Application Overview

Polyethylene filaments are a residual by-product generated during textile production processes. If not properly extracted, these lightweight materials accumulate rapidly, clogging machinery, causing blockages and reducing production efficiency.

DustArrest engineered a customised industrial vacuum system designed specifically for continuous suction in a high-output textile manufacturing environment. The objective was to eliminate filament build-up at source, prevent workflow interruptions and ensure safe, uninterrupted operation.

The Challenge

The client required a high-capacity vacuum solution capable of collecting large volumes of polyethylene filaments without interrupting production. Traditional collection methods resulted in downtime during discharge cycles and increased risk to operators during maintenance.

Engineered Solution: Dual Pre-Separator Continuous System

DustArrest designed a fully customised suction system integrating a powerful three-phase industrial vacuum unit (SV1-836-MBA18-Z21) with two heavy-duty pre-separators operating in alternating mode.

The system ensures continuous, uninterrupted extraction. While Pre-Separator 1 is actively vacuuming, Pre-Separator 2 discharges collected material. The roles then automatically switch, eliminating production pauses typically associated with container emptying.

Core System Configuration

• SV1-836-MBA18-Z21 industrial vacuum unit
• Two Ø570 mm heavy-duty pre-separators with pneumatic discharge
• Sliding damper system for controlled airflow switching
• Dual 100 mm inlet connections for high-volume material transport
• Discharge into one-cubic-metre Big Bags
• Fully grounded installation for maximum operational safety

The sliding damper regulates airflow between the two separators, ensuring precise alternation during suction and discharge cycles.

Given the significant material volumes processed, discharge is carried out into large Big Bags to reduce handling frequency and maintain production efficiency.

Intelligent Switching and Overflow Protection

Through the control panel, operators can set the switching interval between separators based on workload requirements, for example every 10 minutes.

Two electronic level sensors continuously monitor fill levels within each separator. If a unit reaches capacity earlier than expected, the system automatically triggers an early changeover.

This prevents material overfill, protects upstream pipework and ensures constant suction efficiency without interruption.

Advanced Safety System

Operator safety was central to the system design. The discharge zones of both pre-separators are enclosed within protective cages equipped with interlocked access gates.

Visual Safety Monitoring

• Four flashing status lights: two above the pre-separators and two in the discharge area
• Pre-separator lights: red during operation, green when idle
• Discharge area lights: red when operating, green when safe to access
• Orange warning phase provides five-minute pre-lockout notification

If an operator attempts to access the discharge area while the system is active, an alarm siren immediately sounds and the entire installation automatically shuts down.

Industry 4.0 Control Panel Integration

The installation is configured for remote Industry 4.0 management, enabling operational data transmission directly to the company’s ERP system.

This allows:

• Real-time performance monitoring
• Separator cycle tracking
• Operational efficiency analysis
• Data-driven maintenance planning

The intuitive control interface simplifies system management and bridges the gap between production machinery and business analytics.

Vacuum Unit: SV1-836-MBA18-Z21

The suction unit selected for this installation is the SV1-836-MBA18-Z21, a medium-to-high power industrial vacuum engineered for continuous duty applications.

Technical Specifications

• Power: 12.5 kW
• Maximum airflow: up to 1120 m³/h
• Filtering surface: 45,000 cm²
• Collection capacity: 175 litres
• Robust side-channel blower
• Tangential inlet design for improved separation efficiency

Filtration and Safety Features

• M Class antistatic star filtration system
• Fully grounded construction
• High-capacity 175-litre collection bin
• Industrial-grade continuous operation design

Operational Results

The installation now enables continuous collection of polyethylene filaments without interrupting production cycles. Accumulation at machinery is eliminated, reducing blockages and improving overall throughput.

• Reduced unplanned production stoppages
• Improved housekeeping standards
• Enhanced operator safety
• Higher process reliability and efficiency

Custom Industrial Vacuum Engineering by DustArrest

DustArrest designs, engineers and integrates high-performance centralised industrial vacuum systems tailored to demanding production environments. From textile filament extraction to high-volume scrap handling, our solutions combine continuous suction performance, intelligent control systems and advanced safety architecture.

If you require a customised industrial vacuum solution or would like to arrange a technical site assessment, contact DustArrest to discuss your operational requirements.