Get the Most Value from Your Existing Equipment Money Saving Tips and Ideas Doug Brewster, Customer

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Get the Most Value from Your Existing Equipment
Money Saving Tips and IdeasDoug Brewster,
Customer Service Manager
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Conveying Systems
Switch older, smaller receivers to larger
receivers to reduce the number of cycles and gain
pump capacity, both saving cost through
efficiency. Upgrading receiver size will also
save time, and save equipment wear.
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Conveying Systems
Energy Saver Consider buying an Idle Mode Valve
or Vacuum Relief Valve to eliminate demand loads
of pumps starting and stopping. This has three
primary advantages 1. Reduces demand
in-rush current eliminated. Saves energy costs.
2. Reduces wear and tear on equipment. (starter,
motors, blowers) 3. Improves instantaneous
conveying rate by eliminating start-up time.
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Conveying Systems
Note that the use of the Idle Mode Valve or
Vacuum Relief Valve greatly reduces the in-rush
current demand, by lessening the frequency of
start-up cycles.
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Conveying Systems

• Adjust feed tubes and take-off boxes for the best
  balance of air-to-material
• ratio to get better pump utilization and reduce
  cycle times on existing
• loaders.

Click the illustration to play video. Note how
by pulling the valve out, the vacuum pressure
increases accordingly. It is important to find
the position in the valve travel, where the
pressure is in the normal range, moving the
greatest amount of material possible.
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Conveying Systems

• Conveying Optimal Performance Checklist
• ? Check the filters if your pump does not have
  an automatic blow-down feature. Old filters
  become impregnated with dust reducing the system
  delivery capacity.
• ? Check the seals on the ratio valves. Open
  seals are a source of leaks.
• ? Replace/repair leaky seals.
• ? Check all belts and maintain equipment as
  directed in the appropriate Conair User Guide.
• ? Check and change sheaves when necessary.
  Make sure that the pulleys on the motor are in
  alignment with each other.
• ? Check the screen on loaders, make sure it is
  clean and unrestricted.

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Conveying Systems

• Conveying Optimal Performance Checklist
• ? Check all hose connections for tightness.
• ? Secure loose connections. Replace worn hose.
• ? Check all valve seals for leaks.
• ? Replace/repair any leaky valve seal.
• ? Check and secure coupler connections.
• ? Check all material and vacuum lines.
• ? Eliminate any unnecessary bends or any kinks
  in the line.
• ? Reduce 90 degree bends and height changes
  where possible.
• ? Adjust conveying time or use fill sensors to
  ensure optimal load cycle.
• ? Limit use of purge function to only required
  applications.

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Conveying Systems High Percentage of Regrind

• Consider purchasing application-specific loaders
• Designed for heavy regrind conveying.
  Conventional
• loaders with screens plug or become laden with
  heavy dust.

Filtered Loader/Receiver
Conair Patented Filterless Loader
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Conveying Systems - High Percentage of Regrind

• Conairs patented Filterless Loader maintains
  high performance.
• The filters on filtered loaders will become
  clogged over time, decreasing
• the performance of your conveying system. See
  next slide for graphic representation.

Conairs Filterless Loader handles all types of
materials, including regrind. The Filterless
vacuum has the ability to convey dusty materials
and free-flowing powder larger than 100 microns
in diameter. Each Filterless Receiver has a
patented filterless insert that uses continuous
reversal of vacuum air to separate incoming
material from conveying air without filters or
screens. The process provides dramatic
air/material separation without relying on
filtration. The loader is also self-calibrating
it uses a sensor to determine material level.
Filter becoming clogged
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Conveying Systems High Percentage of Regrind

• As the filter clogs on a filtered
  loader/receiver, the hopper does
• not fill as it should. This causes a time-out
  situation in your
• manufacturing process, reduces productivity,
  increases wear on
• equipment, and increases energy consumption.
  Note how the
• Conair Filterless loader never loses
  productivity.

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Conveying Systems

• Consider purchasing a ratio valve with an
  independent control to retrofit a
• loader when your existing control does not have
  the features. The ratio
• valve retrofit kit works with any equipment and
  is easy to install.

Retrofit Kit
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Conveying Systems

• Angel hair is created when plastic is transferred
  from one location to another.
• This can even be in the plastics manufacturing
  plant, before you receive the
• plastic. As the plastic travels, small pieces can
  rub onto the walls of the
• tubing, building up and eventually creating small
  streamers or skins
• referred to as angel hair. Conairs Angel Hair
  Remover can eliminate angel hair
• from your process.

Angel hair builds up and then breaks off in the
tubing during high-velocity conveying.
Easy to clean and easy to use.
Angel Hair Remover placement
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Conveying Systems

• Additional angel hair solutions include
• Limit railcar/truck unloading pressures to 6.5
  psi maximum.
• We recommend hanging a sign at the unloading
  valve stating
• a maximum of 6.5 psi unloading pressure.

Receiver
Do not exceed 6.5 psi!
Railcar Unloading
Angel Hair Remover
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Conveying Systems

• Additional angel hair solutions
• Use spiral groove, or rifled pipe, which greatly
  reduces or eliminates the amount of streamers
  which can be created in your tubing.
• Use high-wear elbows to eliminate streamer
  build-up in bends of tubing.

Impact zone
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Drying

• Consider extending existing drying hoppers to
  gain additional residence time.
• The use of the Conair hopper extension allows
  more capacity for your hopper.
• Contact a Conair representative to determine if
  this will improve your process.

Without extension
With extension
See next slide for more details.
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Drying
200 lbs
X-ft3
960 lbs
960 lbs
960 lbs additional 200 lbs 1160 lbs. 1160/4
290 lbs/hr
W200
960 lbs/4 240 lbs/hr
Drying capacity 300 lb/hr
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Drying

• Use spare dryers to incorporate tandem drying.
  Put hoppers in series to
• gain residence time in a pinch. (See next
  slide.)

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Drying

• Use spare dryers to incorporate tandem drying.
• Put hoppers in series to gain residence time in a
  pinch.

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Drying

• Consider buying a dryer retrofit kit to switch
  electric to gas for a lower
• cost alternative where power is expensive.
  Contact Conair for specific
• application options.

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Drying

• Drying Optimal Performance Checklist
• ? Check return air filters on dryers. This
  could limit drying capacity. Air delivers BTUs
  to the process.
• ? Calrod heaters are prone to failure. Losing
  one or two can cause a dryer to work harder to
  achieve or maintain temperatures.
• ? Filters, heaters, and kinks in hoses will
  restrict airflow and can effect drying in many
  applications.
• ? Check and maintain equipment as directed in
  the appropriate Conair User Guide.
• ? All filters should be cleaned and replaced
  regularly. Know when replacement is necessary.
  (Do not over-use an old filter.)

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Drying

• Drying Optimal Performance Checklist
• ? Clean aftercooler coils as necessary.
• ? Use energy-saving features on equipment
  (dewpoint control, setback feature 3-6 hours,
  Powermiser 1 Deluxe)
• ? Turn dryer off when not using material.
• ? User properly sized equipment for
  application.
• All Conair Equipment
• ? Follow the preventative maintenance
  schedules in your Conair User Guides and on-line
  at the Service link. Contact Conair service for
  discount rate service contracts that include
  preventive maintenance.

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For additional information

• Doug Brewster, National Sales Manager
• Rick Cardy, Parts Manager
• 724-584-5500