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WiN woodworking INTERNATIONAL 2020/1

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USER REPORT The bathroom

USER REPORT The bathroom furniture manufacturer Pelipal GmbH manufactures with whisper-quiet filter technology Looks good but can hardly be heard. This MultiStar purge air filter is acoustically barely audible at 35 dB(A). Bernd Osterloh (r.), Production manager at Pelipal with Christian Horns (l.), Project manager of Höcker Polytechnik. Sssshhhh! It is relatively difficult to explain how quiet, “Quiet” actually is. In any case, you should whisper when you explain it, so that you can hear just how quiet it is. A sound level of 35 dB(A) for example lies somewhere between whispering and the soft twittering of birds, a commercial vacuum cleaner is hard to miss with its 75 dB(A) and 115 dB(A) are not uncommon at rock concerts. Sometimes, there are things that one would have previously classified as loud, but are especially quiet - for example, a filter system. Höcker Polytechnik has achieved less than the magical 35 dB(A) limit and a total volume flow of 120,000 m 3 /h with a MultiStar vacuum filter system specially designed for noise reduction. This opens up completely new possibilities for companies who manufacture close to residential areas - meaning that three shift and weekend operation are possible. Premium quality bathroom furniture made in Schlangen - made by Pelipal Today near Paderborn, in the East Westphalian Schlangen, a whisper-quiet MultiStar filter does its job 24 hours a day at Pelipal GmbH. Pelipal GmbH is one of Europe’s leading manufacturers of bathroom furniture and with a range from economical entry level to exclusive luxury bathroom furniture with multiple design awards, it ensures a pleasant and functional atmosphere in the European bathroom world. The family run company was founded in 1906, has over 550 employees at various locations and has had its headquarters in Schlangen since 1967. While 50 years ago it was not necessarily a problem to operate in direct proximity to residential areas, in recent years the legal provisions, sensitivity to noise and, last but not least, the much more powerful machinery have made it difficult to manufacture in such locations. Pelipal actively deals with these challenges and along with its machinery has modernised the filter technology. The investment in an extremely quiet exhaust system is intended to create reserve capacity and allow Pelipal to expand its production capacity. In 2016, the planning for the new filter system began. The existing MultiStar purging air filter system from Höcker Polytechnik had been providing perfect service at Pelipal for more than 12 years, but had hardly any reserve capacity for the future and more importantly: due to the construction and design, retrofitting of soundproofing components would not have been possible. A new filter system with reserve capacity and with all available noise reduction features was therefore absolutely necessary, since the only possible location of the filter was a mere 65 metres from the adjacent residential area. 30 No. 1 • February 2020

USER REPORT Perfect planning to get below the 35 dB(A) level Sebastian Fella, one of the managing directors of the Pelipal Group, comments: “We have been mastering the challenge of modern production at our special geographical location for several decades. Modern, high performance machinery is particularly important to us, since it is precisely humid bathroom areas which place the highest demands on material processing - after all, our customers should enjoy the product for a long time. And in order to meet the demand of our customers in a timely manner, the expansion of production capacity was particularly important to us. The topics of extraction and dedusting were important subjects for discussion during planning; Christian Horns from Höcker Polytechnik and his team assisted us in this. Together, we had to work hard to design a work of art, a new filter system with a capacity of 120.000 m 3 /h that under no circumstances would exceed a noise level of 35 dB(A). Our Production Manager Bernd Osterloh together with the Düsseldorf Institute for Sound Technology, Room Acoustics and Thermal Insulation (ISRW) Dr. Ing. Klapdor GmbH and the exhaust specialists from Höcker Polytechnik formed a think tank and began with the planning. Every source of noise, from the motor to the rotary valve had to be encapsulated in sound boxes as far as possible, resonances in the filter housing were to be minimised by intensive sound insulation, all pipework required noise insulation and all this had to be assembled in a constructively perfect way. We have been using the new filter system since August 2017, it exhausts our machinery in an optimum way and works so quietly that operating noise is barely perceptible. All test measurements fell well below the level of 35 dB(A). Nothing now stands in the way of an expansion in production.” MultiStar purge air filter with integrated energy saving features Pelipal now operates a MultiStar purging air filter from Höcker Polytechnik with a filter surface of 1,244 m 2 . The required total volume flow of 120,000 m 3 /h are supplied by the six frequency controlled, energy efficient 37 kW fans (IE3) in the fan attachment module. An integrated heat recovery module with residual dust monitoring ensures additional economic gain, since the valuable heat energy of the dusty raw air extracted from the machines is largely retained. The filtered air is returned to the building during winter operation (residual dust content

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