CUSTOMIZED CENTRALIZED INDUSTRIAL VACUUM SYSTEMS
iVision Vacuum designs and manufactures customized, high-efficiency industrial vacuum systems compliant with industry regulations and tailored to your company’s specific production requirements.
IMPIANTI DI ASPIRAZIONE INDUSTRIALE SU MISURA E CENTRALIZZATI
INDUSTRIAL WASTE MANAGEMENT REQUIRES CUSTOMIZED SOLUTIONS
Every manufacturing facility must manage dust, metal or wood chips, oils, and emulsions that, if uncontrolled, can compromise product quality, worker safety, and operational continuity. Standard vacuum systems are often inadequate in complex, high-production, or regulated environments. For this reason, iVision engineers fully customized centralized extraction systems designed around each client’s operational and regulatory requirements.
ANY MATERIAL. ANY INDUSTRY. ONE ENGINEERED SOLUTION
SPECIALIZATION THAT MAKES THE DIFFERENCE
iVision Vacuum is highly specialized in designing and manufacturing customized and centralized industrial vacuum systems for all production sectors.
Each system is designed according to the requirements of the working environment, the type of pollutants and waste to be managed, and the level of performance required, with customized solutions designed to guarantee:
Maximum operational efficiency
Reduction in machine downtime
Effective cleaning and sanitation of work environments
Increased operator protection and workplace safety
Full compliance with environmental and ATEX regulations
ADVANTAGES OF A
CENTRALIZED AND CUSTOMIZED VACUUM SYSTEM
DESIGN OF A CUSTOM EXTRACTION SYSTEM
Technical Consultation and Operational Assessment
We evaluate the materials to be extracted, current regulations, and the customer's production challenges. We conduct an on-site inspection to define the optimal system configuration.
Customized design
Precise sizing of the extraction network, filter units, and control systems.
Simulations and testing
We use advanced software to simulate the operation of the system and optimize air flow. Subsequently, in our internal area entirely dedicated to functional testing, the entire system is subjected to stress tests and testing using the original material to be treated.
Installation and support
Final performance testing and ongoing technical support to ensure long-term efficiency.
SUCCESSFUL CASE STUDIES
88DENT – ADVANCED ZIRCONIA PROCESSING LABORATORY
Customized centralized extraction system for high-precision dental manufacturing.
Problem
The customer operates in a highly specialized environment for the processing of zirconia, an abrasive and volatile material used in the production of dental prostheses. The dust generated is extremely fine and dangerous if inhaled, especially in closed environments. In addition, the laboratory uses more than 10 CNC workstations simultaneously, causing dust accumulation, production inefficiency, and continuous machine downtime for manual cleaning.
Solution
We designed a customized centralized extraction system capable of:
- Simultaneously extracting from all workstations, integrating signals from the CNC to the system and vice versa.
- Removal of ultra-fine zirconia dust through high-efficiency filtration systems.
- Airflow optimization through variable frequency control.
- Include an automatic filter cleaning system with clogging sensors and monitoring sensors to avoid machine downtime.
Result
The client achieved a healthy work environment, compliant safety standards, zero production downtime, and improved final product quality.
BORMIOLI LUIGI
Glass and foundry
Problem
Bormioli Luigi needed to extract incandescent dust (up to 350°C) generated by industrial furnaces and melting lines. If not extracted quickly, the particles caused:
- Accelerated wear and tear on machinery
- High risk of fire
- Prolonged plant downtime for cooling and cleaning
- Difficulty in ensuring workplace safety
Solution
We have developed a suction system with immediate cooling of the material using a high thermal resistance water filter, designed to suck up:
- Incandescent dust and waste.
- Abrasive and heavy residues.
We have designed a vacuum cleaner with optimized height (200 cm) so that it can be transported freely within the factory, complying with the constraints indicated by the customer.
The industrial vacuum unit is multifunctional and can vacuum both incandescent material and material at room temperature thanks to the dual configuration requested by the customer.
The accessories supplied are specifically designed to withstand high temperatures.
Result
Increased safety, 24/7 operational continuity, and reduced maintenance costs.
SILGA
Precision electronics and printed circuit boards
Problem
SILGA, a leading manufacturer of high-precision printed circuit boards, operates in a sector where even the smallest particle can compromise the entire production cycle. The company’s CNC PCB machines (including automatic drilling and milling machines) generate extremely fine, conductive dust, which is hazardous not only to the health of operators but also to the integrity of electronic microcomponents.
The challenge was twofold:
- Continuous extraction from 10 machines connected to the system, all operating simultaneously with a total of 40 electrospindles.
- Ensuring a micro-dust-free environment to comply with the quality standards of the electronics industry (almost “clean-room” environments).
Solution
iVision designed and installed a customized centralized extraction system with the following features:
- Simultaneous connection of 10 CNC stations dedicated to printed circuit board processing.
