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  • Plant-related Combustible Dust Dangers - One Point Lesson

    What are the specific plant-related dangers of combustible dust? Facilities that process combustible dust may be unaware that combustible dust is accumulating in and around the ceiling and overhead horizontal surfaces and structures, behind walls and other enclosed areas. The potential for a catastrophic event increases over time for reasons such as combustible material contamination. Facilities that process multiple types of combustible dust have greater potential for deflagration or rapid expansion of gases that develop into an explosion due to the combined chemistry between various compounds and types of combustible dust. Facilities that manage combustibles in proximity to other processes where heat, moisture, chemicals, and incompatible reactive materials may be at greater risk for a catastrophic event. Depending on the dust explosivity category, the plant may be severely damaged or destroyed by the explosive force of the fuel whether from low or high Kst values. For example, fiberglass gel coat dust has a higher explosivity than wood dust or grain dust. Kst is the rate or velocity of burn for the material. Black powder burns at a rate of 500 to 200 feet per second. Kst is established while evaluating the explosivity of the dust under laboratory conditions

  • Are you able to centralize a vacuum indoors?

    One Point Lessons All Industrial-Duty vacuum cleaning systems properly designed and manufactured can be centralized either indoors or outdoors if the manufacturer has taken this aspect into account during the engineering process. HEPA–certified, high-efficiency particulate arrestance filters are an absolute must when using vacuum cleaners indoors. HEPA filters must be matched to the maximum flow of the vacuum exhauster. In addition to combustible dust, employees are sometimes exposed to hazardous dust or HAPS referred to as hazardous air pollutants the industrialized vacuum cleaner can handle. Additionally, most factories emit dust and debris from specific manufacturing operations that can infiltrate other critical processes. The vacuum system (low volume high pressure) can be fitted to these operations to capture quality killing particulates from affecting in-process or finished goods. Vacuum as a utility. Vacuum cleaning systems equipped with this capability can be adapted to “lift” material over 100 feet vertically thus performing double or triple duty as a bulk lifting or material transfer tool for large amounts of material accumulations on horizontal surfaces or large piles of steel shot or even powdered tungsten weighing 1200 lbs./cu ft.

  • Air Dynamics Q&A: 3 Questions many companies should ask to succeed with a central vacuum unit:

    One Point Lesson: 3 Questions many companies should ask to succeed with a central vacuum unit: Q. How do I know if I need PTFE filters or polyester filters? A. Filters are selected based on the type of material collected. PTFE is a plastic coating bonded to the base polyester media to enhance filter performance. Polyester felt or spun-bond media is the typical go-to for most applications. Q. What type of metal tubing should be used for stick material? A. Vacuum systems are usually deployed using galvanized coated tubing. Other materials such as aluminum and 304 stainless steel are selected based on the application's environmental or sanitary requirements. Q. How much maintenance does an Air Dynamics Central Vacuum need? A. Typically 8 to 25 hours a year. The maintenance primarily includes filter changes and general performance upkeep.

  • Why centralize a housekeeping vacuum cleaning system?

    One Point Lesson: Reasons to centralize a vacuum cleaning system: 1. High-value plant floor space unencumbered by portable vacuums. 2. Minimizes risk of employee exposure to fire, explosion, or hazardous materials. This allows for minimal exposure to hazardous material in the plant. 3. Flammable material can be conveyed outside to a single location minimizing the chance fire can develop at multiple indoor plant locations. 4. Reallocation of employees from waste handling back to production.

