New Componit

Performance and Maintenance

When visiting industrial plants, you can come across many situations and unforeseen difficulties, like finding sediments on walls.

Usually, sediments on walls are the result of residual unburned powders or stored powders which, if not promptly and adequately removed, tend to solidify and damage the relative equipment or structure.

To our customers who have reported this problem, we have recently started to offer the Safefon® sound cleaning system, which is a horn powered by compressed air, whose terminal diffuser, placed inside the structure to be cleaned, is able to remove the dust sediment from walls, through the emission of a sound wave.

Want to improve comfort and performance in your plant with a tailored solution?

In an industrial plant, whatever the sector it belongs to, several problems can arise; some of them are common and therefore easily solved. In other cases, however, may occur problems which are more complex to solve.

This is the case of granular materials: we are talking about that dust, which is formed during the industrial process and which can damage the equipment.

As it often happens, in these situations we tend to postpone a problem that doesn’t seem imminent or whose consequences are not immediately visible.

But it is exactly in these cases that, over time, develop encrustation which risk to compromise the proper working of industrial boilers, silos, furnaces, bag filters, heat exchangers, industrial fans, scrubbers, ducts and bag filter housing.

The industrial fields involved are the most different, just think about:

  • Dust from ceramic industry;
  • Steel dust from foundries or steelworks;
  • Gypsum from cement industry;
  • Dusty substances from food, chemical, or pharmaceutical sector;
  • Combustion ashes from power plants;

The incrustations that form are the result of the presence of unburned powders or stored powders which, if not correctly removed, tend to solidify, risking damaging the machinery or jeopardizing its functioning.

Let’s see some examples together:

  • in industrial fans, the accumulation of deposits on the blades can unbalance the rotor and cause dangerous vibrations.
  • ash deposits in boilers and heat exchangers can clog the pipes;
  • in silos the materials risk depositing and creating blockage.

In all these cases, we erroneously think that the dust removal entails expensive, bulky, solutions, also difficult to install/remove or even worse, that interrupts the production cycle.

New Componit has developed SAFEFON® horns, a sound cleaning system, which, unlike more traditional systems, such hammers, air blowers and mechanical retractors, it is versatile and efficient in removing dust.

The low-frequency and high-intensity sound waves create some internal vibrations, that affect the residual deposits and have a fluidifying effect.

The sound impulses are emitted by a pneumatic generator, their frequency is then modulated by a diffuser which can have different shapes and sizes depending on the application requirements and installation needs.

The Safefon® sound cleaning system:

  • doesn’t cause secondary effects to structures
  • is easy to install;
  • works in a fully automated way;
  • has no unwanted stops;
  • guarantees a reduction in operating and maintenance costs.

Want to improve comfort and performance in your plant with a tailored solution?

How many different needs and opportunities are there in the world of industrial fans and in air and flue gas vacuum systems?

Always more frequently, those who produce expansion joints, or like us who design and produce fabric solutions for heat and noise control, are contacted by manufacturers of industrial fans, in order to solve problems, that until a few years ago were neglected.

Soundproof expansion joints, resistant to acids, perhaps made with antistatic materials, thermal or thermo-acoustic jackets, are all accessories required as original part of a fan.

For obvious reasons, the producers of fans, are increasingly involved in the search of the most suitable product for their needs and this pushes us to study more and more innovative solutions.

Want to improve comfort and performance in your plant with a tailored solution?

Since the development of our company is based on a process of continuous research, which has allowed us a constant improvement over the years, we often ask ourselves: “How can we guarantee our customers that our products really meet their needs?”

“How can we be sure to satisfy the technical characteristics required by customers or by a tender specification?”

The data reported on technical data sheets are a starting point, but sometimes they are not enough, in particular if we are talking about highly technological or custom-made solutions.

It is exactly in these cases that the possibility to test the products becomes essential to understand what happens, during the working steps, to the different materials, subjected to extreme and stressful conditions.

Tests, reports, videos e analysis can describe the behavior of materials used under particular stress conditions; this kind of information is important to overcome any doubts about the performance of the product

Furthermore, offering this type of service allows the company to differentiate itself from other competitors.

Obviously, it is necessary to assemble a team specialized in “research and development”, which can work in laboratory and test room, equipped with special software for simulating the working conditions.

Want to improve comfort and performance in your plant with a tailored solution?

Innovation has meant for NEW COMPONIT to focus on quality since the beginning of its history.

