Low speed spray filling production lineIt is commonly used in daily chemical (such as insecticide spray), medicine (such as oral spray) and other fields. Its filled spray mostly contains volatile components such as ethanol, propane, dimethyl ether, etc. If gas leakage occurs, it will not only cause loss of raw materials, cause potential safety hazards (such as open fire explosion), but also endanger the health of operators. In response to the characteristics of "low-speed operation and intermittent operation" in production lines, a leakage prevention and control system needs to be constructed from four dimensions: equipment sealing, real-time monitoring, ventilation and purification, and process control to ensure production safety.

From the perspective of optimizing the sealing of the core components of the equipment, the "dynamic and static sealing points" of the filling system are high-risk areas for leakage, and targeted sealing design needs to be strengthened. For example, the connection between the filling valve and the nozzle (static seal) uses solvent resistant fluororubber sealing rings instead of traditional nitrile rubber. Its resistance to volatile gas corrosion is increased by three times, which can avoid leakage caused by aging and cracking of the sealing rings after long-term use; The shaft (dynamic seal) of the filling pump adopts a "dual mechanical seal+oil seal" combination structure. The first mechanical seal blocks most of the gas, the second seal intercepts residual leakage, and the oil seal prevents lubricating oil from infiltrating the material. The dual protection keeps the shaft leakage rate below 0.1mg/h, far below the industry limit of 1mg/h. Through this transformation, a daily chemical factory reduced the leakage rate of the pesticide spray filling line from 3 to 0 every month, and reduced the consumption of raw materials by 15%.

Real time monitoring system is the key to "early detection and early disposal", which needs to cover the entire production line and coordinate emergency measures.Low speed spray filling production lineTwo types of monitoring equipment can be installed: one is to install fixed volatile organic compound (VOCs) sensors near the filling station and material storage tank, with a detection accuracy of 0.1ppm. When the concentration exceeds the safety threshold (such as 200ppm ethanol gas), it will immediately trigger an audible and visual alarm and automatically close the material valve in the corresponding area; Secondly, operators should be equipped with portable detectors that can monitor the gas concentration at easily accessible leak points such as hands and cuffs in real time, to avoid inhaling excessive gas. In addition, monitoring data will be synchronized to the central control system to form a curve of leakage concentration changes, making it easier to trace the source of the leakage. A pharmaceutical enterprise once found a small amount of leakage during the filling of a batch of oral spray within 10 seconds through a fixed sensor, and stopped the machine for maintenance in time to avoid the diffusion of volatile components to other areas of the workshop.

The ventilation and purification system can quickly dilute and process leaked gases, reducing the concentration of workshop environment. In response to the characteristic of "local leakage concentration" in low-speed production lines, a combination of "local exhaust+overall ventilation" mode is adopted: universal exhaust hoods are installed above each filling station, and the hood mouth wind speed is controlled at 1.5m/s, which can quickly capture the leaked volatile gases; A roof exhaust fan is installed at the top of the workshop, with a ventilation rate of 12 times per hour to ensure overall air circulation. The extracted gas needs to be treated by an activated carbon adsorption tower with an adsorption efficiency of over 90%. It can only be discharged after meeting the standard to avoid environmental pollution. Through this system, the concentration of volatile gas in the workshop of a spray factory was stably controlled below 50ppm, and the occupational health risk of operators was reduced by 60%.

Operating standards and regular maintenance are the 'long-term guarantee' for preventing and controlling leaks. Strict operating procedures need to be established: for example, before filling, it is necessary to check whether the seals are intact, apply soapy water to the sealing points for "bubble testing", and only start the equipment if there are no bubbles; If any abnormal odor is found during the filling process, the machine should be stopped immediately and a portable detector should be used to locate the leakage point. It is strictly prohibited to operate with leakage. At the same time, establish an equipment maintenance ledger, replace seals every 3 months, calibrate VOCs sensors once a month, dismantle and inspect mechanical seals every six months, and replace "post failure maintenance" with "preventive maintenance". By implementing this system, a food spray production line reduced the downtime caused by equipment leakage from 2 hours per month to 0.5 hours, and the production efficiency increased by 8%.

Compared with the high-speed production line, the low-speed spray filling line has a small single leakage, but due to the long operation cycle and more manual intervention, more attention should be paid to "detail prevention and control". Through the synergy of the above equipment optimization, monitoring and early warning, ventilation and purification and process control, a whole chain leakage prevention and control system can be built, which not only ensures production safety and personnel health, but also provides support for the stability of spray product quality. With the increasing requirements for environmental protection and safety, the futureLow speed spray filling production lineAI technology can also be integrated to predict the aging trend of seals through monitoring data, achieving "early prevention and control" of leaks.