AES helped Mercury Paper support two new tissue lines with a turnkey tissue dust collection and air conveyance system that captured waste from converting machines, managed fine dust from the manufacturing process, and improved safety with explosion venting, flame and spark detection, and extinguishing protection.
Overview
Mercury Paper, a producer of paper towels and tissue products located in Strasburg, Virginia, expanded its production capabilities by adding two new tissue lines. With the added production capacity, the company needed a reliable way to capture and convey waste from converting machines while managing the fine dust generated during manufacturing.
AES was selected to provide a turnkey dust collection and conveyance solution that included front-end engineering, equipment selection, fabrication, installation, controls, startup, commissioning, and training.
What problem did AES solve?
Mercury Paper needed a system that could support new converting equipment while safely handling tissue dust and production waste. The solution had to capture material at the source, convey it through an integrated air system, manage fine dust, and meet strict NFPA compliance requirements.
AES provided a complete tissue dust collection system with exterior dust collectors, explosion venting, air conveyance ducting, material handling fans, flame and spark detection, extinguishing protection, MCC controls, structural supports, and turnkey installation.
Scope of Work
- FEED & Project Management
- Dust Collectors with Explosion Venting
- Air Conveyance Ducting
- Material Handling Fans
- Flame & Spark Detection System
- Extinguishing System
- System Start-Up, Commissioning & Training
- Mechanical Installation
- Electrical Installation
- Welding & Fabrication
The Challenge
Mercury Paper expanded its production capabilities by adding two new tissue lines, which increased the need for reliable waste capture, air conveyance, and dust collection throughout the converting process.
Tissue converting can generate fine dust that must be controlled safely and efficiently. The new system needed to capture and convey waste from the converting machines while managing airborne dust and supporting NFPA compliance requirements.
The main challenges we had to address:
- Two new tissue lines required dedicated dust and waste collection support.
- Waste from converting machines had to be captured and conveyed efficiently.
- Fine dust from the manufacturing process needed to be safely managed.
- Exterior dust collectors required explosion venting for NFPA compliance.
- Flame and spark detection had to be installed on each new converting line.
- Structural supports, ladders, safety rails, controls, and installation had to be coordinated as one turnkey project.
AES needed to provide a complete system that combined engineering, dust collection, air conveyance, safety protection, fabrication, controls, installation, startup, commissioning, and training into one coordinated solution.
The AES Solution
AES designed and installed a turnkey tissue dust collection system built around Mercury Paper’s new converting lines. The system included air conveyance ducting, heavy-duty industrial material handling fans, and two exterior dust collectors with explosion venting to support NFPA compliance.
AES also installed a flame and spark detection and extinguishing system on each new converting line. The system was controlled by a 460V motor control center, with fabricated support structures, man ladders, and safety rails included as part of the complete project package.
AES System Components
The tissue dust collection system included:
- Air conveyance ducting
- Heavy-duty material handling fans
- Two exterior dust collectors
- Explosion venting
- Flame and spark detection system
- Extinguishing system
- 460V motor control center
- Structural support fabrication
- Man ladders and safety rails
- Custom integrated dust collection and conveyance layout
The completed system gave Mercury Paper the dust collection, conveyance, and safety infrastructure needed to support its expanded tissue production capabilities.
By combining FEED, project management, dust collection, air conveyance, spark detection, fabrication, controls, installation, commissioning, and training, AES delivered a turnkey system built for safe and efficient tissue converting operations.
The Results
With the new tissue dust collection system in place, Mercury Paper gained a turnkey solution to capture and convey waste from its converting machines while managing fine dust generated during the manufacturing process.
The completed system supported the company’s two new tissue lines with exterior dust collectors, explosion venting, flame and spark detection, extinguishing protection, MCC controls, fabrication, installation, commissioning, and training.
Download the Full Case Study
Download the complete Mercury Paper case study to see how AES designed and installed a turnkey tissue dust collection system with air conveyance, dust collectors, explosion venting, spark detection, MCC controls, fabrication, installation, and commissioning.
A Turnkey Tissue Dust Collection System Built for Safer Production
This project shows how a properly engineered dust collection and conveyance system can support production growth while helping manage fine dust, waste capture, and safety requirements. For Mercury Paper, AES helped support two new tissue lines with a system designed around converting equipment, air conveyance, dust collection, controls, and compliance needs.
For tissue manufacturers, paper converters, towel producers, and other facilities handling fine dust and lightweight production waste, AES designs custom systems around the real production environment, material flow, equipment layout, safety requirements, and long-term operating goals.
Frequently Asked Questions
A tissue dust collection system captures and conveys fine dust and lightweight waste generated during tissue, towel, and paper converting operations.
Mercury Paper added two new tissue lines and needed a turnkey system to capture waste from converting machines while managing fine dust from the manufacturing process.
The system included air conveyance ducting, heavy-duty material handling fans, two exterior dust collectors, explosion venting, flame and spark detection, extinguishing protection, a 460V MCC, structural supports, man ladders, and safety rails.
Flame and spark detection and extinguishing protection were included to help identify and suppress ignition risks in the dust collection and conveyance process.
Yes. AES designs and installs custom dust collection, air conveyance, spark detection, fabrication, controls, and turnkey installation packages for tissue, paper, converting, and other industrial manufacturing facilities.
