Isolated Foundations

Manufacturing businesses are often looking for ways to minimise their waste in terms of spoilage or rejection by upgrading to newest state of the art machinery. However, manufacturers could be thinking beyond their actual products and the items used on-site, to re-evaluate if they could be reusing manufacturing equipment and infrastructure. In doing so they could not only reduce the need for new installations but also make significant financial savings.

Reusing existing isolated foundations for new machinery in a beverage can plant

Isolated foundations and other vibration control solutions are frequently used in factories and manufacturing plants to reduce levels of transmitted vibrations that affect the health and safety of workers as well as the accuracy and productivity of surrounding machinery and activity. This is especially true in beverage can manufacturing plants where heavy impact machinery such as cupper presses and bodymakers can generate excessive dynamic loads.

A recent project for Farrat in Cairo, Egypt, was to establish whether a pre-existing isolated foundation could be used for new manufacturing equipment. A member of our Industrial Vibration Isolation team made a visit to the factory to assess the level of performance of some existing isolated foundations that are currently supporting bodymakers.

These results have been used to determine if a spare isolated foundation installed 10 years ago and presenting the same design could be used to support new machine in the near future.

Not only would this enable a significant financial saving but would also negate the need for digging out new isolated foundations and the associated materials and disruption. In addition, repurposing something already in place is a more environmentally friendly option for a business that creates a product that can be recycled an infinite number of times.

Engineering led vibration and noise measuring and analysis

To determine whether existing infrastructure could be used for effective vibration control, contact the Farrat vibration and noise consultancy team, who work with a wide range of clients across the manufacturing sector, using on-site portable instrumentation for vibration measurement and vibration analysis around the world.

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In our latest project showcase below, we share a few of our recent Industrial Vibration Control projects, which highlight how our expert vibration control systems are being used to maximise accuracy, efficiency, and ensure the health & safety of production employees across can making and power generation industries.

The Lakeside EfW facility, UK

Based near Slough, this energy from waste power plant processes over 450,000 tonnes of residual waste per year, whilst generating 306GWh of power. It led the way in terms of environmental impact back in 2017, by becoming the first in the country to achieve the zero waste to landfill target by recycling all the residues left behind from waste processing and turning it into sustainable energy.

An education centre is located adjacent to the facility, where schools and other groups can learn about sustainable waste management and energy from waste to promote the switch to zero waste in the future.

Farrat have designed and manufactured a bespoke vibration control system, which is currently being installed on critical overhead machinery within the facility, to maximise efficiency and minimise the effects of vibration on the surrounding structure.

Farrat NR62 Hybrid Bearings and bespoke Shear Key Bearings form part of the overall solution to support the crane structure.

Ceylon Beverage Can, Sri Lanka

This is the most advanced facility in the region with state-of-the-art technology in metal forming and printing. The plant is equipped with the latest machinery and quality gauges with the capacity of producing 720 million cans and 2 billion ends per year. With cans as a highly recyclable liquid packaging option on the increase due to their sustainability credentials, the efficient running of this facility is essential to meet demand.

Farrat recently completed a machine foundation isolation project for a cupper press and bodymaker that was installed on site. The vibration isolation system comprised of Farrat Isomat , which is made from Nitrile rubber, and Vidam, which is made of cork composite.

Farrat Isomat offers excellent damping characteristics for impact applications such as presses, while Vidam works well to damp lateral loads coming onto the foundation walls. Together the anti-vibration materials work to mitigate the impact of vibration on the machinery, and ensure high levels of productivity and efficiency.

Pomini Tenova, Italy

Pomini Tenova is a global leader in the production of roll grinders, for rolls belonging to flat products mills such as steel and other non-ferrous metals such as copper and aluminum, processed in beverage can manufacturing plants and paper mills. Pomini Tenova also delivers special machines for the grinding of heavy components across the industrial sector.

A bespoke Farrat Isolated Foundation system was recently supplied for two roll grinding machines, that went on to be installed at a sheet metal plant in the United States.

This form of precision equipment should be protected from all sources of external vibrations, to avoid chatter marks on the finished rolls (reducing wastage), and also to ensure the health & safety of both the machinery and employees.