  • Case Study | Silica Containment & Control

    OVERVIEW Air Dynamics Industrial Systems Corporation manufactures an industrial dust collector ventilation system for PPG. The dust collector was designed to be used by their workers to reduce personal exposure limits for airborne nickel dust in their factory while simultaneously protecting the workers by utilizing silica dust containment. THE APPLICATION Air Dynamics Industrial Corporation was approached by PPG Industries for assistance in complying with OSHA mandates by designing and installing an industrial ventilation system for their process. PEL (Permissible Exposure Limit), or Threshold Limit Value for OSHA, levels of heavy metal in their Carlisle facility were concerning, and PPG wanted to be sure safety was a priority. Heavy metal or nickel dust is known to affect lung function, cause cancer, and possibly even death depending on the extreme levels of exposure. OSHA has a set of guidelines and standards that are to be used wherever employees are being exposed to these toxic dusts. (1) THE CHALLENGE PPG, formally known as Pittsburg Plate Glass Co., was first founded in the late 1800s with a focus on innovation and quality. During WWII, PPG was a premium manufacturer for the military due to its large facilities and numerous employees. PPG has had its hand in many products in a variety of industries such as laminated aircraft glass, solar collectors, synthetic printing, and athletic footwear just to name a few. PPG continues to be a leader in their industry while staying true to its founder’s notion of, “Bring innovation to the surface”, by continuing to improve its products and facilities. The major challenge faced by PPG was a high amount of silica dust being produced in their glass-cutting process. Glass, like many materials used in Facility Before AD Source Capture Hood industry such as cement, ceramics, and abrasive blasting, produces silica dust. Silica is known to cause silicosis, a deadly and debilitating lung disease. (2) Controlling worker exposure in accordance with OSHA’s occupational health regulations requires the following three conditions be met: airborne dusts (silica in this case) are below or at PEL (TLV) permitted levels, flammable or explosive vapors must be controlled, and oxygen levels need to remain above or at the required threshold for employee safety. In this case, the first and second conditions required mitigation and therefore needed to be reduced as quickly as possible. PROVIDING THE BEST SOLUTION When contracted by PPG, Air Dynamics begins its systematic adustpproach to solving a customer’s challenge. Air Dynamics is a turn-key manufacturer, which means the project is taken from concept to installation by Air Dynamics’ project managers. An initial site visit assessment is conducted to determine the exposure assessment and risk analysis. In addition, the project managers focus on not just the main problem for the client but also determine other factors that may improve the overall process. Using the information gathered from site visits, a preliminary design is presented using 3D Auto CAD and CFD simulations to determine the most efficient method. Once the client has reviewed and approved preliminary designs, the project manager works with the design team to produce a detailed concept design. The process then moves to fabrication. Once the system is ready, the fourth phase begins which consists of the installation, start-up, commissioning, and training. The final step is the hand-off, where the project manager walks through the operations and maintenance with the facility’s operator, and training necessary for operation, followed by an industrial hygiene retesting. Air Dynamics supplied PPG with a cartridge dust collector system to handle their silica dust challenge. The site visit by Air Dynamics’ engineers revealed uncontrolled dispersal of silica dust at the saw blade which spread throughout the facility. A general exhaust system would not be sufficient to maintain safe PELs. This led Air Dynamics’ engineers to select a localized exhaust system featuring an enclosed source capture hood. The system was designed with 2000 CFM capacity and two 24” x 24” HEPA filters functioning as safety filters, or final filters. These HEPA filters are extremely efficient, capable of 99.97% efficiency at .3 microns. The source capture hood was designed with a 3D Auto CAD program to ensure proper fabrication and installation. The hood itself was a three-piece hinged hood that was specifically designed to control the grinding and cutting of plate glass. The design for the hood was engineered to not interfere with the cutting cycle’s movement or accuracy. The source capture hood of the ventilation system was uniquely constructed with a one-inch gap in between the conjoining walls which is where the suction air and the dust are conveyed. This design element was crucial in the overall design of the ventilation system because, without it, there would be higher exposure to silica and nickel dust when cutting the glass. The fan was selected to match the system resistance (total system effect) to ensure that pickup velocity was sufficient. The enclosed hood was attached to industrial ductwork that transports the silica and nickel dust to the dust collection unit located away from the source. All ductwork was designed per SMACNA guidelines to prevent failure due to the cutter bridge movement and particle abrasion. The dust collector itself was equipped with features to improve the process at PPG and ensure easier maintenance. The collector was supplied with a drum cover, hose, and clamps to retain the collected material. A differential pressure switch was installed to alert operators when filter differential levels are at capacity. This alert feature included a flashing annunciator light on the control panel. The control panel itself is a NEMA 12 combination starter panel that integrates a 10 HP air mover separate fusing for all motor loads, start and stop buttons, and running indicator lights. Additionally, two Magnehelic gauges were installed on the door panel to assist the operator in monitoring system performance. The overall dust collector design and operation are very reliable, and maintenance can easily be conducted with basic hand tools. After the installation and startup of the industrial ventilation system, the employee exposure was reduced to acceptable levels per an industrial hygienist test protocol. CONCLUSION The industrial ACGIH-certified ventilation system was designed to reduce the fugitive silica dust as the flat glass was being cut in the Carlisle factory. Air Dynamics was contracted and successfully helped PPG with this issue by designing a complex ventilation system that would perform its job to the fullest while not disturbing the other machines that were already in place. With the new ventilation system, the PPG facility became a safer working environment and a better production facility. ABOUT AIR DYNAMICS Founded in 1991, Air Dynamics Industrial Systems Corporation designs and manufactures turnkey Industrial Vacuum Cleaning Systems, Portable Industrial Vacuum Cleaners, ACGIH Certified Industrial Ventilation Systems and Pneumatic Conveying Systems. Phone: (717) 854-4050 Email: sales@airdynamics.net Website: https://airdynamics.net (1) For more information on Silica dust and Nickel and the health effects see OSHA’s website https://www.osha.gov/SLTC/metalsheavy/nickel.html (2) See https://www.osha.gov/dsg/topics/silicacrystalline/ for details

  • Case Study | Industrial Lint Removal

    OVERVIEW The Peppermill Casino in Reno, Nevada was in need of a lint filtration system to handle its heavy-duty laundry operation. They contacted Air Dynamics who was able to provide a superior LRS II system that filters all lint prior to exhausting into the facility's ducting. THE APPLICATION Peppermill Casino in Reno Nevada was concerned about accumulating too much textile lint from their continuous laundry and operations. Their current industrial lint removal system was inefficient and maintenance-intensive. With the near 24/7 operation at the Peppermill Resort, the volume of particulate, and the fine grain nature of the lint, caused it to pass through the mesh screen in the outdated lint systems. Realizing the seriousness of the issue, such as the increased risk of fire, the management at Peppermill worked with Maxwell Mechanical and Air Dynamics to find a solution to their challenge. THE CHALLENGE Peppermill had new ironers that generated more lint into the production area, creating a fire hazard. While the laundry facility was still safe for the time being, prolonged use of the current system could lead to a fire or poor working conditions. Initially, Air Dynamics’ engineers were hoping to perform a retrofit of the old lint removal system. This sometimes is more cost-effective than installing new equipment. However, due to the design limitations of the prior system and its’ inability to handle the output of the laundry/dryer process at Peppermill, it was determined that the entire old system would need to be replaced with more efficient units. Air Dynamics’ engineers recommended the advanced LRS II designed by Air Dynamics to tackle filtration in heavy-duty laundry applications. Already proven in high-volume laundry facilities and marine applications the LRS II is a proven effective solution for minimizing the chance of fire in the exhaust (ducting) systems. PROVIDING THE BEST SOLUTION Air Dynamics performs a ACGIH certified industrial ventilation risk assessment and analysis for each project. This begins with a site visit. Air Dynamics employees visited the Peppermill Casino and took detailed measurements of spacing, laundry system specifications, and dryer details. It is during this phase that additional inefficiencies or issues that may have been previously unknown to the client are identified. Noticing these details is what sets Air Dynamics apart. The solutions are not off-the-shelf, or out-of-the-box. Air Dynamics’ systems are turn-key and M.T.O (made-to-order) so they focus on the entire process to ensure optimal efficiency and performance. Therefore, the comprehensive site visit is essential to the project and is the first step to ensuring a complete solution to the challenge. This is combined with careful research conducted on the dryer and ancillary ventilation systems. Research on the performance of the dryers is critical to match with the lint removal systems capabilities. If it is too small, the system will not handle the quantity of lint being produced in the process, and if it is too large the power requirements will cause wasted energy expenditures. Once the site visit and research were conducted, Air Dynamics proposed their LRS II designed to integrate seamlessly into Peppermill’s laundry system. The proposed design featured the LRS II with a total exhaust value of 12,000 CFM to collect lint for the two Chicago Ironers – Models 3200 & 5200. Each of the LRS II’s feature filters with 99.97% efficiency at one-half micron. An example of the advanced capabilities of the LRS II is obvious when we compare the standard 200 mesh filtration of most lint systems to the LRS II. 200 mesh, or 74 microns, filters material that is about the size of a grain of sand. The LRS II’s filters operating at 0.5 microns are 400% more efficient. This level of filtration can capture bacteria and other pathogens, as well as all lint passing through the system. The lint removal efficiency was optimized at Peppermill by installing compound hoods over the ironers to capture the lint at the source. These special hoods were powered by a boost fan that collected lint into the capture hoods. All the LRS II modules were controlled by a control panel that had both automatic and manual control. The control panel also featured a rotary disconnect for safety. The entire system was connected via ACGIH-certified ventilation ducting and capture hoods designed to transition the dirty air stream through the LRS II filters and exhaust clean air into the existing ductwork of the Peppermill facility. It is critically important when venting highly flammable lint into ducting that passes through the interior of a structure to remove any residual material. Once the LRS II modules were installed the Air Dynamics team followed through the turn-key process by overseeing start-up and commissioning of the system. After determining satisfactory results, Peppermill was provided with a full manual and training by Air Dynamics’ engineers to facilitate full support for future operations. CONCLUSION Air Dynamics successfully provided a customized LRS II system to mitigate any lint from the Peppermill Casino laundry area. Compared to alternative systems, the LRS II outperforms other lint filter systems. This is due to the high filtration efficiency. ABOUT AIR DYNAMICS Air Dynamics Industrial Systems Corporation was founded in 1991 and designs manufactures, and installs industrial portable and central vacuum systems, environmental test chambers, pneumatic conveying, and industrial dust collectors, and other air & material moving systems. All projects are turn-key, where a project manager follows the project from conception and design through installation, commissioning, and start-up. Visit us online to view our successful installations on a global scale. See what we're capable of online or give us a call to discuss your specific air and material moving challenge. Phone: (717) 854-4050 Email: sales@airdynamics.net Website: https://airdynamics.net

