DEOS Technology s.r.o. 4 months after signing the contract, handed over the Line for processing sorted waste to FCC Česká republika s.r.o. for trial operation. It therefore managed to complete the order from design, through production to assembly within the promised time. In addition, the delivery included a completely new Bag opener machine.
Now we will briefly describe the sorting line production process, which precedes the ceremonial handover and successful operation.
1 Requirements analysis and project brief
The process begins with a detailed definition of the customer's requirements and operating conditions. The material to be sorted, the line's performance requirements, the sorting method, the operating mode, the installation space, the automation, safety and service requirements must be specified. The output of this phase is the development of the technical specifications for the project, which serve as the basis for the design.
2 Structural design of the sorting line
The design of a sorting line consists of a conceptual design, where an experienced designer selects the sorting technology and determines the general concept of the line, designs the layout of individual machines and determines the main functional nodes. After that, he can proceed to 3D modeling of individual components in the CAD system. He must certainly not neglect the strength calculations of the supporting structures. He will also design drives, protective covers and other safety elements. The output is complete design documentation, including drawings, bills of materials and diagrams. At this stage, the designer is in close cooperation with the electrical designer, who will design the control system and the entire electrical installation.
3. Technological preparation for the production of a line for sorted waste
Based on the design documentation, the technologist will prepare production procedures and bills of materials. He will select the appropriate material according to the drawings and ensure the necessary subcontracting. At the same time, the project manager will plan the production and assembly work so that the set project schedule is met.
4. Production of mechanical parts
The production of individual parts is carried out by cutting, machining and welding according to the production documentation. During production, the responsible person performs continuous quality control, including dimensional control, visual inspection of welds and inspection of surface finishes.
5. Pre-assembly and completion
The individual modules of the sorting line are assembled into functional units. Workers assemble mechanical parts, bearings, drives and other components. The pre-assembled units can then be subjected to functional tests. The aim of pre-assembly is to minimize assembly work at the customer's site.
6. Electrical installation and automation of the waste sorting line
The electrician will manufacture and then connect the switchboards according to the approved electrical project. He will program the control system and integrate the safety functions. He will then verify the functionality of the electrical installation and control system through testing.
7. Installation of a waste sorting line at the customer's premises
After the sorting line is transported to the installation site, the mechanical assembly of the individual modules is carried out. The installers anchor and geometrically align the supporting structures, followed by the implementation of the electrical installation. Before the start of the test operation, the work is checked to ensure that it is in accordance with the project documentation.
8. Commissioning and testing
Before the line is put into operation, empty tests are usually carried out, followed by a test run with material. The sorting parameters are set and the operation is optimized. The achievement of the required performance and sorting quality is verified. Any defects and unfinished work are eliminated.
9. Training of operators and service personnel
The authorized person will familiarize the customer's operators and service personnel with the function of the sorting line, the principles of safe operation and maintenance procedures. He will hand over the operating and service documentation to the responsible person.
10. Successful handover of the sorting line
After verification of compliance with the guaranteed parameters, the sorting line is officially handed over to the customer, who signs the handover protocol. After that, the warranty period begins.
