarantees pneumatic equipment protection to an unrivalled standard. The mesh or sponge internal element of traditional filters gets overwhelmed by high moisture or particulate content. Failure to maintain efficiency means contaminants can pass downstream, leaving pneumatic equipment vulnerable to contamination.
Expel was the perfect solution because it ensured a high level of continual protection against three primary sources of contamination. Expel filters guarantee the removal of 99.999% of liquid water, oil emulsions, and solid particulates down to 1 micron. Therefore, the airlines in the transfer area will never have liquid water in the lines to freeze or cause damage.
Expel put an immediate stop to the problems the site was having, and the maintenance manager reported to us that:
“This is the first year we haven’t had ANY problems with water and ice in the lines, and it is all thanks to the Expel unit.” – Mick Abbott, Maintenance Manager, Wienerberger.
The Results:
- Reduced Downtime: Expel completely stopped the machines from freezing and being damaged by ice and liquid water. The conveyors could still operate, and the solenoid valves were no longer failing, no matter how cold outside.
- Reduced Costs: The site no longer spends money replacing moisture-damaged pneumatic equipment. Expel does not require replacement filter elements or maintenance costs.
- Increased Productivity: Expel filters are the only compressed air treatment method that has solved the issues Wienerberger was experiencing.
- Reduced Wastage: The Expel filter’s performance never drops below 99.999% efficiency, which means no more damaged pneumatic equipment goes to landfills. Expel stops ongoing wastage because it does not require any replacement elements.
Our team is ready to answer your questions.
David specialises in improving business efficiency. By building strong industry relationships, David ensures Expel’s revolutionary technology delivers real value to businesses.
With vast pneumatics knowledge, Johan specialises in on-site assessments to identify strategic installation points to maximise performance and eradicate contamination.
Lauren is a key point of contact for customers. She handles general inquiries and provides exceptional after-sales support, ensuring a smooth customer experience.