The Farrat industrial vibration isolation solution was engineered from a combination of Farrat Isomat base isolators and Farrat Isofoam Wall isolators. This solution effectively isolates all incoming frequencies from the base, as well as walls of the foundation, and improves the overall efficiency of the machine.

On a mission across the globe

The growth of the can-making industry means that with the right incentives, liquid packaging using cans could become 100% recyclable, and our vibration isolation solutions ensure that the manufacturing of these cans and tops can be done at optimal levels of productivity and efficiency.

Where businesses are committing to zero waste, onsite recycling, and energy generation through original approaches, Farrat is equally committed to using our specialist knowledge and bespoke vibration isolation solutions to optimise these innovative solutions.

For more information on Farrat Industrial Vibration Isolation solutions including Isolated Foundations take a look at our Industrial Vibration Control centre, or our  Can Making Hub.

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Cupper Presses are often used in canning factories, producing cups for 2-piece beverage cans from aluminium or steel coil, or draw-redraw food cans from steel, aluminium, coil or sheet.

It is important to isolate a Cupper Press because the vibrations created by the machinery will not only interfere with the efficiency, productivity and accuracy of surrounding machinery, but it can also affect the health and wellbeing of those working in the factory, and those living and working in the surrounding area.

Ahead of choosing the best option for isolating a Cupper Press, it is recommended to organise an investigation to understand the level of the vibrations the Cupper Press will be transmitting. The results from this investigation provide crucial inputs helping design team choose the best solution for your environment.

Installing a Cupper Press Isolation system

In order to isolate a Cupper Press, the area should first be clean and tidy, so make sure that the floor is clean and dry. First step is to install base void fillers along the edges at the bottom of the pit. These voidfillers are supplied in form of sheets that are easy to cut on site. Farrat provides project specific installation drawings to help the installers or the contractor to identify the correct product type and the sizes to be cut. Once the strips are cut to the specified size, install them along the edge of the pit. Next, start installing wall void fillers with the help of adhesive tapes supplied.

Adhesive tapes hold the void fillers intact on the walls and minimize the possibility of the isolation layer falling into the pit until the concrete is poured. Once the wall void fillers are installed, the next step is to install the stiffer top strip. Higher stiffness of the top strips brings more stability to the inertia block, minimizing chances of rocking under dynamic loads. All joints should be sealed to avoid seepage of wet concrete into the isolation strips.

A typical foundation pit with completed wall isolation looks like this:

Next step is to cover the remaining are of the foundation base with voidfillers. Due care should be taken by the installer to not damage the base voidfiller. A flat surface, such as light weight plywood, should be used when one needs to move around in the pit.

Below image represents completed base void filler installation:

Next step is to install the base isolators. This starts with marking the area in the base isolators as shown in the installation drawing. Once the locations are marked, respective size of voidfiller should be cut out from the base voidfiller to make space for isolators. Isolators should be carefully installed in the cut our space and the joints should be sealed with joint line tape.

A completed foundation is shown adjeacent.

The last step is installing the DMP membrane throughout the pit base and wall. This is a secondary layer to prevent any seepage of wet concrete in the isolation strips. The rebar cage should be designed in such a way that the support points are on isolators and not on the base voidfiller. Rebar cage should be carefully lowered into the pit to avoid any damage to wall voidfiller sot the DPM sheet.

The concrete should then be poured carefully and evenly across the entire area to ensure that the concrete does not build up in mounds (which could crush the voidfiller). It may be advised that the concrete is poured in 2 stages to ensure a flat and even load spreading base.

A Bespoke Approach for Cupper Presses

Isolating Cupper Presses isn’t a one size fits all approach. It is only by adopting a bespoke approach that you will effectively isolate a Cupper Press to a level where it no longer affects the efficiency of nearby machinery.

Farrat engineers are available to support you right from vibration investigation to installation. For more information on solutions for the can making industry, visit our Can Making Hub here or submit an enquiry with our engineers here.

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Farrat was recently instructed to conduct a vibration survey on two different Isolated Foundation systems supporting Cupper Presses in a canning factory in Europe. The aim of the investigation was to evaluate and compare levels of system performance and to identify any opportunities for improvement.

