Plastic processing to the highest standards: The advantages of central extraction

The second extraction system in plastic production with two cyclone pre-separators (right), filter unit (middle, again from the DS6 series), and drive assembly (left). (Image: Ruwac)

In one of the two new extraction systems in Gaplast's production, two modular dust extraction units from the DS6 series (right) handle the filtration. In the foreground: the cyclone separator for the preliminary separation of plastic particles. (Image: Ruwac)

Gaplast GmbH manufactures high-quality plastic components at two locations in the Bavarian Alps – Saulgrub and Peiting – primarily for the pharmaceutical industry and medical technology. As part of an operational expansion, two extraction systems with different capacities were installed, which directly extract and treat the exhaust air from the machines.

Gaplast employs around 300 staff members and produces a broad and demanding range of products for applications in the pharmaceutical and cosmetics industries, but especially in medical technology – for example, implant syringes, airless bag-in-bottle systems, and closure systems for containers.

Very high standards are required not only for process and error safety but also for cleanliness. Production is partly carried out in cleanrooms, and even where it is not necessary, cleanliness takes priority. This is exemplified by two new extraction systems designed by Ruwac, which were installed during an expansion at the Peiting plant and extract air directly from the workspaces of the machines.

The first system processes air containing plastic particles of about three millimeters in diameter (Image 1). A cyclone separator performs preliminary separation. The filter unit comes from the DS6 series and is equipped with generously dimensioned cartridge filters of dust class M. The cleaning as needed is performed by compressed air pulses (Airshock).

The second extraction system (Image 2), installed in a different production area, uses two cyclone separators to perform preliminary separation either individually or in parallel before the dust collector. This allows the necessary airflow velocity in the ductwork to be maintained depending on the number of active suction points. The fill level of the cyclone separators is monitored by vibrating fork sensors.

The drive units of both systems can be regulated as needed via a frequency converter that communicates with the higher-level control system. The separated plastic parts are fed back into recycling in the spirit of circular economy.

The managers at Gaplast are fully satisfied with both systems and see clear advantages in centralizing the extraction technology – including in terms of efficiency, energy savings, and CO2 footprint. And because the extraction systems are now housed in separate rooms, there is no risk of contaminating the production environment during the handling of the extracted material. This is also an advantage of centralized extraction systems.