How A Large Plastics Manufacturer Reduced Workshop Noise

In any manufacturing environment, the constant hum and hiss of machinery is a given. But when that noise becomes a safety hazard, it’s time to act. This was precisely the situation for one of our local clients, a local plastics manufacturer, who recently approached us at our Hamilton headquarters to tackle a common but critical issue: excessive noise from compressed air usage.

The result? A quieter workshop, safer operators, and a highly effective solution that proves small changes can make a massive difference.

The Challenge: Tackling Noise and Enhancing Safety

The Health and Safety Coordinator from the site visited us with a clear goal: find safer and quieter alternatives for their compressed air guns used in the production area. Their primary application was blowing swarf (small plastic shavings) off extruded plastic pipe—a crucial step for quality control.

The existing setup, like many we see, was likely using an open pipe or a low-cost, inefficient nozzle. While it moved the swarf, it did so at a significant cost:

1. High Noise Levels:  Open-ended pipes generate dangerously high decibel levels, often exceeding workplace safety limits and contributing to long-term hearing damage for operators. We discussed the high Sound Pressure Levels (SPL) that were a major concern.
2. Safety Risks:  These basic blow-off tools can pose a serious risk if the tip is blocked, potentially causing air to be injected into the operator's bloodstream—a life-threatening situation.
3. Wasted Energy:  Inefficient nozzles consume vast amounts of expensive compressed air, driving up operational costs.

The team knew there had to be a better way to maintain a clean production line without compromising the well-being of their staff.

The Solution: The Silvent 59002W-H Safety Air Gun

After discussing their specific needs—application, budget, and operator comfort—we landed on the perfect tool for the job: the Silvent 59002W-H Safety Air Gun.

This wasn't a random choice. Here at Spray Nozzle Engineering, the Silvent 500-series is one of our favourite product lines, and the 59002W-H model ticked all the boxes:

• Engineered for Quiet: The patented Silvent nozzle technology is the hero here. It optimises the air stream, using surrounding air to boost the blowing force while significantly cutting noise levels—often by more than 50% (10 dB(A)). This immediately addresses the primary health and safety concern.
• Uncompromising Safety: The nozzle is designed to be impossible to "dead-end," meaning it meets and exceeds stringent safety standards. The airflow cannot be blocked in a way that endangers the operator.
• Superior Ergonomics: This is where personal experience comes in. The 500-series guns feature a longer, denser handle that provides a much better hand-feel and balance compared to other models on the market. For operators using the tool throughout their shift, this ergonomic design reduces fatigue and improves handling. It’s a cost-effective gun that feels like a premium tool in your hand.
• Powerful Performance: A quieter, safer gun is useless if it can't do the job. The 59002W-H generates a strong, focused jet of air that is perfect for effectively and quickly clearing swarf from the plastic piping.

The Result: A Win for Everyone

By implementing the Silvent 59002W-H, they achieved an immediate improvement in their work environment. The reduction in noise was noticeable, creating a less stressful and safer space for their production team. The operators have a tool that is not only safer and more comfortable to use but also highly effective at its task.

This case study is a perfect example of our philosophy at Spray Nozzle Engineering: applying targeted expertise to solve real-world industrial problems. It isn't just about selling a nozzle; it's about providing a complete solution that enhances safety, boosts efficiency, and delivers tangible value.

Are you dealing with excessive noise or safety concerns from compressed air in your New Zealand facility? Contact the team at Spray Nozzle Engineering in Hamilton today. Let's find the right solution to make your workplace safer and more productive.