The Investigation

Cupper Presses are typically connected to their foundation by resilient mounts, offering a soft connection. The inertia block placed below is supported by anti-vibration material and is therefore isolated from the rest of the factory.

Two vibration isolation systems were measured during the investigation.

The first vibration isolation system comprised of a cupper press running at 156 RPM, installed on a 3.9 m x 3.9 m inertia block. The cupper press foundation was isolated by a competitor vibration isolation material. The second vibration isolation system comprised of the same type of press running at 158 RPM, installed on a Farrat Isolated Foundation.

The latter system was configured using a 6.1 m x 4.8 m x 1.5 m inertia block supported by Farrat Isomat pads.

Impact on nearby machinery

Located close to the cupper press production line in a nearby office was a direct laser exposure system using a laser engraving method. This machine is used to produce masks that decorate the variety of cans produced within the factory. This process requires machine precision and stability.

It was reported by the Line Manager that this sensitive machine was subjected to excessive vibrations, altering its process quality and interrupting business functionality. To determine the influence of the press, vibrations were measured on the printer in three directions while the press was on and off.

The first few peaks – all located below 20 Hz – were generated by other machines, positioned only 7 meters from the printer. However, clear differences are noticed in all directions between 20 and 50 Hz, presenting the influence of the Cupper Press, even though it was located 30 meters away from the printer.

Note: Z axis means vertical direction, X axis is defined as parallel to the length of the machine and Y axis refers to the width of the machine.

Conclusion

Farrat was asked to find a vibration isolation solution to mitigate this problem and a bespoke solution was designed. Farrat vibration isolation pads made of polyurethane foam were installed below the printer to soften the connection from the machine to the floor and tackle the disturbing frequencies. As a result, there have been no further complaints regarding the process quality, and the issue is considered resolved.

One of the key objectives when designing a vibration isolation system is to maintain a low level of vibration within the machine to help plants reduce spoilage and increase productivity. Another key aspect is to limit vibration transmission to the surroundings. This investigation highlighted the impact that an ineffective isolation system can have on sensitive machinery positioned nearby – decreasing productivity and resulting in complex and costly engineering solutions.

The client’s requirements have been met by the Farrat Isolated Foundation solution, which has significantly lowered the movements of the machine while maintaining a quiet environment for nearby buildings. This demonstrates the efficiency of Farrat Isomat systems for Cupper Press machine applications, where bespoke design solutions are needed to solve complex engineering challenges.

Vibration Isolation Systems from Farrat

For more information on how our application engineers can work with your design teams, production managers and OEM partners to integrate industrial vibration control and Isomat System, contact our team here.

#onamission

A Cupper Press was recently installed in a new can making factory in Europe, which was built near to commercial and office buildings in the surrounding area. Following recommendations from a consultancy specialising in vibration and structural dynamics, the Cupper Press was installed on top of an inertia block supported by spring elements and visco-dampers, offering a system natural frequency of 1.25 Hz. However, high movements were reported on the machines Spring Foundation during production and as a result the vibrations were emitting outwards to the neighboring buildings.

The impact of this movement was premature wear on the machine and increased spoilage, reducing the overall productivity of the plant. 

The Challenge

Farrat were contacted to provide a replacement solution that would reduce the excessive movement of the Cupper Press and create a quieter environment for the neighbouring buildings. 

Cupper Presses are commonly used in can manufacturing to produce cylindrical cups from rolls of aluminium or metal. The primary action of this type of machine is to punch discs from sheets at high speeds. This action generates vertical excitations at frequencies determined by the speed of the machine, also known as ‘shocks’.  

These heavy vibrations have damaging effects on the functionality of the machine installation, its systems and components, and the machines overall productivity. Shock induced vibrations can also damage the building by generating waves and noises that propagate out into the environment. It is therefore crucial to ensure that Cupper Presses are installed on suitable vibration control systems to mitigate against these effects. 

The primary element of this challenge was to stiffen the overall system, while preventing excessive vibrations being transmitted around. 

The Solution

Farrat’s application engineers considered several system criteria during the design phase, such as the mass, dimensions, and operating speed of the machine, as well as system stability and the isolation performance required to meet the clients challenging requirements.