- High-efficiency central unit, with calibrated flow rate and vacuum to maintain the same power on all lines.
- Multi-stage filtration.
- Automatic filter cleaning system, integrated with an intelligent clogging sensor to ensure consistent performance.
- Smart Connected 4.0 technology for remote monitoring of operating parameters and predictive maintenance.
- Installation of abrasion-resistant suction branches, with inspection capability and smart anti-clogging system.
Result
Thanks to the iVision system, SILGA now ensures continuous and clean production, with 10 CNC machines always running and a work environment compliant with precision electronics standards. Smart monitoring guarantees consistent performance and zero unexpected downtime.
ZINGERLE GROUP
Metallurgy and extrusion
Problem
The company had an old, inefficient 44kW suction system. The customer needed a system capable of extracting large quantities of chips produced by 12 automatic aluminum cutting machines. The main problems were:
- Unsatisfactory suction performance
- Frequent clogging of filters.
- Difficulty emptying containers.
- Production downtime due to manual maintenance.
Solution
iVision Vacuum created a customized suction system that, with only 22 kW of power (half that of the previous system), significantly increased suction performance. The system’s energy efficiency allowed the project to qualify under Industry 4.0 and 5.0 incentive programs, enabling the customer to benefit from significant tax advantages.
Based on the characteristics of the Extrusion Line, the system supplied is equipped with:
- High-flow vacuum unit with frequency inverter for performance balancing on the 12 machines.
- High-efficiency cyclonic pre-filter, which captures over 90% of chips and dust before they reach the filter; longer filter life means better performance over time with no maintenance.
- More than 80 m²of filtering surface.
- Continuous discharge with fill sensors, so the production process is never interrupted.
- Filter clogging sensors and Smart Connected system for remote management and predictive maintenance.
- Design and installation of over 100 meters of rigid and flexible piping for total coverage of the production area.
Result
24/7 production continuity, multi-day collection autonomy, reduced maintenance, and zero risk of machine downtime.
GC NAUTICA
Problem
GC Nautica, a company specializing in the maintenance of large boats and surface treatments in general, uses sandblasting as a fundamental step in its finishing processes.
This process generates large quantities of heavy, abrasive dust, which quickly accumulates in the workplace, compromising visibility, operator safety, and the proper functioning of equipment.
The main challenges of the project were:
- Ensuring continuous, high-flow suction during intensive sandblasting cycles.
- Designing an abrasion-resistant system with minimal maintenance and 24/7 operation.
- Reducing machine downtime and improving environmental quality in the processing departments.
- Drastically reducing the work of operators involved in the manual cleaning of the sandblasting cabin, which is very heavy and time-consuming.
Solution
iVision has developed a fully customized SAND line system designed to meet the specific needs of industrial sandblasting. Key features include:
- Centralized system with high-power unit and high resistance to abrasive dust wear.
- Cyclonic pre-filtration to protect filters and reduce maintenance
- Double pre-separation of the material to discard sandblasting waste, dispose of spent abrasive, and return reusable abrasive to the process.
- Automatic discharge via rotary valve directly into the sandblaster to ensure continuous operation and extremely close sandblasting cycles.
- Advanced remote diagnostics and predictive maintenance tools to minimize unexpected downtime and ensure operational continuity
- Custom design based on the customer’s production layout.
Result
Thanks to the iVision system, GC Nautica optimized its sandblasting process with a powerful, durable, and fully automated solution, improving workplace safety while reducing costs and management time.
GRASSI PIETRE
Extraction and processing of natural stone from the quarries of Vicenza, Italy
Problem
GRASSI PIETRE, a long-established Italian company specializing in the extraction and processing of natural stone, handles very large volumes of material every day.
Cutting and polishing operations inside the quarry generate large quantities of fine, persistent dust, which quickly accumulates throughout the work area, compromising the cleanliness of the environment, the safety of operators, and the durability of machinery.
The customer’s main requirements were:
- To extract large volumes of fine and heavy dust from even very distant locations.
- To have a flexible and well-equipped system to cover multiple operating points.
- Collect the vacuumed material efficiently, with automatic discharge.
Solution
iVision designed and built a fully customized extraction system engineered for the management of fine dust in quarry environments, with particular focus on robustness, high airflow performance, and operational versatility.
Main features:
- Extended-reach suction hose, designed to easily reach all operating areas of the quarry.
- Wide range of professional accessories, essential for the various stages of cleaning and dust collection.
- High-flow central unit, engineered to maintain consistent performance even across long extraction distances.
- Cyclonic pre-filter and continuous discharge into Big-Bags via rotary valve, to facilitate the management of large volumes of fine, dry vacuumed material.
- Customized configuration to adapt to the customer’s space and operational flow.
Result
The system designed by iVision Vacuum has enabled GRASSI PIETRE to efficiently handle even the most demanding operations, with a powerful, modular solution tailored to the specific needs of a quarry environment.