  • Case Study | Dust and Lint Control

    OVERVIEW Milum Textile Services approached Air Dynamics Industrial Services for a specialized central and portable vacuum system. The system was built to accommodate the specific needs regarding Milum's lint and dust cleaning issue. Due to Air Dynamics careful design and engineering, all specific needs of Milum were met. THE APPLICATION Milum Textile Services is located in Phoenix, Arizona. The company's main focus is on the commercial linen and laundry service throughout most of Arizona, including many significant health care providers. Milum ensures a clean process that removes dangerous biohazards commonly produced in medical environments such as hospitals, surgery centers, hospices, and many other types of organizations. Specifically, Milum was concerned about recent health incidents involving hospital linens. The president of the company, Mr. Craig Milum heard about the Children's Hospital in New Orleans, LA, suffering five independent child patient deaths to an initially unknown infection.(1) The cause was determined five years later to be airborne soil particles and lint contaminated by a potentially infectious mold. Due to cleaning procedures employing widespread use of compressed air at this facility, the hospital's "clean" processed linens were contaminated. Since Milum deals with a large amount of hospital and health care linens, they wanted to be proactive in preventing catastrophes like this in the future by improving their cleaning methods. THE CHALLENGE Air Dynamics Industrial Systems Corporation was approached by the president of Milum Textile Services, Mr. Craig Milum, with a need for a more efficient and adaptable vacuuming system. Due to the high volume of linens cleaned daily in the plant a significant quantity of lint accumulates. Milum is regularly cleaned with compressed air to "herd" dust, followed by a manual sweep to remove the settled particulates. However, the use of compressed air even on a managed and controlled basis launched some dust and lint into the air introducing the potential hazard of re-contaminating clean, processed re-usable linens. Also, in the course of a day besides housekeeping activities, the processing of linens, airborne lint was generated some of which accumulated on overhead surfaces until removed by routine, conventional cleaning. Besides the potential threat to clean linens, the laundry and housekeeping practices increased the risk of fire.(2) Milum sought out a viable solution to their health and safety risks. After researching and contacting industrial vacuum companies, Milum chose Air Dynamics due to their extensive knowledge of the field. Craig Milum commented that "Daniel Lehman was several times more knowledgeable [than the competition]" and "I took it as he's probably as knowledgeable as anybody in the country, actually, about the use of industrial vacuums". In addition to expertise, the vacuum system would need to drastically reduce the time it would take to perform the cleaning process. Air Dynamics was able to provide a versatile central and portable vacuum engineered specially for Milum's needs. PROVIDING THE BEST SOLUTION When approached with the lint problem at Milum Textile Services, Air Dynamics recommended their versatile PLECO HEPA Vacuum system. The PLECO incorporates several U.S. patents. It also features an innovative vacuum system design that performs a variety of applications. One of the key features of the PLECO system is its adaptability. This is critical due to the wide range of hazardous dust, lint, and particulates generated in many factories and industries. In the case of Milum Textile Services there were three major requirements that the PLECO needed to meet to perform its task properly: Vacuum up all particulates in the facility (i.e. lint and dust from textiles) Perform its duties in an easy and accessible manner Provide significant reduction to the maintenance of the cleaning facility Additionally, design the PLECO to support two simultaneous users to increase productivity In order to meet the needs of Milum Textile Services, Air Dynamics Industrial Systems Corporation engineered a PLECO vacuum system specifically for Milum. The PLECO system installed featured an 11.5 horsepower vacuum motor coupled with approximately 350' run for the vacuum line. The central system was connected to twenty-five individual 2.125" drops spread throughout the facility 30" above the floor. In order to provide ease of access and full coverage of the facility the drops were connected with an interchangeable 10' hose that spanned the distance between each drop-down tube. The operator can suction dust with a flexible 25' housekeeping hose. This hose can be equipped with a variety of nozzles and brushes capable of handling Milum's range of cleaning operations. As a holistic system, the PLECO provides a high-efficiency vacuum cleaning system with its primary filtration maintaining a 99.97% efficiency @ 1/3 micron. The combination of a centralized vacuum supplemented with a convenient and efficient portable unit provided the necessary versatility for proper maintenance at Milum Textile Services. In addition to the adaptable PLECO system, flooring to optimize the cleaning process Air Dynamics recommended that Milum polish their flooring to optimize the cleaning process. The polish prevents lint from clinging to the floor and allows the PLECO system to function at a higher capacity. CONCLUSION The PLECO Portable HEPA Vacuum System easily met the demands of Milum Textile Services. The adaptability of the PLECO was demonstrated once again by applying the right equipment to the precise needs of the customer. The president of Milum Textile Services, Mr. Craig Milum praised the efficiency of the PLECO HEPA Vacuum system stating that: "Average time spent with compressed air "herding" daily is estimated at two and a half hours. Now we are doing the same areas with much higher quality in about 40% less time. We anticipate continued significant improvement during the next three months as we develop better techniques and tools" Less wasted time and higher efficiency mean greater fiscal gains. Milum Textile Services was able to realize these gains while simultaneously providing a cleaner and safer work environment for its employees. Clearly, the PLECO HEPA Vacuum System was the right choice for Milum, and very well could be the one for you too. Please consult our knowledgeable sales staff with questions or for a quote. ABOUT AIR DYNAMICS Founded in 1991, Air Dynamics Industrial Systems Corporation designs and manufactures turnkey industrial air cleaning systems. See what we're capable of online or give us a call to discuss your specific air and material moving challenge. Phone: (717) 854-4050 Email: sales@airdynamics.net Website: https://airdynamics.net (1) http://www.nola.com/health/index.ssf/2014/04/childrens_hospital_investigate.html (2) See https://www.ccohs.ca/oshanswers/chemicals/combustible_dust.html & https://www.osha.gov/dsg/combustibledust/ for more details

