Case study

Hybrid solution – Dust extraction of high and low vacuum applications with a single dust collector

Key achievements

Compliance with ATEX directives

Bag-In Bag-Out (BIBO) system for increased operator safety

Optimised handling of dust discharge

Customer:

Pharmaceutical manufacturer of OSD products

Location:

Netherlands
 

Sector:

Pharmaceutical Industry
 

Solution

For this project, Camfil recommended the Quad Pulse Package II dust collector, which is specifically designed for extracting dust from pharmaceutical processes and to operate on high-vacuum applications. The installation contains the following:
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  • Compact dust collector with two filter cartridges, operating with the quad pulse cleaning system which pulses one quadrant at a time so that the dust collector is always online and air flow is never interrupted.
  • An additional integrated H13 HEPA filter guarantees the desired degree of filtration before the cleaned process air enters the outdoor environment.
  • The integrated Bag-In Bag-Out (BIBO) safe-change system for the two main filter cartridges as well as the included secondary H13 HEPA filter stage provides the necessary protection for operators performing filter change.
  • The space-saving design and the pressure shock resistant housing make the QPP2 ideal for indoor installation close to the process (ATEX explosion protection certified to category 1).
  • For additional protection, the installation includes a Fast Acting Valve (FAV) which creates a mechanical barrier within the ducting that effectively isolates pressure and flame fronts.
  • The installation contains two linked fans which secure the enormous mandatory under pressure (25kpa) combined with the necessary air volume, combining the vacuum application and dust extraction in one piping system.
  • The unit operates with an energy efficient Variable Speed Drive (VSD) inverter in order to always provide a constant air volume.

Process overview  

The core business of the customer is to manufacture Oral Solid Dosage (OSD) products for the pharma industry. The task on this project was to replace an existing dust collection system for the extraction of process dust from five tableting machines as well as dust from a central vacuum system with 7 high vacuum extraction points. Both the dust extraction and vacuum cleaning process had to be handled simultaneously and the customer was looking for a solution providing a higher air volume.

Due to the installation situation, the project had to be carried out it two phases in order to reduce production downtime. First thing was the installation of the dust collector, second phase started with the installation of the ductwork and the commissioning of the entire system.

Challenges  

The ideal dust collection solution should be able to handle the extraction or process dust from machinery but also the dust from a central vacuum system with up to 7 extraction points  simultaneously.
The customer required a containment system to protect operators from exposure to harmful pharmaceutical dust while performing maintenance work.
Limited space for the installation of an dust extraction system.

Product

Product:
Quad Pulse Package
Model:
QPP2 PX
Airflow:
3,000 m³/h
Filter Offering:
2 x filter cartridges, secondary filter stage HEPA H13
Accessories:
Dual valve (waste dust discharge system), Fast Acting Valve (active explosion isolation device), BIBO safe-change system, Variable Speed Drive inverter
Application:
Tableting, central vacuum cleaning
Installation Date:
2022
Learn more about the quad pulse package dust collector

Results

Project planning: Due to tight project planning, Camfil delivered, installed and commissioned the desired extraction solution in the given timeframe and therefore minimised production downtime.

ATEX compliance: Thanks to the pressure shock resistant housing, no additional explosion protection equipment is needed and the small footprint of the QPP2 allows installation in the nearby storage room.

Personnel safety: The integrated BIBO safe-change system provides the required safety for operators performing filter change.

Project extension: According to changed process conditions, Camfil upgraded the dust discharge from a regular bin to a continuous liner system in combination with a Camfil Dual Valve (CDV) system, what in turn reduces the workload when changing bags.

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