General view of the Ogden Road frontage ot the Doncastar-based lactory of Mac-awber Engineering, Limited, a leading manuiacturer
`of pneumatic conveying systems for
`the laundry industry.
`-
`
`Macawber Engineering,
`
`Limited, embark on further
`
`Expansion
`
`Research and Development Block will expand
`Applications for Dense-phase Pneumatic Conveying
`
`teature shows how a Doncasler-
`This short
`based firm, Maeawbar Engineering, Limited,
`in,
`the short span ot
`lour years. has become a
`major supplier ol pneumatic conveying systems
`to the toundry Industry. Described below are the
`company's manulacluring facllltles, soon to be
`
`augmented by a research and development
`block which Is expected to expand the applica-
`tions for the "Denseveyor” pneumatic convey-
`ing systems. Also included In the article is a
`typical example ol a pneumatic sand handling
`system based on Macawber equipment.
`
`finding
`are
`systems
`sand-handling
`Pneumatic
`industry.
`adoption
`in -the ' foundry
`increasing
`Amongst a number of advantages are flexibility of
`layout, the avoidance of expensive pitwork or struc-
`tural-steel support systems, _low maintenance and
`the promotion of a cleaner
`foundry atmosphere.
`Admittedly,
`a
`pneumatic
`transportation system
`requires
`compressed air—so the
`foundry which
`instals such a system may well find itself faced with
`the need to acquire further compressor ca-paci-ty.
`Energy requirements, per ton of sand moved, are
`likely to be higher with a pneumatic system com-
`pared with conventional handling layout.
`
`Phenomenal Success
`
`The foothold which pneumatic conveying has gained
`in foundries is well
`illustrated by the phenomenal
`success of one comparative newcomer to the busi--
`ness Macawber Engineering, Limited, of Doncaster.
`In just over four years, the Firm has progressed from
`its original premises in a small garage to a pair of
`nursery units on an industrial estate on the outskirts
`of Doncastcr and thence to its present purpose-built
`
`premises totalling 8,000 sq. ft. on a four-acre site in
`Ogden Road.
`A labour force of 60 is engaged in the manufacture
`of dense-phase pneumatic handling systems under
`the registered trndemai-l<“ "Denseveyor”. The com-
`pany, initially registered with a capital of £100, has
`now achieved an annual turnover of £1m.
`Macawber are quick to claim that this success has
`largely been due to the enterprise and innovation of
`their young team of executives. The result has been
`a number of design features which have ironed“ou.t
`many of the problems which once presented obstacles
`to the widespread application of pneumatic convey-
`ing in foundries. The abrasive properties of foundry
`sand are well known. It was therefore not surprising
`that manyearly versions of pneumatic transportation
`systems were plagued with breakdowns due to wear
`at pipe bends and around pressure—vessel seals.
`Macawbcr point out that these difficulties have been
`eradicated in several ways. Long-radius pipe bends,
`often cast
`in abrasive-resistant alloy, have been
`replaced by right-angle bends incorporating a trian-
`gula.r—chamber which, as it fills with impacted sand,
`provides the means of deflecting moulding material
`
`“asst AVAlLA3LE COPY
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`DYNAMIC AIR INC.
`
`EXHIBIT 1041
`
`DYNAMIC AIR INC.
`EXHIBIT 1041
`
`

`
`
`
`the main erection shop within the Ogden Road la:lcr-y ol Macawber Engineering. Limited. The head-room cl 6.5 m.
`General view oi
`below the Morris (Ive-tonne-capacity crane provides ample room tor the construction oi
`largo Items of staolwork such as silos.
`
`around a bend without moving sand-to-metal con-
`tact, Equally ingenious is a dome-valve gate with
`wear-resistant cutting edge. This mushroom—shaped
`device chops across through an arc of 90° to close
`off the entry to the pressurised transporter vessel.
`Hemtetic scaling is then achieved by the inflation of
`a rubber insert around the periphery of the dome
`valve. The acmation of the valve mechanism is said
`to be highly effective in cutting ‘through abrasive
`material. One example quoted is of a hopper moun-
`ted above a Denseveyor transporter containing 100
`tonnes of coal,
`the valve operating successfully,
`despite
`the weight bearing down on the valve
`mechanism.
`
`Important Sector
`The mention of coal gives a clue to the other impor-
`tant sector
`in which Macawbcr are involved,
`the
`handling of fuel and ash in large-scale boiler instal-
`lations and at
`fuel depots. Experience in handling
`hot ash, often at temperatures as high as 700°C has
`enabled the company to approach the handling of
`hot sand with confidence. In fact,
`in one hot—nsh
`application,
`the transporter vessel feed chutes were
`seen to be glowing in the dark. -Despite such arduous
`conditions,
`the systems continue to operate,
`the
`essential valves and other components being water-
`coolcd for effective protection.
`
`the essential assets
`0.-re ol
`at a company engaged in the
`manufacture
`o!
`pneumatic
`conveying
`systems
`to
`be
`incorporated
`in what
`are
`often complex loundry plants
`5:. an otficient and welhstalfed
`drawing
`cities. This picture
`:haws
`the
`socflan
`of
`the
`lacility at Macawber Engin-
`r.*rlng.«LlmIzed. dealing with
`detailed pipe layouts.
`
`

`
`
`
`This photograph shows‘ part
`cl
`lhe manutaciurlng section
`in which
`the Dsnsevaycr
`transporter
`vessels
`are
`assembled.
