CASE STUDY

Foot Science International | Extraction System Redesign

Foot Science International designs and manufactures customised orthotic insoles using robotic CNC milling as part of its production process. This machining generates fine dust and particulate that must be extracted to protect equipment, maintain product quality, and support a safe working environment.

To reduce consumable spend, speed up servicing, and support ongoing system upgrades, a Caliber engineer was embedded within the FSI team to refine their extraction system concepts. The outcome is a practical, buildable solution that can be manufactured and supported locally, delivering measurable improvements in efficiency, uptime, and operating cost.

KEY TASKS

• Build and trial a prototype of a water-based pre-separator (water trap)
• Develop a boxed production version of the water trap with easy clean-out
• Design a trolley for easy filling, draining, and maintenance
• Provide fabrication drawings, specifications, and BOMs for manufacture and support

HOW WE DELIVERED

Building on the client’s existing concepts, the Caliber engineer designed and delivered a set of targeted filter upgrades to meet the brief. The main filter was re-engineered to simplify carbon media replacement, reducing servicing time and eliminating unnecessary mess. The pre-filter was redesigned with a removable lid, allowing fast change-out using readily available local elements.

To protect the system upstream, a water trap was introduced to capture sticky dust and fines before they reached the extractor. A rapid prototype and trial confirmed the approach, after which a robust boxed unit was developed with easy clean-out access and a purpose-built trolley to support safe draining and refilling.

The result is a cleaner, more serviceable extraction system that improves uptime, lowers operating costs, and extends filter life.