  • Case Study | Wood Dust

    OVERVIEW Matthews International approached Air Dynamics Industrial Corporation with a wood dust dilemma. Through careful calculation and technical know-how, Air Dynamics successfully installed three PLECO Industrial HEPA Vacuum systems at Matthews solving their problem with the best solution, by providing the best product. THE APPLICATION Matthews International produces ornate wooden caskets supplied throughout the world. These containers are constructed entirely in-house. As such, the entire process at the facility produces a massive quantity of wood dust and particulates. To maintain a safe and functional work environment, Matthews had instilled a housekeeping standard to remove the wood dust. However, the system was not capable of producing the cleaning results that Matthews needed to adhere to OSHA standards, as well as their own personal policies of safety and cleanliness. After reviewing different options available, Matthews International decided to enlist the engineering and technical skills of Air Dynamics Industrial Systems Corporation. THE CHALLENGE The wood dust issue at Matthews was extensive. Four separate lines of production were spreading large quantities of fine wood dust in the air. The quantity of wood being cut and sawed would produce several semi-truck loads of wood dust daily. The current method of compressed air blowing, or “herding”, and then a vacuuming sweep via a shop vacuum was not sufficient to collect the fine wood dust. The collecting dust was accumulating in high layers around the facility’s ceiling and ledges. Furthermore, the cleaning process currently underway was hazardous in itself. The shop vacuums used were not suited for the task at hand. Wood dust would quickly fill and clog the bulky shop vacuums causing longer maintenance time. The issue became so severe that a shop vacuum even caught on fire from overheating due to the clogged wood dust. Realizing the extensive issue required a permanent solution, Matthews began searching for quotes on central vacuum systems that could handle the workload required. Upon contacting Air Dynamics Industrial Systems, the personnel at Matthews found a solution that exceeded their expectations and reduced their expected cost for the system by 70%. PROVIDING THE BEST SOLUTION After consulting with Air Dynamics’ engineers, Matthews decided on an initial purchase of one PLECO Portable Industrial HEPA Vacuum System. The PLECO is an adaptable and versatile system ranging in different sizes and energy consumption depending on the challenge at hand. The engineers at Air Dynamics began with an analysis of the workstations in need of a wood dust solution. After carefully calculating the dust produced and the scale of the space in question Air Dynamics’ team decided on using the PLECO portable model PPR22. The PPR22 model contains an 11.5 horsepower regenerative blower and was paired with a Drum Top Cyclonic Separator mounted on a 55 vacuum-rated drum with a wheeled drum cart. The Cyclonic Separator was specifically designed for Matthew's dust issue. This design met the PFPA rule 654 regarding combustible dusts. These units were connected with Cam-lock fittings to facilitate quick and easy separation for either piece of the system. This PLECO unit was attached to the outlet side of the separator via a 3” section of flexible hose. The inlet side of the portable drum unit was attached to another 3” flexible hose that transferred the wood dust via a metal tubing system designed and installed by Air Dynamics. Working closely with Matthews International’s employees, as well as the manufacturers of the sanding units, Air Dynamics was able to engineer the tubing system for precise configuration with the sanding systems. The PLECO PPR22 model was selected due to the specific needs of Matthews International. The vacuum system required had to perform a high volume of suction at an extremely high rate to remove wood dust from the sandpaper that was spinning concurrently. To ensure a complete system, 1½” utility vacuum outlets were placed adjacent to each workstation so that workers could have access to a vacuum for cleaning dust out of and on the surface of the product. Six-piece industrial quality tools kits were made available to workers with 25' of flexible 1½” vacuum hose to clean any residual dust in the production area. Application tests conducted revealed that the PPR22 with the 11.5 HP motor would handle up to seven workstations simultaneously. After this initial installation and the refinement process conducted by Air Dynamics’ engineers, Matthews International was so pleased with the results they purchased two more PLECO central units and their drum separator counterparts. CONCLUSION Matthews International was faced with a large challenge regarding the proper maintenance of their facility. The significant quantity of wood dust produced required a system that would rise above the standards of most companies’ central vacuum products. Air Dynamics Industrial Systems Corporation was able to meet and exceed the expectations of Matthews International. The PLECO Industrial HEPA Vacuum System PPR22 provided extensive coverage of the facility coupled with an efficiency that no other system could provide. In addition, budgetary estimates by Matthews International anticipated a price of a vacuum system fully 70% higher than the final price of the PLECO system. This is due to the portable PLECO unit maintaining a better efficiency than a standard, large-scale, and expensive central vacuum system. Quality, affordability, and precision. The PLECO can do it all and more. ABOUT AIR DYNAMICS Founded in 1991, Air Dynamics Industrial Systems Corporation designs and manufactures Turn-key industrial air cleaning systems. Call us today to discuss your possible housekeeping or maintenance needs with an experienced engineer today. Phone: (717) 854-4050 Email: sales@airdynamics.net Website: https://airdynamics.net

