Major project successfully implemented for Swiss mechanical engineering company
In the plant engineering segment, ESTA specialises in large and often complex extraction systems for industrial applications with multiple extraction points. From individual consultation, planning and design to production and commissioning, ESTA provides customers with everything from a single source. A current project for an international company in Switzerland demonstrates how this concept is implemented in practice.
A Swiss company specialising in machines and systems for processing bulk materials commissioned ESTA to plan and implement a central extraction system for approximately ten welding and grinding workstations. ESTA plant engineering expert Benedikt Mühlhauser assumed responsibility as project manager, and developed a customised extraction solution where the individual components were precisely coordinated. "Due to the large number of overhead cranes, piping in the factory workshop was difficult, which is why we opted for two self-contained extraction systems," explains Mühlhauser, describing the project's general framework conditions.
ESTA installed two high-performance DUSTMAC W3 cartridge filter systems, which are specifically designed for processing high-alloy steels. Thanks to their high separation efficiency of more than 99 %, the filter systems reliably capture even fine hazardous dust and fume particles. Both filter units are each operated by a highly efficient fan including a frequency converter. This ensures flexible and, above all, energy-efficient operation of the system.
Spot extraction, fire protection & summer / winter switchover
The two DUSTMAC filter units together process more than 16,000 m³ of air per hour and offer a total filter area of approximately 280 m². Air pollutants are captured with pinpoint accuracy via flexibly pivoting extraction arms with efficiency hoods, which are connected to the filter units via a robust spiral-seam duct system.
With the integrated summer / winter switchover, the cleaned air can either be discharged outside or recirculated into the production shop. Depending on the season, this provides a noticeable reduction in heating or cooling costs – real added value for the indoor climate and the energy balance.
Fire protection was also taken into account. As flying sparks cannot be ruled out during welding and grinding, ESTA installed a spark pre-separator on each intake nozzle, which eliminates potential sources of ignition before they enter the filter unit and thus significantly reduces the risk of fire.
Work booth for grinding work
As part of the extraction system, ESTA also installed a customised, sound-insulated work booth with an integrated extraction wall. This separates the grinding area from the rest of the production environment, significantly reducing dust and noise exposure for employees. "This major project ran smoothly and underscores the breadth of our plant engineering team's expertise. We are able to fully adapt to our customers and the respective on-site conditions," says Benedikt Mühlhauser in summary, and with satisfaction.
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