Partial restrictions in Pneumatic Conveying Systems normally do not appear without any warning. This article lists some of the early warning signs and thus enables actions to prevent a partial restriction becoming a total shutdown.

Sudden Drop or Spike in Line Pressure

A sharp drop in line pressure (indicated by the corresponding change in the reading on the pressure gauge) could indicate that a blockage has occurred, with resulting bypass of the material by the air; a sharp rise in line pressure may be an early warning sign of a restriction building up in the line.

Irregular or Pulsing Material Flow at Discharge

Material flowing through the pneumatic conveying line in steady flow should discharge smoothly and consistently from the end of the line. When material is discharged in irregular surges or even stops for periods then there is a problem somewhere upstream of the blockage in the line.

Unusual Motor Load or Fan Noise

The fan or motor may indicate that a restriction is building in the conveying line. A change in pitch of fan noise can often go unnoticed until it is reported by another person. It is therefore wise to cross check the instrument readings with any reported changes in fan noise.

Settling at Bends and Low Points

Pneumatic conveying, like those found at  www.aptech.uk.com/pneumatic-conveying-systems.requires that the air velocity is high enough to hold the material in suspension. Thus when the velocity drops for any reason, the material will settle at bends and low points in the conveying system first.

Rising Cycle Times or Falling Throughput

However, if a batch is taking longer than normal to complete, then the material is being conveyed against a restriction. As mentioned previously, the build-up of pressure due to blockages in pneumatic conveying systems can cause a number of problems, increasing the risk of injury in the workplace. Therefore, falling throughput needs to be addressed as a safety issue as well as a productivity issue.

By recognising these warning signs you can prevent partial blockages developing into complete shutdowns and thereby keep production running safely and for the shortest possible time.

Pager systems can have advantages over mobile phones. Although mobile phones are widely used, pagers are often more reliable for quick communication between staff. They are designed to send short, clear messages without the distractions that come with a smartphone, such as social media, personal calls, or apps.

A pager can often last for several days

One of the biggest advantages of pagers is their long battery life. A pager can last for several days without needing to be charged, while mobile phones may need charging every day. This means staff are less likely to lose communication during a busy shift because of a flat battery. Pager systems can also work well in hospitals where mobile phone signals may be weak.

Some pager systems use their own network, making them dependable even when mobile coverage is poor or the Wi-Fi is unavailable. This is important in emergencies when staff need to receive messages straight away. A pager system from specialists like www.dinggly.com/us/ keeps staff and customers connected. Pager systems can be used in a variety of places, including outpatient departments.

Another benefit is that pagers are simple to use

Staff can quickly see who needs assistance and where they are needed. This helps them respond faster. However, mobile phones do have benefits, such as allowing staff to make calls, send detailed messages, and access care records. Many healthcare organisations continue to use pagers because they are reliable and effective for urgent communication. Their battery life and design make them a useful tool for helping staff communicate quickly.

There are three stages in the sheet metal fabrication process; prototype, batch processing, and mass production. In this brief but informative guide we give you a quick overview of how each process takes place.

Prototype

A prototype is the first step and involves making a mock-up of the final part. A prototype may show up things that need to be changed, such as dimensions or finish. The prototype stage is hugely important as it can prevent losses from batch producing parts that are not quite to your needs. Prototypes can also be used to demonstrate at trade shows or to show investors. Companies such as //dkmsheetmetal.co.uk/ provide prototypes as a key part of their design and development service.

Batch Processing

At this stage of the part in question is produced at a low volume, anywhere from 25 to a thousand pieces. This is an especially necessary step for parts or products that are new and need time to grow in the market. The batch production stage can also respond to changes to the prototype.

Mass Production

Mass production is the stage when a client is ready to sell the part on a large scale. This will usually only be requested once the batch process has proven successful and when there is some sort of guaranteed contract for large scale sales.

All new products should start at the prototype stage to reduce risk and get the final product just right. Mass production should only be entered when you know you have the buyers for your part.

Most systems continue to operate year after year without incident until the point is reached where patching problems to keep the system operating is no longer cost effective and it is time to replace the system a number of times.

Dead Zones That Never Improve

If staff are missing calls in specific parts of your building and repositioning the receiver in different locations does not make a difference then the range of your system has probably deteriorated over time. Radio frequency signals have less consistency with older radio hardware and even with the best of setup there is a point at which no further adjustments can be made.

Missed Calls Are Becoming Routine

The occasional missed call is never going to be perfect but when it becomes a regular occurrence the problem has become apparent. A system that fails to function at its primary function is useless. In addition to normal operation, staff may start to work around the problem by shouting down corridors or using their personal mobiles.

Parts Are Discontinued or Hard to Source

When a manufacturer stops supporting a product line for which there are no more new units in warranty the chances of finding replacement receivers, transmitters, etc. and adequate stocks of batteries in due course also rapidly diminish. As a general rule, the costs of maintaining equipment in a workplace to a satisfactory level of reliability must be balanced against the risks of running an unsupported product but if in doubt it is best to err on the side of caution.

Staff Are Working Around It

Watch how your team behaves during a busy shift. If your staff have stopped using a particular function on a system no longer, then they are working around the problem. This is a much clearer indicator that there is a problem than a fault report.

It Won’t Pair With Newer Hardware

Because many older systems are not able to be paired with newer call button technology, it is likely that you will need a wireless call system that works with current hardware. If you are looking for a Pager System, see https://www.dinggly.com/us/.

If two or three of the above indicators apply to your specific situation then it is time to start looking for a replacement.