  • Case Study | Combustible Dust Control

    OVERVIEW Air Dynamics Industrial Systems Corp. manufactures another turn-key vacuum cleaning system for World's Leading Pet Food Maker - Mar's Pet Care. The Industrial Vacuum Cleaning System is used by sanitation workers to collect and dispose of pet food kibble and combustible organic dust. THE APPLICATION When the world’s largest pet food producer needed a housekeeping system for their facility, they turned to Air Dynamics Industrial Systems Corporation. Air Dynamics successfully competed for the procurement of the industrial central vacuum system. The statement of work included special requirements to uphold MARS corporate guidelines and standards for capital equipment procurement. It was understood that the supplier was expected to be an expert in the field of industrial duty central vacuum cleaning systems. After over two decades of engineering vacuum systems, Air Dynamics Industrial Systems Corporation exceeded this requirement. THE CHALLENGE In order to meet the requirements of MARs, Air Dynamics Industrial Systems Corporation designed their system specifically for the needs of the client. The combustible dust sanitation system included pneumatic conveying system design experience, familiarity with NFPA guidelines, OSHA's Safety Directive CPL-03-00-008 (Combustible Dust National Emphasis Program), and the Code of Federal Regulations - 29 CFR 1910.22, 29 CFR 1910.176 (c), 29 CFR 1910.272. The owners’ procurement team included a Project Manager, Technical Project Manager, and Technical Buyer. The Air Dynamics team required a Project Leader Commercial, a Project Leader Technical, and a Senior Site Supervisor. The central vacuum cleaning system was designed to serve six simultaneous operators at 50 locations across four processing areas over an 800-foot span of the facility. PRINCIPLE OF OPERATION To meet OSHA's mandate, the industrial vacuum system was installed as a housekeeping and sanitation system to collect and safely dispose of pet food kibble, combustible organic dust, and a preventative measure for organic dust that may become contaminated with salmonella. Cleanliness and food safety are ingrained in every facet of every MARS Pet care facility; it’s a high priority that everyone including suppliers, take seriously. The system was designed to meet all sanitation, safety, technical, and performance requirements while minimizing total energy demand. In addition to design, the project required manufacturing, delivery, start-up, and commissioning of the complete housekeeping vacuum system. Key aspects of the central vacuum system were: 3-D CADD design and layout of the vacuum piping system, filter/receiver, deflagration protection/isolation, hopper discharge, industrial vacuum producer, follow National Fire Protection Association Guidelines, provide OSHA safety devices, compliance with the National Electrical Code, automation controls and instrumentation, intrinsically safe industrial vacuum cleaning tools and attachments, and vacuum system spare parts. PROVIDING THE BEST SOLUTION The heavy-duty vacuum system designed by Air Dynamics Industrial Systems was designed to withstand the pressures of deflagration and comply with NFPA guidelines for preventing or protecting against dust explosions. All aspects of the vacuum system structural design (mechanical engineering) and vessel integrity/pressure design criteria of the vacuum system were subject to review by the client’s safety consultants and professional engineers. The main filters were selected to provide greater than 99.9% efficiency at half a micron while the safety filter was selected to provide 99.9% efficiency at one micron. Operator controls include HOA (hand/off/auto) selector switches and visual run indicator lights to facilitate troubleshooting and maintenance. Automation in the electrical design scheme provides operator-less sensing of the receiver level with an indicator light and automatic shutdown upon bin full, breach of the explosion vent, high differential pressure, loss of rotation of the discharge valve, or other faults. Special totally enclosed fan-cooled motors were required to reliably operate the industrial vacuum system at a high ambient temperature of 122 degrees Fahrenheit (50° C). The combustible dust housekeeping vacuum system was designed to operate six hours per day, seven days a week, 52 weeks a year, with a minimum service life of 10 years. Air Dynamics Industrial Systems Corp. guaranteed the noise level in an open room, measured three feet from any part of the equipment; to be less than 80 dB(A); normal volume of a conversation is about 72 dB(A). The compact design of the vacuum system required a four-by-four-foot area while the vacuum producer required a three-foot by seven-foot area. The vacuum system endured a series of customer tests and inspections to ensure the vacuum system was performing optimally, with specifications initially set forth by the client. After startup and commissioning, all requirements in the statement of work were met. The Site Acceptance Evaluation included Inspection and Review of the Fit and Finish, Sub-systems Testing, Mechanical Standards, Electrical Standards, Industrial Hygiene and Occupational Safety requirements. The state-of-the-art central vacuum cleaning system is currently serving this facility “where the operators say the vacuum system works really, really well!”, as reported by Larry Cloar, at MARS. System requirements included, but were not limited to, as-built 3D CADD layout drawings, electrical drawings, operation and maintenance manuals, and a summary of expected total cost of ownership, spare parts, maintenance costs, and energy consumption. The central vacuum piping network consisted of purpose-built vacuum tubing and fittings, 30' operator hoses, metal industrial vacuum tools, and attachments. The product is conveyed through the system piping at 6,500 FPM minimum conveying velocity. Start-up services included programming, system balancing, commissioning, and operator training. Warranty support included a one-year warranty period - excluding normal wear items. CONCLUSION Air Dynamics Industrial Systems partnered with the people at MARS to provide a system that ultimately serves to protect the people at MARS, and the plant infrastructure, and assist the plant sanitation workers to produce a safer product while protecting future earnings for the company. ABOUT AIR DYNAMICS Founded in 1991, Air Dynamics Industrial Systems Corporation designs and manufactures Turn-key Industrial Vacuum Cleaning Systems, Portable Industrial Vacuum cleaners, and Pollution Control Systems. See what we're capable of online or give us a call to discuss your specific air and material moving challenge. Phone: (717) 854-4050 Email: sales@airdynamics.net Website: https://airdynamics.net

