Overview
A large flooring manufacturer producing vinyl-based products relied on pneumatic conveying systems to move fine vinyl powder through multiple stages of production. This powder plays a critical role in producing finished flooring materials, and uninterrupted, clean material flow is essential to maintaining plant safety, efficiency, and output consistency.
Persistent leakage issues in the material transfer process created operational and safety concerns, prompting the manufacturer to seek a more reliable rotary airlock solution.
Challenges
The vinyl powder handling process presented several ongoing challenges:
- Repeated shaft seal failures in rotary airlock equipment
- Vinyl powder leakage causing material loss and cleanup issues
- Safety risks created by powder accumulation in processing areas
- Frequent production interruptions due to seal replacement
- Elevated maintenance demands and downtime
- Reduced overall efficiency of the pneumatic conveying system
The existing sealing approach was unable to withstand internal conveying pressures over time, resulting in recurring failures.
Solutions
An upgraded rotary airlock and sealing solution was engineered to address leakage, reliability, and maintenance concerns.
Key elements of the solution included:
- A heavy-duty rotary airlock designed for fine, non-abrasive powders
- A non-contacting labyrinth-style mechanical seal to eliminate shaft leakage
- Sealed, maintenance-free bearing arrangements
- A direct replacement design to simplify installation and integration
- A sealing configuration that creates a positive barrier to retain material within the valve
The solution was designed to withstand pneumatic conveying conditions while reducing wear and eliminating common failure points.
Results
The upgraded airlock system delivered meaningful operational improvements:
- Elimination of vinyl powder leakage at transfer points
- Cleaner, safer production areas with reduced cleanup requirements
- Improved reliability and consistency in material conveying
- Reduced maintenance effort and fewer unplanned stoppages
- Increased production stability and operational efficiency
- Lower overall material handling and operating costs
By resolving the root cause of seal failure, the manufacturer achieved a safer, more efficient vinyl powder handling process.
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