Our customer, Auria Solutions USA, required automotive acoustic carpet trim removal to improve productivity and increase recycling.
Auria Solutions is the world’s second largest supplier of automotive acoustic and other fiber-based products, with it’s global headquarters is in the UK with operational centres in the USA and Germany.
Auria contacted Impact Air Systems for a solution to remove and bale hand stripped skeletal fibre waste and blanks from its automated moulding line, water cutting cells at the Freemont, Ohio facility. The skeletal trim waste was particularly large in overall size measuring around 2.8m x 2.0m and needed to be pneumatically conveyed from the production cell, whole, without any further size reduction (shredding). After Impact carried out proof of concept trials that pneumatically conveying such large material would be possible, Auria Solutions were confident they had selected the right project partner to help increase their production efficiency, reduce labour costs and increase recycling of waste materials.
Our solution
Due to the unusual characteristics of the material to be collected, Impact’s technical engineering team designed bespoke troughs which are located between each pair of water cutting cells, suitable in size to allow ease of use by the operators, but small enough to allow the waste material to be drawn away once waste is offered to the hood.
The material is conveyed via an extraction ductwork circuit and discharged by a rotary material separator and onto an incline belt conveyor feeding material to a twin-ram hydraulic baler.
Impact partnered with Recycling Equipment Inc. (REI), South Carolina, who manufactured and installed the baler for this project. Impact and REI have enjoyed a long standing working partnership within the USA and have completed numerous projects together. Final baled material from the Auria Freemont site is then transported to another Auria Facility where it is recycled and reused into new Auria products.
The system is designed to operate from only one of the two collection points at any one time and is controlled based on a sequencing system to provide service to each collection point as demand requires. This approach allowed us to keep the overall size of the system to a sensible size and also allows future collection points to be added with minimal upgrading of the main system infrastructure.
A summer/winter diverter system was included to vent the warm, clean exhaust air from the system outside the building in the summer months, and in the winter months, this exhaust air would be discharged inside the factory building.
Customer testimonial
Todd Hickmann, Auria Plant Manager, commented on the installation:
“Impact Air Systems have delivered 100% on all aspects of the solution required. The project was on time, on budget and met our expectations straight out of the box.
Impact have demonstrated, at every step of the project, how professional and knowledgeable they are and have been a pleasure to deal with. This expertly engineered solution is proving to be effective and efficient, and will provide many years of benefit to the Auria business.”
From full turnkey trim extraction systems to standalone extraction units...
From full turnkey trim extraction systems to standalone extraction units...
Download DocumentationFor all enquiries, please complete the form below or email us and we will get back to you very soon. Alternatively, call us on 0116 2448855 to discuss your requirements.We look forward to hearing from you!
Our robust range of solutions allows us to confidently manage your dust issue.
Our robust range of solutions allows us to confidently manage your dust issue.
For all enquiries, please complete the form below or email us and we will get back to you very soon. Alternatively, call us on 0116 2448855 to discuss your requirements.We look forward to hearing from you!
Impact’s ventilation systems remove moist, warm air and replaces it...
Impact’s ventilation systems remove moist, warm air and replaces it...
For all enquiries, please complete the form below or email us and we will get back to you very soon. Alternatively, call us on 0116 2448855 to discuss your requirements.We look forward to hearing from you!
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