Industry Sectors : Beverage Can

Beverage Can Industry Solutions

During our many years of trading, we have established vast experience providing a range of solutions to support modern day, high speed production of beverage cans. Working with leading international beverage can manufacturing companies, specialist canning facility consultants and OEM suppliers, Impact has been able to install a range of systems and solutions all over the world.

Waste Extraction Solutions
To support high speed recovery of steel or aluminium scrap, generated from the cupping presses, body maker trimmers and whole reject can collection points, Impact are able to offer an efficient, robust and cost effective waste extraction system which incorporates a number of special features. These key features ensure improved durability to ensure trouble free operation expected during 24 x 7 operations.

These features include:

• High performance cupping press / trimmer waste collection hoods.
• Whole reject product collection hoppers or telescopic extraction nozzles.
• Heavy duty conveying ductwork and special bevcan grade flanged joints (available in galvanized or high quality powder coated finish).
• Inline oil mist separation to remove the bulk of oil mist generated from the body maker trimmers for recycling or disposal.
• Heavy duty chopper fan with special features to ensure improved durability and performance.
• Up-rated advance screen material separators.
• Baler feed chute with integrated pre-weigh hopper and standby facility.
• State of the art system controls, automation and diagnostics.

 

Sprayer powder extraction / recovery

To eliminate unwanted odours and dangerous overspray from the lacquer that is applied to the internal surface of the beverage can, Impact are able to offer a highly efficient and fully certified spray powder and conveyor fume extraction system.

Over spray from the lacquer spray application is efficiently extracted along with the solvent fumes emitted from the transportation conveyor to the IBO.

 

Explosion rated ductwork conveys the spray dust and fumes to a fully automatic reverse jet filter assembly. This filter unit provides primary recovery of the dust and is fully Atex compliant and includes vertical discharge explosion relief panels and discharge chute. A second stage bag filter followed by a third stage absolute filter will ensure a very high cleaning efficiency of above 99.9% is achieved and also acts as a backup security filter in the unlikely event of malfunction of the primary filter assembly.

The conveying air stream is provided by a high efficiency backward curve, direct drive centrifugal fan with spark minimising features which is installed on the clean side of the extraction system.

 

 

Inker temperature controlling module
As the printers print the logo or label on each beverage can at high speed, they generate heat and need cooling. To provide optimum print quality, the ink temperature needs to be constant. As different colours are used in different quantities depending on the desired label configuration, so the amount of heat generated by the inking rollers varies.

Impact are able to offer an inker temperature controlling module which provides individual controllable cooling or heating circuits to maintain a constant temperature to the ink ducts / roller gearboxes, helping to optimise print quality and reduce overhead costs. The cooling duty of a printer is typically 35KW and this has historically been provided by the dedicated chiller plant.

We are able to replace this cooling duty offered by conventional chiller units with a ‘free cooling’ system, created by installing a heat exchanger on the incoming mains water to the wash. This can generate up to 250KW of free cooling.

When heat is required to maintain the ink temperature during a shutdown of the printer unit or when the can feed stops, the inker temperature controlling module incorporates a 6KW titanium heater element to prevent the cooling water ‘over cooling’ the ink ducts / roller gearboxes, which could cause problems at start up.

The inker temperature controlling module can typically accommodate up to eight head printer units with  individual temperature control to each head. A heavy duty water pump provides circulation of the cooling / heating water working in conjunction with a series of values to ensure the water is fed to the point of requirement. The unit is neatly housed in a mild steel powder coated enclosure. A floor mounted manifold unit installed in close proximity to the printer unit ensures a neat installation to minimise flexible hose runs between the printer and temperature controlling module.

Basecoater / Decorator / Over Varnish – fume / mist extraction and filter system Can production facilities have traditionally endured strong solvent odours, fumes and fine airborne particles as a result of the various production processes coupled with very warm ambient temperatures making the working environment unpleasant.

Modern day production facilities demand clean, airy, pleasant working conditions. Impact Air Systems have developed a number of solutions that fully support these objectives, including a range of fume and mist extraction and filtration systems for the can base coater, printer and over varnish unit.

To provide efficient extraction to the application rollers on the base coater, printer and over varnish unit we typically install a bespoke, custom fabricated stainless steel extraction hood, mounted in close proximity to the application rollers. These hoods enable any over spray and fumes to be collected efficiently without impeding operator access or machine operation. Each hood is ducted from each roller via flexible hose into a central ductwork system to a pre separator unit.

 

A central pre filter and absolute filter unit provide the final collection of dust and fine particles before discharging the clean air to atmosphere outside the factory. The filter media used ensures long life expectancy whilst ensuring reliable particle capture. A pair of high efficiency direct drive centrifugal fan assemblies installed in series will provide the necessary extraction volumes to ensure the correct air volume is applied to each extraction hood. To give a constant air flow over the life of the filter units, we incorporate variable speed motor drive to the main fan, which takes a signal from a pressure transducer installed within the discharge duct.