We recently completed a major scrap handling system upgrade for DS Smith that included replacement of an existing cyclone and ductwork, installation of a new 80,000 CFM cyclone system, new material handling fans and rooftop ducting, and integration of a new Balemaster E-1070 auto-tie baler.
This project required our team to coordinate equipment design, demolition, mechanical installation, rooftop construction, ductwork, rigging, and baler integration as part of their conveyance system upgrade, as well as keeping the plant operational during the install.
Replacing the Existing Cyclone and Conveyance System
The project involved replacing the facility’s existing cyclone and associated ductwork with a new 20-foot cyclone designed for 80,000 CFM at a 500-velocity outlet.
The new cyclone configuration included an exhaust muffler and sprinkler heads, along with multiple incoming conveyance lines. These consisted of two 18-inch inlets, five 16-inch inlets, and two 13-inch inlets, all equipped with backdraft dampers.
AES also supplied the cyclone support steel and incorporated a fan platform into the structure. Bringing these components together required the new equipment and ducting to be engineered around the facility, its existing production equipment, and the material flow requirements of the scrap handling system.
New Fans and Rooftop Ductwork with Baler chute and Divert Valve Integration
The upgrade included new fans serving multiple production machines throughout the DS Smith facility, including the Corrugator, Ward 66, Martin 924, Latitude, GeoPFert, Martin DRO, EMBA 245 FFG, and Bobst 160S.
With the exception of the corrugator fan, the new fans were installed on the cyclone platform. New rooftop ductwork connects the production equipment to the upgraded scrap conveyance system and cyclone.
The project also included a new baler feed chute with roof flashing and a baler chute divert valve. These components create the connection between the overhead scrap handling system and the baling equipment below. The cyclone, ductwork, chute, and baler were designed and installed as parts of one coordinated material handling system.
Industrial fans, duct sizing, equipment locations, and airflow requirements all have to work together as part of that system. We design custom conveyance systems like this around factors including material type, required air volume, pressure requirements, duct layout, and downstream equipment.
See our case studies for a closer look at the engineering, planning, equipment integration, and installation work that goes into upgrades like this.
Balemaster E-1070 Auto-Tie Baler
At the end of the scrap handling system, AES installed a new Balemaster E-1070 auto-tie baler for DS Smith.
The baler installation included:
- Feed chute
- Fused disconnect
- Air-to-oil cooler
- Touchscreen operator interface
The auto-tie configuration allows the baler to handle the tying portion of the baling cycle automatically, making it well suited to an integrated, high-volume scrap handling application.
Choosing the right baler depends on more than the type of material being processed. Throughput, loading method, available space, automation requirements, and future capacity all play a role in selecting equipment that fits the operation. If you’re evaluating equipment for your own facility, read our guide to choosing the right baling equipment.
AES integrated the new baler with the upstream cyclone, ductwork, and material handling equipment so collected production scrap can move through the system to its final baling stage.
Crane Rigging, Mechanical Installation, and Demolition
Completing an installation of this size required significant project management beyond supplying the equipment. The project required demolition and removal of the old cyclone and ductwork, after having the new system operational.
Once removal was completed, AES handled the mechanical installation and provided the rigging equipment required for the project, including cranes used to position major components on the roof.
Coordinating the demolition, crane work, structural installation, mechanical connections, and equipment placement was an important part of the overall project.
The Result: A Turnkey Scrap Handling System Upgrade for DS Smith
This project demonstrates the scope involved in replacing and modernizing an integrated system to an existing facility. The completed project combined the new cyclone and multiple material handling fans, pneumatic ductwork, structural steel, baler chute components, and Balemaster auto-tie baler into one turnkey scrap conveyance system.
AES projects include upfront engineering and system design, project management, equipment installation, commissioning, and operator training. Managing those stages together allows AES to account for how the individual components need to interact within the facility rather than approaching each piece of equipment as a standalone installation.
For manufacturers considering a cyclone replacement or upgrade, AES can evaluate the complete material handling process and engineer the equipment, airflow, ducting, structural requirements, and downstream baling system around the application.
Need Expert Help Upgrading Your Scrap Handling System?
Our team at AES is always ready to help you with expert advice and support. Contact us today.