  • Case Study | Combustible Dust Control with Key Plastics

    OVERVIEW Air Dynamics Industrial Corp. manufactures an Industrial Dust Collector for Industry Leader - Key Plastics. The industrial dust collector was to be utilized for source capture of synthetic graphite dust at the Felton, PA factory. The industrial dust collector was designed to reduce employee exposure to combustible dust such as synthetic graphite dust generated during the cutting, grinding, and machining of large pieces of synthetic graphite. THE APPLICATION Air Dynamics Industrial Systems Corporation was approached by one of the largest manufacturers of automotive interior plastic lens assemblies and was seeking to purchase an industrial dust collector to minimize employee exposure to synthetic graphite, improve product quality and improve employee working environment. The synthetic graphite infiltrated all areas of the production and administrative area of the facility. The company wanted to ensure exposure levels were well below OSHA recommendations for synthetic graphite dust produced during the mold-making process. Air Dynamics was contacted and specified a dust collector for Key Plastics and their facility. This was the first time that Key Plastics tried to fix their problem. THE CHALLENGE This client is an industry leader in indoor and exterior door handle assembly as well as sail panels, mirror shells, pressurized coolant, and power steering bottles along with brake reservoirs, battery trays, ignition housing, and engine covers. Although an industry leader, Key Plastics had some indoor air quality obstacles to overcome during the processing of synthetic graphite in their shop. Synthetic Graphite Dust was being disbursed into the shop and other areas of the building during specific operations such as sawing, machining, and grinding of the graphite work pieces. Working with Air Dynamics, Key was able to enhance their process while creating a more employee-friendly environment. PROVIDING THE BEST SOLUTION Air Dynamics provided complete Turnkey design and installation of the dust collection system including source capture hoods, industrial duct, dust collector, installation, and startup. Key Plastics was provided with total integration of an industrial ventilation system as well as knowledgeable employees during the installation of the indoor air pollution controls. The collector was expected to be installed in accordance with federal and state regulations. Organizations such as OSHA protect employees and their work environments to keep the workers safe while performing their jobs. Key engaged an industrial hygiene specialist who conducted an overall shop as well as tested a number of personnel with an air sampling survey. The industrial hygienist performed dosimeter tests to check exposure levels prior to the installation of the dust collection system. Air Dynamics provided recommendations outlined in Industrial Ventilation - Manual of Recommended Practice published by the American Conference of Governmental Industrial Hygienists to correct the indoor air pollution problem. The dust collector was a Turnkey project delivering 13,000 cfm with the air being filtered at a 99.5% @ 2.5 μm efficiency level. Eight-inch ducts were to be routed to four CNC machines specified by Key Plastics. Two eight-inch ducts were also routed to the surface grinders and additional drops were split into two or three separate flexible collection hoses. The open CNC machines were serviced with two, 4-inch flex lines with hoods at each end. The enclosed CNC machines were serviced with three, 3-inch flex lines, without hoods. Each surface grinder was serviced with two, 4-inch flex lines; one line having a source capture hood, with the other being attached to the top of the grinder wheel shroud. Table grinders had two dust collection pickup points - this was to capture the high-velocity particles of synthetic graphite dust thrown from the grinding wheel. The second pickup point was directly opposite where the material was currently being discharged. There were twenty-four- four filter cartridges inside the dust collector and the fan was top-mounted. The system was located on the south side of the building resting on a concrete slab with traffic guards. The dust collection system was installed with fifteen inlets in total. Air Dynamics' responsibility was to install the system per the approved drawings. The ductwork that was supplied was a high-performance duct manufactured by Nordfab products. The system allowed simple modifications, ease of cleaning, and reusability. Included with the proposal was a one-year dust collector preventative maintenance plan that included visits to inspect the blower assembly and the filter array. A written report was to be provided with each visit along with any recommendations after the inspections were completed. CONCLUSION The dust collector was successfully installed by Air Dynamics at the Felton factory in York, Pennsylvania. When the machine was fully installed, the Industrial Hygiene Specialist returned to Key Plastics' facility to run another air sampling survey evaluating exposures of synthetic graphite dust and the effectiveness of the new ventilation system. The Result - The synthetic graphite dust levels were well below the ACGIH, TLV, and the OSHA PEL for all five samples collected; results can be seen in Table 1. In this case, it is 15 mg/m3 in reparable fraction for synthetic graphite. The main reason that Air Dynamics was contacted was to return clean filtered air to the workshop, and by the end of this project, that goal was reached. ABOUT AIR DYNAMICS Founded in 1991, Air Dynamics Industrial Systems Corporation designs and manufactures Turnkey industrial air cleaning systems. Our specialized approach is "designed to fit your specific needs". Give us a call or visit our website to see what we can do for you. Phone: (717) 854-4050 Email: sales@airdynamics.net Website: https://airdynamics.net