To resolve both of the clients issues, Farrat engineered a replacement vibration isolation system configured with bespoke bearings made of a steel base and 2 layers of Isomat isolators.

Learn more about the material properties of Farrat Isomat here.

Performance Results 

A vibration investigation was conducted by Farrat to measure the level of vibration emitted before and after replacement of the spring packs, to assess the efficiency of the Farrat Isomat System.  The results of the survey are presented in the adjacent plot, showing the vertical accelerations measured before replacement with the blue curves, and after installation of the Farrat Isomat Bearing with the orange curves.

Vibrations measured at the feet of the machine are shown on top, on the inertia block in the middle, and on the surrounding factory floor at the bottom. The results were observed at all measured operational machine speeds, between 110 and 170 RPM.  

A significant vibration reduction can be seen in each part of the system, particularly at the operational speed of the Cupper Press at slightly below 2 Hz. This is the frequency where the machine is most likely to be moving & rocking, impacting the process quality. The pre-existing system of springs with visco-dampers has proven unsuitable because of its extremely low natural frequency, which is excessively close to the disturbing frequencies generated by the Cupper Press – increasing the risk of resonance issues. 

Conclusion

The client’s requirements have been met by the Farrat Isolated Foundation solution, which has significantly lowered the movements of the machine while maintaining a quiet environment for nearby buildings. This demonstrates the efficiency of Farrat Isomat systems for Cupper Press machine applications, where bespoke design solutions are needed to solve complex engineering challenges.

For more information on how our application engineers can work with your design teams, production managers and OEM partners to integrate industrial vibration control and Isomat System, contact our team here.

#onamission

Industrial machinery has the potential to generate structure-borne sound and vibration that propagates to the surrounding floor and structures affecting nearby sensitive equipment and workers, having an influence in its precision and damage to inner tooling and potentially having significant effects on its performance. It is, therefore, necessary to minimise the transmission of the disturbances.

An Isolated Foundation can be engineered to protect sensitive machinery from external vibrations (passive isolation) or reduce vibrations and prevent them from being transmitted to the surrounding environment (active isolation).

How do they work?

Isolated Foundations are a vibration isolation solution, frequently used across industrial, construction and power generation sectors. The system comprises of a concrete inertia block, to which equipment or machinery is rigidly or softly connected based on the application. Vibration isolation material, provided by Farrat, surrounds the foundation to prevent vibration from either entering or leaving.

The isolation efficiency – usually measured in terms of transmissibility – depends on different aspects that must be taken into consideration when designing an Isolated Foundation. The mass, dimensions, and operating speed of the machine – as well as system stability and isolation performance required – are all factors used by our R&D engineers to determine the material and overall isolation system that can meet particularly challenging clients’ requirements.

Typical configurations

With over 60 years of experience in providing vibration isolation solutions for machinery and equipment, Farrat provides the most cost-effective and easy-to-install Isolated Foundation solution for each enquiry. This enables machinery to maximise its productivity while maintaining a safe working environment. The main components of the isolation system are:

• Inertia block – adds mass to the system, increasing the level of compression of the anti-vibration pads to improve their isolation performance. It also provides more stability to the structure and reduces the rocking of the machine because of increased stiffness and lower centre of gravity, thus maintaining alignment during changes in static and dynamic loads. This is known as “mass damping”.
• Cork composite strips – used on top of the side walls to add lateral stiffness. They prevent rocking of the foundation and increase its stability. It also helps to reduce the lateral vibrations from being transmitted in or out of the system.
• Void Former – used to support the strips on the walls and ensure a flat surface on the base to distribute equally the loads from the inertia block and machine onto the anti-vibration pads. It supports the wet concrete until it hardens, then creeps under the loads to allow the pads to take the full load and perform.
• Anti-Vibration pads – flexible elements used between the inertia block and its supporting structure to attenuate the transmission of shock or vibration and isolate the system. They are usually made of rubber which offers ideal performances for a large number of applications but can also be polyurethane foam or helical steel springs for special types of enquiries.

Next steps

We recommend that anyone looking for a vibration control solution for machinery explore our range of services and solutions here.

Technical information regarding Isolated Foundations can be found in this brochure.

