Recently, one of the world’s largest producers of aluminum initiated a study to determine the costs associated with material spillage in their facilities. The purpose of their internal investigation was to quantify the time, money, and production losses derived from material spillage and accumulation in their rodding shop (the portion of the aluminum making process in which the anode rods are recycled). Their findings were astounding.
Underneath the conveyors in the rodding shop were mountains of spilled material. This material would accumulate to dangerous levels, causing safety hazards for workers to potentially slip or trip, interference with conveyor belt operation, an inability to service the conveyors, and a constant cleaning requirement. Essentially, the accumulation of material would reduce the lifespan of conveyor components while simultaneously preventing maintenance personnel from being able to service the failed components.
So, the spilled material would be vacuumed from the affected area, conveyor maintenance would be performed, and then the (vicious) cycle would repeat.
Overall, these spills cost over $85,000 per year in cleaning costs (vacuuming spilled material weekly at a cost of $1,650.00), 7100 minutes of unscheduled downtime loss (the process must be stopped during vacuuming and repair to the conveyors), an increased safety risk due to slips and trips on the spilled material, and reduced life of their conveyor belting, rollers, and pulleys due to operating in bath of rubble and dust.
Finding a solution for this problem was no small matter. This customer needed a permanent and reliable solution to eliminate the mountains of material underneath their conveyors. And that solution was to install EXAIR Super Air Knives on the underside of the belts, aimed opposite the direction of belt travel, and aimed toward the dust collection system, as shown below. Before and after photos of the installation are shown below as well.
The images above show how the Super Air Knives perfectly solve this problem. They prevent the accumulation of material underneath the conveyors, eliminating $85,000/year in cleaning costs and 7100 minutes of unscheduled downtime, removing the safety and maintenance concern, and adding longevity to the conveyor components.
Cleaning intervals were revised from daily requirements to an interval up to 12 weeks in some locations. (The shortest interval was revised from daily to every 3 weeks.)
So, the burning question is “How much did this solution cost the end user?”
Total costs to implement this solution were $16,000.00. Based on the cleaning costs alone, the return on investment for this project was under three months. When the downtime and additional conveyor maintenance is factored in, ROI is realized even faster, perhaps in under two months.
For EXAIR Application Engineers, thoroughly identifying customer problems and integrating an optimal solution is one of our specialties. In this case we were able to see the benefits our products can have on a single process, saving the customer tens of thousands of dollars per year.
If you have a problem plaguing your facility and would like to discuss potential solutions using EXAIR products, contact one of our Application Engineers. We’ll be happy to help.