  • Case Study | Pneumatic Conveying

    OVERVIEW Air Dynamics was approached by Evergreen Community Power to complete a pneumatic conveying system for their bio-fuel facility in Reading, PA. The design and installation were successful, spanning a distance of 550 ft. horizontally, and 65 ft vertically. The design was also uniquely engineered to not interfere with the material conveyance for the facility. Air Dynamics proved once again its ability to create a complete turn-key solution, from design to installation. THE APPLICATION Interstate Resources, Inc. is a group of manufacturing facilities, headquartered in Arlington, Virginia, that employs over 1,500 people in Georgia, Maryland, Massachusetts, New Jersey, North Carolina, Pennsylvania, South Carolina, Tennessee, and Virginia. Evergreen Community Power LLC operates an energy-efficient boiler and steam generator. The company engages in the generation of electricity. The company was founded in 2006 and is based in Reading, Pennsylvania. Evergreen Community Power LLC operates as a subsidiary of Interstate Resources, Inc. The company’s Reading facility can produce 33 mega-watts in a combined heat and power facility utilizing bio-fuels. The biomass plant's electricity and steam output support the manufacture of 350,000 tons of kraft liner-board per year and 180,000 tons of recycled corrugated medium per year. Fundamentally, the power plant is comprised of a boiler with a steam turbine and generator. The circulating fluidized bed boiler produces 330,000 lbs. of steam at 1,200 psi with a thermal efficiency of 87%. The steam from the boiler is directed to an extraction, condensing steam turbine. The three turbine extractions allow precise control of the paper mill and plant parasitic loads. The turbine condenser maximizes the amount of electricity produced from the excess steam. The generator is rated for 33 MW, much larger than the attached plant and mill electric loads. In situations when it is economically favorable, the ECPP generates excess electricity and opportunistically sells power back to the grid. THE CHALLENGE Founded in 2016, Evergreen Compounding is a division of privately held, Evergreen Community Power, a member of Interstate Resources, Inc. Evergreen Compounding provides plastic products (compounds and/or masterbatches) made with renewable energy. Biofuels or wood burning creates two types of ash by-products. Bottom ash is a non-combustible residue that falls through the bottom of the boiler. Fly ash is driven through the boiler and escapes with the flue gas where it is separated, transferred, and stored in a 2000-ton silo. The plant would cart the residue to a landfill at a rate of approximately forty semi-trailer loads of fly ash per day at a cost of over $1M per year. Enter Evergreen Compounding. Evergreen Compounding was formed to convert the landfill product (fly ash) into sustainable and recyclable wood filler. The new product, named BioFillTM reduces virgin plastics usage and replaces natural minerals used to convert plastic products. Now that there was a use for the fly ash, there was only one problem. The compounding facility was over 800 feet away from the fly ash storage silo. Trucking the material from the storage silo to a day silo was cost-prohibitive and too slow. To effectively serve the compounding operation with a reliable supply of fly ash, Evergreen Community Power (ECP) sought out a company with the capability to design and manufacture a complete pneumatic material transfer system. Numerous firms could deliver all the necessary parts for a four TPH ash transfer system - in the typical 20-to-22-week delivery period. However, ECP wanted more, ECP wanted a design-build company that could provide the know-how to put together a harmonistic system. The fly ash transfer system had to move the material at a rate of four tons per hour (4 TPH) with a bulk density of 55 lbs. per cubic foot. The fly ash was introduced into a piping system at the base of the 2000-ton storage silo to a day silo located 550 feet horizontally and 65 feet vertically away. The horizontal pipe followed a unique path incorporating ten different, non-standard piping bends and two elevation changes so as not to interfere with raw material receiving. Upon reaching the ash air/material separator, the product falls through a double-dump type true airlock. The device is unique compared to a rotary-type valve such that there is little to no leakage as the material dispenses from the pneumatic receiver into the day bin even when there is a pressure differential of twelve plus inches of mercury. In addition to the pneumatic transfer system, ECP needed a bin vent to facilitate venting of the air displaced as fly ash filled the day silo. The bin vent filtration had to comply with the strict environmental limits within the city of Reading, PA. Lee Samuelson, an engineer at ECP further describes operations at Evergreen Power – “At our power plant we take construction materials such as wood, tires, and small bits of plastic. We take that material and we burn that in a boiler to create power for both this facility and to provide to the public. Before the compounding facility was built, we were moving between many tractor-trailer loads of both bottom and fly ash to the landfill. We take a waste product and transform it into a usable consumer product.” PROVIDING THE BEST SOLUTION System Operation – The pneumatic transfer system design incorporated a vacuum-type verses a pressure-type conveying system. Since the material is abrasive and contains about 20% silica, the vacuum system lends itself well to any leaks (inward) that may develop due to abrasion. Material is entrained at the main storage silo where fly ash is metered or fed into the 5-inch convey line. The pick-up velocity is approximately 3600 feet per minute. Motive air is produced by a constant volume variable pressure pump. Pumps like this have mechanical clearances of .004 or four-thousandths of an inch. This makes them ideal for long piping runs and troublesome materials. As the material resists, the pump persists – the pressure rises to overcome clogs, large irregular pieces of ash etc. As the material moves through the pipeline, the rarefied air expands and accelerates as it moves toward the positive displacement pump. Material enters the air/material separator radially via a silo inlet to reduce wear on internal mechanical components. Since the ECP site had very stringent environmental criteria for exhausting process air, PTFE membrane media was necessary to meet environmental regulations. Prior to air entering the pump, a safety filter serves to prevent damage in the event of a primary filter failure. A challenge for any type of vacuum conveying system arises at the point where the conveyed product dispenses into a receiver or hopper that is at atmospheric pressure. A rotary-type valve presents challenges due to clearances at the rotor housing. Therefore, the designer must take adequate precautions to prevent leakage and wear at this point in the system. Flap-type valves are good choices for vacuum-concented abrasive material. The fly ash is dispensed into a silo at atmospheric pressure. A bin vent on the silo served to filter air displaced because of the 145 cubic feet of fly ash conveyed per hour. Energy Requirements – The energy required to move eight-thousand pounds of fly ash per hour over the project distance (615 feet) is relatively insignificant. The fly ash transfer system required one horsepower for every 350 pounds of material moved per hour. The fly ash system moves the equivalent of seven, fifty-pound bags of material over a distance of 550 feet horizontally and 65 feet vertically for each horsepower or 23 brake horsepower per 8000 pounds of ash conveyed per hour. The selection of the piping size for any project is a balance of pickup velocity and terminal velocity. If the pickup velocity is too low, there is a risk of material dropout within the pipe system. If the velocity is too high at pickup, the terminal velocity may erode the system components prematurely. Automation can increase the efficiency of almost every function at a power plant. Pneumatic conveying lends itself well to automation - through instrumentation. If too much material enters the line for example because the material size varies, the feed rate can be slowed to compensate for the product size and density. Costs for these types of additions are minuscule compared to the overall benefit. Air/Material Separation – Separating air from a product conveyed to a receiver via vacuum or pressure requires an understanding of the material characteristics as well as taking advantage of filter manufacturer's media specifications, experience, mathematical calculations, and performance data. Evergreen Power required a warranty that the filter/receiver and the bin vent exhaust effluent will not exceed an average of 0.02 gr/DSCF (Dry Standard Cubic Foot) after being properly installed and maintained. Compressed Air and Dew Point Considerations for Outdoor Equipment – It is vitally important to consider the application of instrument-quality air to certain key aspects of a pneumatic transfer system. This system was no exception. Instrument air serves a special purpose when equipment resides outdoors. Diaphragms and solenoid valves require dry air to function properly under conditions at or below the dew point temperature. On-time delivery – The pneumatic conveying system was delivered on time and exceeded the four TPH design specifications by 2000 lbs. /hr. Air Dynamics differentiated itself with our in-house ability to take a project from concept all the way through to delivery, startup, and commissioning. This capability was something that Evergreen Power was able to quickly identify in the offeror's proposal. CONCLUSION "Working with Air Dynamics was an incredibly enjoyable experience for our engineering firm. They brought expertise to the table that we did not necessarily have in-house, and they conveyed it in a way that was easy for us, our shareholders, and our executives to understand". – Lee Samuelson ABOUT AIR DYNAMICS Air Dynamics Industrial Systems Corporation is a veteran-owned company, founded in 1991. We pride ourselves on our over two and half decades of experience solving numerous unique challenges. If you have a challenge that needs a precise, turn-key solution, give us a call. We get the job done right. The best solution is to design the best possible product. Phone: (717) 854-4050 Email: sales@airdynamics.net Website: https://airdynamics.net