`
`
`
`Another claim upon which Macawber base their
`competitive stance is
`the injection of
`the correct
`amount of air into the pressure-vessel, sufficicnt to
`propel the slug of sand or other granular material to
`its terminal station without the need to incorporate
`separate booster inlets.
`
`Export features high on the company’s list of priori-
`ties. Denseveyor systems are in operation or in man-
`uf-acturc for Germany, Denmark, Iran, Yugoslavia,
`Australia, South Africa, Ghana,
`India, Turkey,
`USA, Sweden, Norway and Greece. A German sub-
`sidiary, Macawber Grnbl-I has recently been joined
`by a new American operation, Macawber Engineer-
`ing Inc. at Maryville, Tennessee. A 1-icencee and
`associate company is located in Australia and «there
`are other associate companies in Denmark, France,
`South Africa and India.
`
`The Ogden Road plant was opened in September
`1977. It consists of a single-storey suite of offices
`flanking the roadway, against the back of which lies
`an erection shop, 36 m. by 14 m. in area. The design
`is such as to allow the building of two more iden-
`tical bays. One important feature is the height, 6.5
`m. to the Morris 5~tonne-capacity crane. This allows
`the handling of the massive silos and other structural
`steelwork which customers
`frequently request
`in
`conjunction wi-th their transportation systems.
`The work flows in a logical sequence through the
`organisation, application engineers preparing the
`initial designs and layouts against which the Com-
`pany-will quote. The order received, a further draw-
`ing/proiect oflioe prepares the detailed pipe layouts
`and maintains a liaison, where necessary, with other
`foundry suppliers who often incorporate Denscveyor
`systems in thciroverall designs.
`
`Research and Development
`Research and development functions are soon to be
`housed in a new block, the total area of which will
`approach that of the ma-in erection bay——2.S by 17 m.
`
`A number of systems will be installed in this facility
`to prove materials and to demonstrate the flexibility
`of pneumatic handling to potential customers.
`It is expected that
`the final phase of the projected
`site development will be reached in 1979 when a
`total area approaching 30,000 sq. ft. will be utilised.
`This will include 4,800 sq.‘ ft. represented by one of
`the original nursery units which Macawber still
`retain.
`
`Siled a short distance from the main buildings, and
`within the same industrial estate, the nursery unit
`houses an assembly shop for valves and transporter
`vessels. Here too is sited a machine-shop and stores/
`spares department. One interesting facet of Macaw-
`ber’s conveying-system activities is the design and
`
`One of the successful lealures ol Macawbar-designed pneumatic
`conveying systems I:
`the use oi right-angled pipe bends Incor-
`porating a rrlangular chamber. This fills with impacted sand.
`thus providing a means of deflecting moulding material around
`a band wlthout moving sand to metal contact.
`
`
`
`BEST AVAILABLE COPY
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`
` Weldnr engaged in the lubrication of ti Denseveyor switch valve.
`
`The changeover action is based on a novel parallel motion
`which requires only a
`small movement
`to reallgn Inlet
`and
`outlet czmponants for the new direclion.
`
`Fitters making final adjustments to a switch valve used in the
`Denssveyor system to lorrn two branv.-.hes
`in a conveying line
`handling loundry sand.
`
`construction of their own control systems. A small
`building houses an electronics department where
`electrical technicians assemble control cabinets and
`ancillary equipment.
`
`Useful Literature
`
`to prospective custo-
`Another feature is the issuing,
`mers, of a very useful range of literature from which
`the founder, if he so desires, can even design his own
`pneumatic
`conveying
`system using Dcnseveyor
`equipment. The firm provide El range of charts show-
`ing performance data for dry, wet and prepared
`moulding sand setting out air requirements and pipe
`dimensions. There is also an application handbook
`for handling sand over a temperature range up to
`480°C.
`
`One recent example of a UK application is -the
`installation of a Denseveyor system at G. Clancey,
`Limited. Based at Halesowen, the foundry is one of
`Europe's major producers of valve guides and tap-
`pcts for
`the automobile industry. The pneumatic
`sand transport
`layout
`is based on a Model 8/8
`Denseveyor unit which was purchased as part of a
`major changeover undertaken in 1976 when Clan-
`cey’s adopted a new moulding system based on dry
`sand to replace an ageing high-pressure moulding
`plant.
`
`the laundry of G.
`This Modal 8/8 Oensai-'_eyor unit Installed at
`C|ancey._Llm!!9d,
`leading manufacturers ol valve guides and
`tappots.
`is typical ol units ol such type installed In the plants
`of casting producers throughout the world.
`
`The requirement was for a conveyor system which
`would carry large quantities of highly-abrasive silica
`sand 63 metres from an exterior storage silo to twin
`hoppers within the production area. Because the
`major part of -the run was through the busy foundry
`area, it was essential that the system should keep the
`sand free from all contaminants and be as unobtru-
`sive as possible.
`
`tubc—-more normally
`steel
`BS1387 heavy-weight
`used to convey water or
`steam——to handle sortie
`1,700 tonnes of sand each week, wear is reported to
`have been negligible.
`This ends a profile of one of the foundry industry's
`newest suppliers. Certainly to have grown to such a
`stature over four-and-s-half years says much for the
`entrepreneurial drive of
`the company’s directors
`backed up by an enthusiastic workforce.
`that -the system employs standard
`BEST AVAILABLE COPY
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`Despite the fact