Soundproofing Cabin for Kaolin AD

Project Overview

Founded in 1924 and located in Tsenovo, Bulgaria, Kaolin AD is a prominent supplier of mineral resources, catering to customers across Europe, the Middle East, and North Africa. As a subsidiary of Quarzwerke GmbH, Kaolin mines and processes kaolin, feldspar, silica sand, limestone, dolomite, and chamotte. Recently, the company faced significant noise issues arising from a rotary fan in their production facility in Vetovo. The excessive noise not only created an adverse working environment but also heightened stress levels among employees, prompting Kaolin to seek DECIBEL's expertise for a soundproofing solution.

Challenge

The noise levels generated by the rotary fan reached over 113 dB, posing a serious risk of permanent hearing loss for employees not equipped with appropriate personal protective equipment (PPE). Kaolin AD engaged DECIBEL to design and install a soundproof cabin that would meet four specific requirements:

• Detachable
• Equipped with natural ventilation
• Incorporating lighting
• Accessible for maintenance and operation

Kaolin was attracted to DECIBEL due to the engineering team's extensive experience in handling similar soundproofing challenges.

Scope of Work

• Conducted comprehensive noise assessments of the rotary fan.
• Developed an innovative design for the soundproof cabin, considering all specific requirements.

Solution

One of the primary challenges faced by DECIBEL's engineering team was the limited space available for constructing the cabin. The walls could not exceed 66 mm in thickness, as opposed to the standard 100 mm for most soundproofing solutions. To address this, DECIBEL developed thin yet highly effective sound-insulating panels.

Additionally, the fan's inlet and exhaust plenums were amplifying noise, generating levels of 95 dB. To mitigate this, DECIBEL created a detachable, lightweight cabin mounted on high-performing vibro-insulating pads. Key features included:

• Soundproof panels constructed from stainless steel, fabricated with advanced cutting and folding techniques and welded using precision robotics.
• A powder paint finish to withstand harsh environments, ensuring durability.
• A high-performance silencer designed specifically to handle the fan's frequency range while allowing for natural ventilation.
• Viscoelastic materials coated in high-strength steel to dampen noise from the intake and exhaust plenums.

Results

The final installation resulted in a lightweight cabin, only 75 mm thick, that successfully reduced the noise from the rotary fan from 113 dB to 82.9 dB. The entire project was completed within five days, creating a significantly improved working environment for Kaolin AD's employees.

Industry Insight

In the mining and minerals industry, noise pollution can severely affect productivity and employee health. Exposure to high noise levels can lead to hearing loss and other health issues, decreasing overall efficiency and morale. Implementing effective soundproofing measures, such as specialized cabins, not only protects workers but also enhances productivity and workplace satisfaction, ultimately contributing to a more sustainable operational model. If your production facility is facing similar noise challenges, contact us today. Our team at DECIBEL is ready to provide tailored soundproofing solutions to enhance your working environment, safeguard employee well-being, and improve operational efficiency.