Employee safety and comfort are paramount for one of the nation’s largest automobile parts recycling companies – as is the need to keep a lid on costs. That’s why they recently used a Zoneworks® insulated curtain wall system to enclose an all-too-noisy grinder at the main facility. The new enclosure has resulted in a 20% reduction in noise, creating a more comfortable and productive work environment.
Noise in the “Grind House”
At the company’s recycling operation, employees begin the process of recycling plastic bumpers inside a stand-alone, 9,000 sq ft facility called the “grind house.” Noise was an inherent issue in that facility, since it includes a heavy-duty grinder that runs virtually non-stop 5 days per week. The grinder is continually fed by an employee during each 8-hour shift while other employees nearby strip the bumpers. The machine’s noise was greatly amplified by the expansiveness of the 18-ft-ceiling room in which it operates.
The company had initially protected employees against grinder noise -- which was recorded at 120 dB — by having workers wear both earplugs and earmuffs. Although the ear protection was considered safe, verbal communication between employees inside the facility was virtually impossible with the grinder running.
The company had planned to build a permanent wall around the grinder to help reduce its noise. Before starting the project, however, they decided to explore other options for keeping noise to a manageable level, hoping to avoid the high costs and delays associated with the construction of permanent walls.
Creating a Sound-Dampening Enclosure
The company turned to Zoneworks for a solution. The local industry specialist recommended the company forego a permanent wall and instead enclose the grinder with a flexible Zoneworks reconfigurable fabric wall system.
Soon after, the company chose to tackle the noise issue with Zoneworks’ SZ2 Insulated Acoustic Curtain Walls. The SZ2 curtain wall is a sister product to Zoneworks’ SZ Acoustic Curtain Walls, which deliver the highest level of noise protection in the company’s product line.
Zoneworks’ walls can be configured to fit virtually any interior space and don’t require anywhere near the time it takes to build permanent walls. Each acoustic curtain is constructed of durable, fire-retardant industrial fabric surrounding multiple layers of recyclable, antimicrobial polyester batting. Individual 5 ft wide fabric panels of virtually any length are interconnected with Velcro to form each continuous wall.
Employees of the parts recycling company installed the sound-dampening wall system around the grinder, which sits against a back wall in one corner of the facility. Two of the fabric curtain walls were extended for the length of the grinder from front to back and were attached to a concrete wall at its back with screws and polyester nailing flaps. At the front-end of the grinder, Velcro connectors secured the front of the enclosure to the two sides. The front wall also included an opening where bumpers can be fed into the machine.
At the top of each wall, the Zoneworks curtains were attached to angle iron previously built above all three sides of the grinder. The weight of the curtains holds the bottom in place on all sides. Inside the enclosure, a 10 in. diameter metal conduit routes the plastic chips from the side of the grinder to a hopper located outside the building.
Although they had never worked with fabric walls, three grind house employees installed the flexible enclosure in just over three days. To check the grinder for maintenance, employees simply pull back a part of the wall where it’s attached with Velcro to gain access.
Decibels Reduced by 20%
With the fabric walls in place, the grinder was completely enclosed. Subsequent tests showed the sound level inside the grind house dropped from 120 to 96 dB, representing a 20% reduction in noise.
With grinder noise under control, employees working in the facility now need only wear earplugs and can more easily communicate with one another. The reduced noise has also made it easier for employees to concentrate, enhancing productivity. Above all, the Zoneworks curtain wall system creates a safer work environment. Company officials say there is little question they will take a close look at Zoneworks curtain walls as a cost-effective alternative to permanent walls for any number of environmental control needs at their facilities throughout North America.
