SolvAir's bespoke Air Solutions solve multiple issues for Aquapak's polymer extrusion line.

Aquapak’s polymer production was hindered by inefficient water removal and cooling processes. On the first stage, wiping was used to dry the extruded strands, with pedestal fans helping to blow the water off, but the wipes became wetter over time and could put water back on the product, which risked recontamination.

The compressed air system used for cooling was energy-intensive and potentially introduced water particles, compromising product integrity. A 55kW compressor was on hire just to supply air at 6bar for this single process, and its 96 flat fan nozzles used all of that compressor’s capacity when in use.

SolvAir created a bespoke two-stage Air System. For water removal, a PX500-4.0kW with two 457mm Aluminium Air Knives replaced the wiping, blowing the water off the extruded strands as they are conveyed through the air stream. For cooling, a PX1000-7.5kW with eight 457mm Aluminium Air Knives was placed at different stages along the conveyor, blowing at an angle down the length of the strands to remove the heat. Because air from the Air Blowers is both clean and dry, it removes the risk of oil or water particles as typically found in a compressed air system.

Mobile enclosures and adjustable controls provided flexibility and minimised energy usage. The full electrical controls allow the blowing pressures to be regulated to maximise efficiency, the Paxton blowers can run at lower speeds and frequencies for further energy reductions, and either system can be removed if it is not needed for other processes.