Mining and Metal Manufacturing Case Study: Syspal Ltd

“The air dryer broke down and there was lots of water in the system, and this definitely saved the company a lot of money”

Rob Pooler – Maintenance Engineering Manager – Syspal Ltd.

About the customer

Syspal Ltd design and manufacture stainless steel and aluminium products for the food, pharmaceutical, veterinary and medical sectors. For more than 40 years Syspal have been a market leader because of the strong emphasis they place on design, craftsmanship and customer service. They supply stainless steel and aluminium products for various areas throughout businesses including washrooms, changing rooms, high and low care production areas, storage and offices.

Project Background

Compressed air dryers tend to break down from time to time which can result in large volumes of liquid water infiltrating the compressed air system which causes extensive damage to pneumatic equipment. This problem was a prime concern of Maintenance Engineering Manager Rob Pooler as the site had recently installed a brand new 15kW laser cutting machine. It is essential that this machine is equipped with the best possible protection against compressed air contaminants including liquid water, oil emulsion fluids and solid particulates because moisture and dirt can easily damage the laser head. A damaged laser head leads to expensive repair costs. For example, a replacement head for a 4kW laser cutter costs approximately £21,000. Therefore, the maintenance engineering manager knew that damage to the 15kW laser cutter would lead to even bigger financial consequences.

The site had also been experiencing issues with the deburring machine caused by moisture and dirt in the compressed air lines. The air jets on the machine are very sensitive to moisture and dirt and failures are extremely inconvenient. When the machine experiences a failure, a service engineer has to come out to rectify the problem and replace any extensively damaged parts. Meanwhile, the job of the machine needs to be done with manpower. Therefore, the efficiency of the site is greatly hindered.

Why did Syspal choose Expel?

“The directors are very happy”

Rob Pooler – Maintenance Engineering Manager – Syspal Ltd.

Expel is doing an excellent job protecting the deburring machine and the laser cutting machine. Since installing Expel, neither machine have experienced any problems with liquid water, oil emulsion fluids or solid particulates. Conventional compressed air filters contain disposable internal elements which reduce in performance over time, can never guarantee complete protection against contaminates, and generate ongoing costs through replacement filter elements. Therefore, the maintenance engineering manager wanted a product which would always ensure the pneumatic equipment was protected. Expel was the perfect solution. Expel offers a revolutionary approach to compressed air filtration. Instead of using inadequate disposable filter elements, Expel contains a filter element designed using Computational Fluid Dynamics which directs the compressed air contaminants out of the unit and into an automatic drain. The internal element of the filter does not need to be replaced and has been built to last. This is reinforced by the 10-year guarantee manufacturer’s warranty we offer on every Expel unit.


Reduced downtime

Reduces Costs

Increased site efficiency

Reduced maintenance


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