In 1992, after a long and hard preparation work, NEW COMPONIT was one of the first small companies in Italy to be certified ISO 9001, accrediting itself with Certificate no. 160, received by CERTIQUALITY.

The preparation was the introduction to a first experience of renewal of the whole business process and the certification opened the way for the qualification at important multinational companies such as General Electric and ENEL in Italy.

NEW COMPONIT helped ENEL to eliminate completely the use of asbestos as insulation material and adopt MIL standard for the choice of alternative material, as already done by US Navy.

Since then, the turbines of thermoelectric plants (steam and gas) have been insulated by means of prefabricated jackets, which perfectly suit the turbine shape and dimension.

These jackets were and still are, made of fiberglass fabrics and felts, that New Componit, faithful to its original mission “textile solutions for heat control”, has hardly looked for all over the world, focusing on products that present lower intrinsic risks and that are classified as non-hazardous to health and with a very low environmental impact.

The commitment for quality has gone in step with the one for safety.

The materials suitable to be used for applications at high temperatures are mainly made of silico-aluminous fibers and require a particular attention and caution to be handled.

NEW COMPONIT has planned its production process of insulation jackets and fabric expansion joints, including particular attention to prevention and protection of the working environment, as well as the use of all necessary defenses to reduce the impact on the workers, who manipulate these materials.

The whole company is equipped with fiber vacuum and air disinfection systems, that ensure a healthy environment.

NEW COMPONIT textile solutions for heat control are always allies in the battle for the defense of environment and the fight against pollution.

Want to improve comfort and performance in your plant with a tailored solution?

The scheduled maintenance of fabric expansion joints has to play an important role in the proper management of production.

Some companies consider the periodic maintenance as a waste of time and money, thinking that it is enough to intervene only when a problem arises.

Skipping the periodic maintenance hoping to save money can be a dangerous mistake, which could cost a sudden stop of the activity and a consequent damage to production, with all the problems that this situation would cause: delays in delivery, product batches to rebuild, equipment to rebuild, etc.

In short , scheduling a periodic maintenance is the first step not to fall into a serious loss of time and an unexpected economic waste which would be difficult to recover.

Is it convenient to plan a periodic maintenance of fabric expansion joints?

Like all other machine components, also fabric expansion joints are subjected to wear and tear, in particular in extreme working conditions.

Not all textile expansion joints are the same, so their working life cannot be predicted exactly.

However, they should not be underestimated, as they play a decisive role in the good operation of the whole system.

The failure of a fabric expansion joint can have even worse consequences than those we have seen so far.

A sudden accident not only causes damages to production, it can also cause an accident to the workers, endangering their health and causing a host of legal (as well as moral) problems for the company.

Is it really worth risking all this?

On the other hand, a regular check helps to identify all the problems – even the smallest ones – so that they can be dealt with immediately.

Fabric expansion joints have to be replaced or repaired at the first sign of wear.

This why a check-up or a thermographic analysis of expansion joints is important to see if the whole system, where they are installed, is working at the correct temperature.

By scheduling preventive maintenance and respecting the timetable, you do all the necessary to ensure the efficiency of your system and protect the environment and the safety of workers.

How to schedule maintenance of fabric expansion joints?

The preventive maintenance plan must be prepared annually by the maintenance manager in cooperation with the company that has been entrusted with the checks.

The timetable and the type of analysis to be carried out will be defined by technical experts according to the needs of the plant and the working conditions of the expansion joint.

This is why it is important to always entrust periodic inspections to skilled and experienced technicians

In any case, it is also essential to train and raise the awareness of the personnel, so that they are able to check constantly the condition of the expansion joints and request, if necessary, an extraordinary check by specialized maintenance staff.

Finally, remember to record, in a maintenance data sheet, all the maintenance activities carried out, whether ordinary or extraordinary, preventive or corrective.

The aim is to keep a record of the control interventions, so that they are always clear and well defined.

Are you looking for a company specialized in the maintenance of fabric expansion joints?

New Componit offers you a repair and maintenance service that helps you to avoid expensive stop in the production of your plant.

For 30 years we have worked in the production of fabric expansion joints, protections and custom-made products for industrial plants.

Our experienced technicians use a unique and complete analysis method: Efficiency Box® , which guarantees a detailed assessment of your plant and offers you the best custom-made solution.

New Componit also ensures:

  • Efficiency tests
  • A dedicated and skilled team
  • Assistance and periodic checks
  • Certifications and guarantees

Want to improve comfort and performance in your plant with a tailored solution?

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