SmartFlow Technology

Excessive Energy Costs: Dust Collection Systems are one of the largest energy users in plants and rarely are all workstations operating concurrently. Reduce your utility costs by up to 80% by retrofitting your existing system.

Overcrowded Dust \ Mist \ Fume Collection Systems: Stretch the capacity of your existing system to improve flow on your workstations and have the ability to add additional workstations.

Optimization of a New Collection System: Integrate our technology into your new system design and reduce the system size by up to 40%. This new efficient system will minimize the cost of ownership and provide additional benefits. For example, the technology enables operators to remotely monitor the system operation for maintenance and production analysis purposes.

Our Dust Collection on Demand Products:

Single Machine System - Control Box One, Autogate and Sensor

Shop / Cell System - Control Box 12, Autogates, CLIP Sensors and optional Variable Frequency Drive

Complete Plant System - Master Serial Control Box, Autogates, CLIP Sensors and Variable Frequency Drive

System Components - Automatic Blast Gates, Senors, and Variable Frequency Drives

Benefits:

Reduction in:

1. Energy Consumption (Up to 80% Savings) for the life of the system.
2. Heating, Cooling and Humidifying Costs of Workspace.
3. Wear and Tear of Dust Collection Equipment
4. Emissions to Atmosphere - Permit Costs

Intangible Benefits:

1. Lower noise level in workspace.
2. Reduction in air pollution(CO₂) at energy source
3. Flexibility to change layout and add on new equipment
4. Remote monitoring of system
5. Data Mining for Production Analysis
6. Hedge against future increases in energy costs or reduction in demand
7. Enhance Image

Dust Collection on Demand Technology is a new efficient approach to dust \ fume \ mist collection design. Our engineers use statistical methods to size the pipe system and components to provide only the air flow for the worst case scenario. Below is a general description of operation.

1. Motorized Autogates installed on each workstation hood open and close as directed by the logic in the System Controller.
   
   
2. Sensors installed on each workstation signal the System Controller which machines are in operation.
   
   
3. System Controller closes gates on non-operating machinery and maintains minimum air volume by opening additional gates when necessary. System Controller outputs signal to VFD to set fan speed based on system logic.
   
   
4. Based on the number of operating machines, the logic in the System Controller regulates the fan speed and performance by a Variable Frequency Drive connected to the fan motor. The modulation of air flow according to demand significantly reduces the system's energy consumption compared to when the system is operated at 100% of the total air volume requirement continuously.

Performance of fans is governed by "Affinity Laws" (also known as "Fan Laws"): a small decrease in CFM (cubic feet per minute) volume by closing the gates (red color in chart) translates into significant decrease in energy consumption (kW, green in the chart). That generates significant energy savings

Fan law chart (CFM= air volume in Cubic Feet per Minute, P is pressure inch of water, HP= fan motor HP (power))

A 20% reduction in Air Volume (CFM) lowers the fan motor energy consumption by 49%

This chart explains how fan motor consumption will drop if the system reduces airflow through the fan by using gates:

Adapted from book Clarence A. Phipps, Variable Speed Drives Fundamentals, The Fairmont Press, Inc