Centralized dust collector for Brake shoe grinding dust collector

Enhancing Dust Collection Efficiency for Automobile Brake Shoe Manufacturers:

Client: Leading Automobile Brake Shoe Manufacturer in Bangalore  /   Industry: Automobile Parts Manufacturing     /     Problem: Inefficient Dust Collection System

Previous System:

• Machine: 10 HP Dust Collector with Autopulse Cleaning System
• Issues: Low suction, frequent filter choking, limited production capacity
• Dust Collection: 50 kg per day

The Challenge:

Our client, a renowned manufacturer of automobile brake shoes, was facing significant challenges with their existing dust collection system. The old 10 HP dust collector, despite having an Autopulse cleaning system, was not meeting their operational needs. Key issues included:

• Low Suction Power: The system's suction was insufficient, causing poor dust extraction from the grinding process.
• Frequent Filter Choking: The filters were constantly choking due to high dust load, leading to frequent maintenance and downtime.
• Limited Productivity: The inefficiencies in the dust collection system were directly impacting the client's productivity, as they couldn't run their production continuously.
• High Power Consumption: The existing system consumed a significant amount of power without delivering adequate performance.

Cleantek Solution:

To address these issues, Cleantek provided a customized dust collection solution:

System Provided:

• Model: UDC700CY Dust Collector with Cyclone Separator
• Power: 7.5 hp, significantly less than the previous 10 HP system
• Features: Integrated dust filter with Autopulse cleaning system

Implementation Details:

• Cyclone Separator: Our cyclone separator efficiently separates 80% of the dust into a dust collection tank, significantly reducing the load on the filters.
• Enhanced Suction Performance: The new system extracts dust from four grinding ports, ensuring high suction performance.
• Reduced Filter Choking: With the cyclone separator handling the majority of the dust, the filter bag only processes 20% of the dust, preventing filter choking and ensuring continuous operation.

Measurable Outcomes

Since the installation of the UDC700CY model 10 months ago, the client has experienced remarkable improvements:

• Increased Productivity: Continuous operation without downtime for filter maintenance has significantly boosted productivity.
• Enhanced Filtration: Higher-level filtration has been achieved with no instances of filter choking.
• Energy Efficiency: The new 2.2 kW system consumes significantly less power than the previous 10 HP system, leading to cost savings.
• Operational Reliability: The client has reported no complaints or issues with the system, reflecting its reliability and efficiency.
• Dust Collection Efficiency: The system maintains effective dust collection, ensuring a clean and safe working environment.

Conclusion:

Cleantek UDC700CY dust collector with cyclone separator has successfully addressed the challenges faced by the automobile brake shoe manufacturer. By providing a more efficient, reliable, and energy-saving dust collection solution, we have enhanced their operational efficiency and productivity. This case study underscores Cleantek’s commitment to delivering tailored solutions that meet the specific needs of our clients, ensuring their success and satisfaction.

Client Testimonial: "The new dust collection system from Cleantek has revolutionized our production process. We no longer face downtime due to filter issues, and our productivity has soared. The system’s efficiency and low power consumption have also led to significant cost savings. We are extremely satisfied with the performance and reliability of the Cleantek solution."