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Scrap System Upgrade in Tight
Shutdown Window
11 March 2026
integratedAIR was appointed to design and implement a
complete upgrade of an ageing scrap extraction and baler feed system within a
high-output can manufacturing facility. The existing system was over 30 years
old and no longer capable of supporting the site’s operational demands.
The project required the full strip-out of the existing
scrap system, installation of new air separators, ductwork, platforms, and
controls, and preparation for the integration of two new balers, all within a
strictly limited factory shutdown period.
This project involved a number of technical and logistical
challenges. The installation of the new system, as well as the removal of the
old one, had to be finished within a set 14-day shutdown period. Due to the
baler room's minimal capacity, there were few possible layouts, and precise
engineering was needed. The age of the existing infrastructure meant that
commissioning also required the careful integration and rebalancing of older
fans and ductwork.
Structural constraints also had to be addressed, with the
existing roof and mezzanine removed and modified to accommodate the new
equipment. In parallel, operational continuity was maintained through extensive
pre-shutdown works, enabling the factory to remain fully operational until
shutdown commenced.
The integratedAIR team was on site two weeks
before the factory shutdown. During this phase, the team made extensive
preparations so that once the shutdown began, all activities could be carried
out swiftly.
The team carried out detailed site surveys and finalised the
installation sequence at an early stage. Opportunities were identified to
fabricate, assemble, and prepare essential elements in advance, including
exhaust fans, silencers, and control panel components. Wherever possible,
sections of the system were built off-site, with crane lifts planned in detail
to minimise on-site installation time. This meticulous preparation meant that
once the shutdown began, all activities could progress without delay.
Once the factory entered shutdown, integratedAIR mobilised
immediately. The baler area's roof was temporarily removed. During the shutdown
period, integratedAIR carried out the full strip-out of the existing scrap
system, excluding the balers, and installed a new mezzanine platform supported
by a complete structural design. The works included installing two air
separators, one with provision for a future whole
can, along with new ductwork, exhaust air ducting, and associated
supports.
New roof-mounted silencers were installed, supported by
structural upgrades to accommodate the additional load. All associated controls
for the weigh hopper, new exhaust fans, and trimmer fan were wired and
commissioned as part of the shutdown works.
The design engineers effort was particularly noteworthy,
ensuring that all equipment fit together within the confined baler room while
still allowing for future expansion.
An external specialist
contractor carried out the physical installation. Due to their position at the
base of the scrap handling process, the balers and all associated equipment had
to be fully installed before integratedAIR could complete the final scrap system
works.
This sequencing was critical, as the scrap extraction system
needed to be designed and configured around the balers to ensure correct
alignment, airflow, and material flow. Once the balers and related equipment
were in place, integratedAIR completed the integration and commissioning
process, ensuring the balers operated correctly in line with the upgraded scrap
system and performed as intended within the modified installation.
The scrap management system saw several notable improvements
as a result of the modification. A contemporary, high-efficiency solution,
created to meet current operational demands, replaced an installation that was
more than 30 years old. To accommodate future expansion, two new air separators
with additional capacity were added. The installation of new control panels enhanced problem
diagnosis and overall system control and existing fans were rebalanced during
commissioning to guarantee peak performance with the new system.
Despite the project’s complexity, the confined space in the
baler room and the tight shutdown window, integratedAIR completed all work well
within the 14-day deadline. As a result, the factory restarted production on
schedule, with a fully upgraded scrap extraction system in place. If you have a project that requires expertise
in large-scale industrial scrap and air-handling systems, contact
integratedAIR today to find out how we can support your operations.