Alongside this, our CPD training resource ‘Industrial Module 02’ from our On-Demand CPD library presents real case studies on the effects and benefits of using Isolated Foundations under Impact Machinery.

#onamission

As part of our recent winter fundraising campaign – during which Farrat employees collectively covered over 3,000km from our office in Altrincham to reach Santa’s village in Lapland raising funds for 5 charities – Senior Project Delivery Manager, Neil Wilson, completed a jog around London to take in some of our recent projects whilst clocking up his distance.  

Setting out from the Everyman Cinema near Kings Cross (where Farrat CineWALL PRO provides the acoustic isolation for auditorium screens), Neil finished up at the new sustainable Google HQ which is currently under construction and integrates Farrat high-performance bridge bearings. 

On his tour, Neil passed a dozen other Farrat projects, including:  

• The former Royal Mail location, which was recently converted into 681 high class residential spaces and utilises bespoke Farrat acoustic floating floors to overcome the vibration control challenges that the busy location generates.  
• A theatre project on St Giles Circus junction in the West End of London, which is surrounded by a tangle of underground tunnels and features another bespoke Farrat floating floor to mitigate noise disturbance. 

• Ilona Rose House, a mixed-use commercial development comprising of retail, restaurants, roof terraces and pedestrian walkways, which are set to generate much needed employment into the area.  Here Farrat supplied Structural Thermal Breaks to reduce heat loss and mitigate against thermal bridging.
• VUE Cinema in Leicester Square, which has originally built in 1938, but re-opened in 2017 following a major refurbishment complete with leather reclining seats, Sony 4K digital projection and Dolby Atmos sound.  Farrat cinema isolation materials were engineered into the IMAX screen to ensure optimal acoustic isolation and the best possible viewing experience.
• Queen Street, a residential property that utilises the Farrat CineFLOOR system to isolate vibrations from the busy surrounding environment. 
• Just down the road, another residential project – 60 Curzon Street – where Farrat designed, engineered and manufactured the structural bearings that hold the weight of the load bearing walls above.
• Claridge’s (a building that needs no introduction in London), which underwent a major extension between 2019 and 2020 and where Farrat supplied acoustic pads within a CineFLOOR LITE system to ensure that surrounding hustle and bustle does not interfere with the guest’s comfort.

• 20 Grosvenor Square, a super prime residential development built between 2014 and 2018.  Farrat worked closely with the project team to not only provided the Structural Thermal Breaks to insulate the building efficiently, but a full building vibration isolation system incorporating the Farrat CineFLOOR PRO range to isolate the building from surrounding vibrations, which became an integral part of the entire project.  
• Neil then passed by the award-winning Royal Academy of Music, where Farrat developed a bespoke acoustic isolation system.  And just a little further along, Regents Crescent, another super prime residential centre where Farrat provided the Structural Thermal Breaks as well as structural bearings and Farrat CineFLOOR PRO for vibration isolation.  

 His last two stops before finishing at the new Google Headquarters were the Royal College of General Practitioners – a 290 seat auditorium with the added complication of being a Grade 2 listed building, with strict regulations to work around – and Cartwright Gardens – central London student accommodation.   

It is amazing to be able to see such huge engineering achievements delivered by Farrat in this one – albeit long – run, and demonstrate how Farrat is playing a key role in developing our nation’s capital; working around networks of underground and overground trains, main roads and surrounding hospitality venues as well as nearby airports, to delight our customers.   

#onamission 

Ambev are a Brazilian brewing company with an annual revenue of over $13 Billion USD.  They are building a new factory with an area of 45,000 square meters. The new factory will house two can production lines (bodymakers) and one lid production line (cuppers) and will run on 100% renewable energy.

It will be their first can factory in Brazil and will come at a cost of $700 Million USD. Ambev have employed Ribeiro Caram as the main contractor to carry out these works.  Staying on schedule is vital to the success of this project but health and safety is also a strong focus for them.

This October 2019, Farrat have been working in person with engineering and construction teams in Brazil, to ensure that their production line machinery will be sufficiently isolated to work safely. The project is still ongoing but a recent on-site visit has meant we have been able to see the efficient future implementation of Farrat industrial vibration control solutions.