  • Case Study | Air Pollution Control - Wet Scrubber

    OVERVIEW Air Dynamics Industrial Systems Corporation was approached by Armstrong World Industries to engineer a new wet scrubber. The new design realized savings in tens of thousands of dollars annually in operations & maintenance costs, eliminated an air pollution problem and reduced energy expenditures. This versatile wet scrubber was then repurposed by Air Dynamics to accommodate changes in Armstrong's product and process. THE APPLICATION Armstrong World Industries is a leader in the ceiling and flooring industry in the United States. Located in Lancaster County, Pennsylvania, Armstrong World Industries manufactures resilient flooring. The PVC flooring is composed of 100% synthetic materials that produce a gaseous chemical discharge. Armstrong was interested in renovating their old air scrubbing process to achieve a more efficient, cost-effective air scrubbing process operation. THE CHALLENGE After resolving to replace their 70's era air scrubber due to deteriorating performance, excessive maintenance and energy deficiencies, Armstrong contacted Air Dynamics Industrial Systems Corporation for a solution. Air Dynamics careful analysis and technical solution for Armstrong's replacement air scrubber design enabled a 74% reduction in operating energy cost, 40% reduction in air pollution, and a 96% total reduction in operations and maintenance (O&M) costs. The impact of these reductions is clear when the old scrubber’s annual operating cost of $187,200 was reduced to only 3.5%, roughly $6,593. The existing air scrubber was installed in 1974, and the inefficiencies were readily apparent upon inspection by the engineers from Air Dynamics. The design of the previous system required sixteen hours of maintenance per week. Leaks around the equipment were readily apparent to Air Dynamic's engineers (See photo below). Several chemical compounds such as Diisoheptyl1, Diisononyl Phthalate2, and Isopar Hydrocarbon Fluid3 are used in the production of vinyl flooring. 4 The high O&M costs were key reasons to renovate the previous design. Armstrong World Industries decided to move forward with Air Dynamics’ design offering to provide a high efficiency, low energy wet scrubber. PROVIDING THE BEST SOLUTION Air Dynamics’ design assured a clean and efficient system via the four-stage scrubbing process. The duct work transports the collected gaseous chemical vapors from the vinyl ovens into the first stage of the wet scrubber where it decelerates and cooled rapidly. Cold water is combined with the hot vapors, rapidly decreasing the temperature from 350 degrees Fahrenheit out of the ovens to approximately 100 degrees Fahrenheit. The cooler, condensed concentration of chemicals pass through a combination of mechanical separation and water cooling. After passing through a media, the majority of the chemicals filter through the bottom of the unit into a sump for storage and later disposition and processing. The remainder travel into the third phase, wherein low pressure passes the air through another level of mechanical separation that removes the remaining chemicals from the air stream. Finally, any chemical droplets are separated in the last chamber through a final permanent media. The air is discharged into the atmosphere via the fan on the clean side of the scrubber. The result is a clean and energy efficient scrubbing process. Air Dynamics Industrial System Corp. assessed the deficiencies in the old system and additionally identified several ways to reduce the O&M costs of the unit while making the new design easy to operate and maintain. The new system cut the size of the old scrubber from 50,000 lbs. of equipment to roughly 25,000 lbs. This eliminated the necessity to replace filters and thus delivering a more efficient and compact solution. The new system Air Dynamics delivered is a low energy industrial scrubber, or an air pollution control device (APCD). The product is a hydrodynamic scrubber, or wet scrubber. This scrubber is designed to convert the chemical vapors from the vinyl ovens into liquid/solid particulate droplets for mechanical separation. The new design was manufactured with 304 stainless steel and equipped with PLC automation and controls. As requested by Armstrong World Industries, Air Dynamics designed the new system horizontally for ease of access. The design additionally improved the scrubbing process with selection of permanent medias within the low energy scrubber. Air Dynamics further increased the efficiency of the scrubber by utilizing a combination of process cooling coupled with progressive mechanical separation. CONCLUSION Air Dynamics Industrial Systems Corporation designed and produced from the ground-up a cleaner, more efficient scrubber tailored specifically for the issues that Armstrong World Industries was facing. The new system met all requirements from Armstrong. The new system additionally realized monetary savings in O&M and reduced excessive energy expenditures that the old system required to operate. A specific example would be the reduction of a weekly 16-hour maintenance routine to a mere four hours a month. Furthermore, the new systems’ permanent media saved an average of $100,000 a year in annual replacement fees compared to the previous fiberglass media in the old scrubber. After quantifying the savings realized for Armstrong World Industries by adopting a new hydrodynamic scrubber system the results are markedly cost effective. By utilizing Air Dynamic’s best solution, best product model Armstrong World Industries was provided with the ultimate long-term solution to their problem, and now represent the cutting edge of wet scrubbing technology. ABOUT AIR DYNAMICS Founded in 1991, Air Dynamics Industrial Systems Corporation designs and manufactures Turn-key industrial air cleaning systems. See what we're capable of online or give us a call to discuss your specific air and material moving challenge. Phone: (717) 854-4050 Email: sales@airdynamics.net Website: https://airdynamics.net

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