Team Members and Role:

Abstract:

The Packaging Corporation of America (PCA) manufacturing plant in Northampton, MA currently uses a visual inspection process to evaluate the clarity of wastewater. A chemical treatment process is conducted to help the ink settle at the bottom of the tank, and afterward, the clear water is drained to the municipal sewer. By designing and producing an assembly that automates the water inspection process, the detection will be more controllable, reliable, and safe. PCA is looking for a one-off solution specifically designed for their tank and wastewater process. Designs were generated based on pump and buoyancy calculations as well as laboratory experiments to understand the chemical properties of the flexographic ink-water mixture. Many sensor types were considered based on cost and their ability to analyze the clarity of the water; a visible light sensor was chosen. The final design concept is a floating mechanical assembly that includes a buoy, housing, hose, and electrical system that pumps clean water. The automated system consists of a through beam sensor connected to an amplifier which controls a solenoid valve on the pump. A full-scale prototype was fabricated and evaluated in a small-scale tank to replicate the real environment. The device will be implemented at PCA and result in a wastewater treatment process that is more accurate, controllable, and safe for the community.