Pfaffinger & ESTA

Pfaffinger Iggensbach: High-tech manufacturing with clean air

At the new company location in Iggensbach, Lower Bavaria, Pfaffinger Anlagenbau & Energietechnik GmbH plans, designs and installs, among other things, gas pressure control and measuring systems, hydrogen and power-to-gas systems, district heating and cooling systems, and industrial pipelines. In two of the six production shops, plant and piping components made of black steel and stainless steel are machined. To prevent dust and welding fumes from spreading during grinding and welding, a tailor-made extraction solution had to be found in time for the site's opening in January 2025.

The requirements

Extraction of grinding dust and welding fumes
Combination of spot and shop extraction

W3 design for shop with stainless steel machining
Low operating costs

Low maintenance

The solution

Modern spot capture systems combined with a shop extraction system in each case

DUSTMAC

Two filter units with integrated spark pre-separator ensure clean air at six extraction points each, and also take care of shop ventilation.

Piping system

The 150 metre long piping systems connect the extraction points to the filter unit. For shop ventilation, a piping system with ventilation grilles is routed on the intake side. The cleaned air is returned to the shops via lateral venting outlets close to the floor.

Extraction arms

Six extraction arms each allow the targeted capture of dust and welding fumes directly at the point of origin.

Drive unit

The necessary negative pressure is provided by a high-performance 15 kW fan, which enables automatic, adjustable system operation by means of a frequency converter.

Extraction table

Workpieces are also machined at one extraction table per shop and the dusts generated are collected via the rear extraction wall.

Hall Ventilation

Thanks to the intelligent DUSTMASTER control system, the shop ventilation based on the stratified ventilation principle is activated as soon as there is no direct capture via the extraction arms or the extraction table.

Jet pulse filter cleaning

The fully automatic jet cleaning system uses bursts of compressed air to clean the filter cartridges during ongoing extraction operations.

W3 certificate

The resulting stainless steel dust, containing chromium and nickel, must be captured precisely in accordance with the legal requirements, i. e. TRGS 528. Recirculated air operation is only possible with a W3-certified system that achieves a separation efficiency of 99.9 %.

TECHNICAL DATA & HIGHLIGHTS

Technical data

Filter unit: 2x DUSTMAC F-126 (W3)
Max. air volume flow: 15,000 m³/h
Drive: 2 x RG-1500 15.0 kW extraction fans
Frequency converter: 2 x including control unit
Capture elements: 12 x extraction arms + 2 x extraction tables
Piping system: 150 m
Discharge type: Dust collection container

Project highlights

Cleverly combined: Spot extraction and shop ventilation systems for completely clean air in the workshop
Flexibly adaptable: For up to six extraction points each
Maximum safety: DUSTMAC filter unit with W3 certificate for stainless steel dusts
Modular system design: Performance, filter package and structure can be individually configured
Low maintenance: Durable technology, robust workmanship
Energy efficient: Recirculation mode saves heating costs in winter

Customer testimonial

Stefan Hartl
Stefan Hartl, Workshop Foreman, Pfaffinger Anlagenbau & Energietechnik GmbH

„The two extraction systems fit perfectly into our two new shops. According to the Pfaffinger 361° principle of 'Always be one degree better,' we want to set standards as an employer not only for our customers, but also for our employees. This particularly includes occupational health and safety.“

Services that convinced Pfaffinger Anlagenbau & Energietechnik

Personal contact with the qualified sales area manager
Sound technical advice in the field of W3 for stainless steel dusts
Optimal design of the system based on flow analysis
Configuration of the extraction system as required: Spot extraction coupled with shop ventilation
On-site measurements
Assembly & commissioning by ESTA fitters
Spare parts and accessories conveniently available in the ESTA Shop
Everything from a single source: Support throughout the entire life cycle of the product