Modern exhausting of a machining centre

The company Zimmermann Fenster und Türen GmbH in Sontra is a leading manufacturer of plastic windows and doors in Germany. The company can look back on a tradition of more than 130 years and has been building plastic windows and doors for over 40 years. Experience, flexibility and innovation in window building are the basis for this success. They know the market and look at the trends of today and tomorrow. Constant product improvements, know-how, flexible production, committed and qualified employees are the basis of this successful company development. 1886 founded by the carpenter Master Eduard Zimmermann as a carpentry, the company is now managed by the family Zimmermann in the fifth generation. 140 employees currently produce on approximately 9,000 m² of production space up to 500 window units per day. In the special construction department, doors, folding systems, lifting sliding doors and custom windows are manufactured.

In the course of the modernisation of the production facilities, a machining centre was acquired of the company Schirmer Maschinen GmbH with headquarters in Verl. Due to the necessary exhausting of the machining centre, Zimmermann contacted the company SPÄNEX. After a local appointment to clarify the customer's requirements and the local conditions, the suction-technical framework data was clarified with the company Schirmer on behalf of the customer. After that, an exhaust speed of 30 m/s was to be kept at 7 suction nozzles and an exhausting hose had to be connected for the recurring manual cleaning of the chip tub. Furthermore, three cleaning tables bad to be vacuumed sporadically. The determined required exhaust volume flow thus was variable between 6,600 and 8,500 m³/h.

In order to solve this suction-technical task, a dust collector from the SMU series (figure) from the SPÄNEX product range was offered with the following technical data:

exhaust nozzle-Ø: 355 mm
exhaust flow: 8.500 m³/h
negative pressure: 2.700 Pa
motor capacity exhaust fan: 11 kW
motor capacity discharging chip container: 0,55 kW
volume chip container: 500 l
maximum sound pressure level: 70 dB (A)
dimensions l x b x h: 3.570 x 900 x 1.965 mm
weights (without underframe): aprox 900 kg

Dust collectors are compact extraction centres that can be placed due to their construction directly in the working area when extracting organic dusts from the dust explosion class St 1. The dedusters are characterized by the following attributes:

  • high suction power

    The flow through the devices is optimally designed so that low internal resistances arise and therefore high external pressures are available.

  • low energy consumption

    As standard, energy-saving fan motors of the efficiency class IE 3 (optional IE 4) are used.

  • quiet operation

The noise emissions are at a particularly low level, as shown in the technical data above.

  • effective filtration and cleaning

    The high separation rate of the used, tested filter material ensures a residual dust content in the return-air of < 0.1 mg/m³. The compressed air cleaning (jet-pulse-system) ensures an effective and at the same time gentle cleaning of the filter elements with low compressed air consumption, so that a long service life is achieved.

  • compactness

    The design of the series in combination with the tried and tested special filter elements has led to compact casing dimensions, which means that extremely small footprints are required with a low height as well.

  • tested safety

    All SPÄNEX compact dust collectors have been tested by the BGHM Professional Association and have received the DGUV test certificate (H3) and the GS mark.

  • multiple disposal variants

    In this case, the separated chips and dusts are collected in a container with a built-in discharging device and conveyed to a big-bag via a type-tested rotary valve. For this purpose, the dust collector had to be placed on a profile steel base.

Another important aspect for the customer was the energy-efficient operation of the plant. Due to the variable exhaust air quantity, a frequency converter was offered for the constant adjustment of the exhaust capacity to the actual demand. The converter changes the speed of the exhaust fan. This speed adjustment is carried out automatically via the PID controller integrated into the circuit.

The offer was presented to the customer and explained, with particular reference to the advantages resulting from the use of the compact dust collector:

  • the machine-close installation in the working area results in short piping paths, which leads to reduced costs for investment and operation, compared to externally installed filter systems.
  • an elaborate return-air duct is not required.
  • a 100% heat recovery is achieved by direct air recirculation.
  • the largely ready-to-operate supply leads to short assembly times and therefore low assembly costs.

The consulting and the offer with the recognizable advantages, especially in relation to the possibilities of installation and the energy efficiency, have convinced the responsible persons of the company Zimmermann, so that SPÄNEX received the order for the supply, assembly and commissioning of the system.

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