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SANTONI ELECTRIC CO. P. LTD. | ||||
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Industrial
Cleaning, |
1. CENTRALIZED DUST COLLECTION SYSTEM
For a Brake-shoe linings and clutch facing manufacturer M/s Brakewel Automotive Components (I) P. Ltd., NOIDA, UP, India (a suburb of New Delhi) approached SANTONI for the replacement of an existing central dust collection system.
This system had been supplied by a typical back-yard fabricator, who understood little about dust collection. Most of the grinding machines were provided with make-shift hoods or the duct hose was simply placed near the source point As a net effect the premises, where toxic asbestos was processed, looked like hell on the earth. Obviously, the workers in the premises, despite the simple filter masks on their noses, were being criminally subjected to inhuman conditions.
The proprietor of the company, though inclined to upgrade the dust collection system, was not willing to invest the kind of money that is required for a dust collection system appropriate for an asbestos processing unit. We studied the working of various grinders in the unit - some of them were vertical grinders, double head grinders, etc. and designed suction hoods which could, post-facto, be installed on the grinders to achieve better extraction efficiency.
After installing a new dust collection system covering some 12 points, the premises does not exactly look like heaven, but it certainly is not the kind of hell it used to be.
M/s K&K Auto P. Ltd. Hosur (Near Bangalore, India), is an ancillary unit of TVS automobiles, manufacturing brake shoes for two wheelers. On their various types of grinders they were using eleven 3 HP dust collectors from one of our competitors with least amount of satisfaction. The reasons for unsatisfactory performance were found to be two fold :
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The supplier had supplied the dust collectors only but no SUCTION HOODS. The user had fitted some make shift arrangement in place of SUCTION HOODS, which of course was not good enough to suck the dust efficiently.
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The dust collectors, though with 3 HP blowers, had a very small filter and the dust was being collected INSIDE THE FILTER BAG choking it very fast.
We offered 0.5 HP dust collectors (SANTONI DC-200) in place of 3HP dust collectors and advised them on the design of suction hoods and the customer, being cautious, purchased one machine to begin with. When the performance was found to be satisfactory he gradually changed all the eleven old dust collectors with SANTONI dust collectors - saving over Rs. 200,000 (USD 4,500/-) in power bills alone per year as a bonus with the higher performance as the main benefit.
M/s I. K. ENTERPRISES, NOIDA, UP, India, manufacture silver-ware. They were using make-shift dust collectors for the buffing machines in their plant. Due to poor extraction (and collection) efficiency the workers were working with cloth masks to protect themselves from the fine dust.
On the advise of Mr. Sandeep Dayal (consultant - jewelry production) the owner of the company Mrs. I. Kochhar contacted us.
Now, the sizes of the silverware manufactured by I K Enterprises is so varied (starting from a an inch to 4 feet) that it was not possible to handle all of them with one type of suction hoods and still be energy efficient. We, therefore, advised her to dedicate one buffing machine to one size range of items (like items up to 6 inches, over 6 inches up to 12 inches, etc.) and designed suction hoods accordingly.
The central duct collector supplied to them is not only made a marked difference in terms of extraction efficiency (almost 100%) but also in terms of collection efficiency (the dust collector paid back for its whole cost within 3 months due to increased collection of recyclable silver).
When the first super computer was installed by the DEPARTMENT OF SCIENCE & TECHNOLOGY at Mausam Bhawan, New Delhi, India, they needed a vacuum cleaner for the SUPER CLEAN ROOM area. SANTONI manufactured the FIRST ULTRA CLEANER IN INDIA for this application, fitted with HEPA FILTER.
M/s ETERNIT EVEREST LTD., New Delhi (with 6 plants at different locations all over India) deal in ASBESTOS based products. Asbestos, being a toxic material, has to be handled carefully and, therefore, they needed vacuum cleaners with HEPA FILTERS. SANTONI has supplied many ultra cleaners to this company over the years which are all working satisfactorily, as per European standards.
Gold & silver bulk jewelry
manufacture
rs
have preferred SANTONI for obvious reasons - it gives them fastest
payback.
But VAIBHAV GEMS LTD. (Jaipur) had a very different application -
to collect any
residual gold dust from the ambient air. We, therefore, had
to work in collaboration with
the company that supplied the air-conditioning
equipment (Blue Star Ltd.). While Blue Star
supplied the chiller plant and
the AHU, along with the cold air delivery ducts, SANTONI
supplied special ducts
for the return air. These ducts were smooth inside with much higher
air
velocity (compared to the return air ducts of normal air-conditioning systems)
so that
the dust would not settle down in the ducts.
This return air was passed through a cartridge filter system with filter media of the cartridge elements from NORDIC (Denmark). This system extracts the gold dust from the air to the extent of 99.99% (down to 1 micron) and 86.6% (down to 0.3 microns). The net result is not only super clean air for the people working in the premises, but also cash profits.
6.
FUME EXTRACTION FROM
A
CNC PLASMA CUTTING MACHINE
Plasma cutting produces a lot of fumes. Extraction of fumes from large cutting tables can be extremely power consuming process (because of large area to be subjected to suction). SANTONI has improvised on it by dividing the 4.5 m x 17 m table into seventeen sections of 4.5 x 1 m each, and a duct with doors opening in each of these sections, is connected to a 10 hp suction blower with stack. The doors are actuated with pneumatic cylinders - in sync with the cutting torches.
This system has ensured exceptionally high efficiency of fume extraction with a relatively small power consumtion.