From our manufacturing facilities in the UK, we have supplied Farrat Vidam and Farrat Isomat Pads to configure bespoke designed Farrat Isolated Foundations.

On site Project Delivery Manager Neil Wilson says: ‘It’s very satisfying to see the Farrat logo on a building site on the other side of the world, knowing how hard everyone works in the UK to make it all happen from enquiry stage through to dispatch.’

Can making machines operate at high speeds and impact loads, which pass noise and vibrations in the surrounding area.  This can seriously affect the health and safety of both the people working there, and people living in the surrounding area.

By installing Farrat Isolated Foundations, these vibrations will be isolated, ensuring a better working environment and securing the safety of people in the area at large.

International projects such as these are a key part of Farrat’s mission in engineering; to provide both direct access to the best technical experts as well as the best solutions.

The recent €1.4bn (£1bn) investment into the new manufacturing facility in Nitra, Slovakia, marks the first time a UK automotive company has opened a plant in the country.

The 300,000m² facility stands at the forefront of aluminium manufacturing and engineering expertise in Slovakia and has been designed with the flexibility to enable smart, connected manufacturing technologies that will support improved process efficiency and deliver up to 150,000 vehicles a year.

Farrat worked with the Structural Engineer and Project Personnel to ensure that a variety of machines within the plant were sufficiently isolated and capable to inspect at high speed with precision.

This included engineering and bespoke-manufacturing components for several vibration isolation systems for robot mounted non-contact sensor systems, CMM’s and Presses across the production line.

Farrat ISOFOAM120 was installed on the walls of machine foundations to provide lateral isolation. This system is typical where a high stiffness foundation is critical but a degree of active or passive isolation is required, even if only from the risk of random events such as dropping heavy items nearby.

Over 1,000 ISOMAT pads of various rubber compounds and sizes, were then used to fine tune dynamic natural frequencies and stabilise each machine for optimum performance.

Farrat ISOMAT Foundation Isolators are the cornerstone of Farrat’s Isolated Foundation Solutions. Our ISOMAT pads have a unique profile coupled with a selection of our elastomers and thicknesses.  Due to extensive testing and experience, Farrat ISOMAT pads deliver highly predictable performance characteristics over many years of service.

Farrat ISOMAT is produced in 3 elastomeric types: IMBR, IMCR and IMNR.

Large automotive manufacturers and leading OEM’s are increasingly designing facilities and machinery to work faster and with more precision, whilst reducing weight and cost.

Farrat Isolated Foundations are consequently integrated into factory design to ensure that the operating conditions (in terms of vibration levels) are controlled to within equipment specifications, to maximise productivity and conform to H&S and local authority requirements.

Whether you are relocating existing machinery, installing new equipment or are involved in detailing foundations, Farrat have the knowledge and experience to provide the right Isolated Foundation solution for your production facility.

Farrat has designed and delivered industrial vibration control solutions for many of the world’s largest and most complex projects in the automotive, canning and aerospace markets. Whether you are relocating existing machinery, installing new equipment or are involved in detailing foundations, Farrat have the knowledge and experience to provide the right Isolated Foundation solution.

For further information:

• View Isolated Foundation Range
• Contact Farrat Industrial Vibration Control Team

Mount Coffee HPP will be the largest power generating facility in Liberia and will operate as part of the CSLG Power Network, which will be used for interchange of power with neighbouring countries. 

The rehabilitation project, which has been identified by the Government of Liberia as the cornerstone of its objective to expand access to sustainable, affordable, and reliable electricity for its citizens, is located approximately 27 kilometers (km) northeast of Monrovia in Montserrado County, Liberia. The plant was originally designed as a run-of-river scheme with the provision for six units, however the powerhouse was only constructed for four units. The original four units will be rehabilitated using Francis turbines supplied by Voith Hydro (alongside generators and associated electro-mechanical equipment for the powerhouse).

Farrat CR60 pads will be used to support emergency spillway bridge slabs to allow for bridge movement. The first pads were required on site within 3 weeks of the order being placed with Farrat. Needless to say that Farrat delivered ahead of schedule.

For more information on Farrat Elastomeric materials and pads please click here.