Ready to Stop Equipment Failure and Save Thousands?
Project Background:
At Saica Pack’s Wigan site, Engineering Manager Tom Leyland wanted to stop the equipment damage caused by compressed air contamination. The printing machines rely heavily on pneumatics. The printers use small pneumatic clamps to open and close the feeding material to print. If compressed air contamination damages the pneumatic clamps, the machine will not function. The printer also uses digital web guiding, an automatic knife, and contact rollers, making the machine extremely sensitive to liquid water and oil emulsion fluids.
When the desiccant dryer failed, the site’s pneumatic machinery was most vulnerable to moisture exposure. When the dryer fails, the volume of liquid water that enters the pneumatic lines drastically increases. Despite installing conventional compressed air filters, water continued through the lines, causing extensive damage and downtime to the printer.
The site is also looking to scale up its production and will commission new pneumatic equipment, including printers, laser cutters, and core-cutting machines. Considering the sizable investment in pneumatic equipment the site wanted to make, the engineering manager sought a solution that guarantees protection for pneumatic equipment even when the dryer fails.
Summary:
Expel inline filters provide the site with the crucial reassurance that the printing machines remain protected even when the desiccant dryer fails.
Expel’s advanced filtration technology guarantees continual removal of contaminants, so it will never allow liquid water to reach the printing machine.
Expel’s patent-protected design uses physics to separate the air from contaminants and discharges them using a gravitational force. The result is a sustained high performance that does not diminish. Conventional compressed air filters contain disposable filter elements that trap contaminants in a mesh or sponge material. As they trap contaminants, they become less efficient, leaving pneumatic equipment vulnerable to contamination.
After installing an Expel unit before the printing machines, the engineering manager reported that Expel solved the problem. Expel was a far superior solution to any other inline filter the site had previously used. The 3-in-1 solution provided the site with a long-term and permanent approach to compressed air contamination.
As a result, the Engineering Manager was very keen to roll out several Expel units across the site. The site demands reliability and the best protection against liquid water, oil emulsion fluids, and solid particulates.
The Results:
- Reduced Downtime: The pneumatic clamps that open and close the feeding material to print no longer fail because of compressed air contamination. Therefore, Expel enables consistent and reliable performance, even when the site’s dryer fails.
- Reduced Costs: By eliminating moisture and dirt particles from compressed air lines, Expel reduces wear and tear, lowers maintenance costs, and extends equipment lifespan. The site now has fewer machine breakdowns and less downtime.
- Reduced Maintenance: No more unnecessary time is spent rectifying the problems caused by liquid water damaging the printing machines, including waiting for replacement parts to arrive and installing them. Expel inline filters are also maintenance-free, so the engineering manager no longer wastes time replacing disposable filter elements.
- Superior Equipment Protection: Expel ensures continual and reliable performance at the site by providing 99.999% efficiency.
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.