report A Magazine for the Production Industry 2/17
SIGMA AIR MANAGER 4.0 4 Automatic 10.04 bar
Station Station Status
Compressors Power 165.51 kW Messages Volumetric fl ow rate 27.60 m³/min C1 C1 - BSD 75 Monitoring
C2 - BSD 75 Energy & costs
C2 D1 F1 C3 - BSD 75 Maintenance R1 C4 - CSD 105 SFC DHS1 Control
C3 D2 F2 Dryer SAM 4.0 Logic
Filter Letter mail 4.0... Time control C4 CT1 Air receiver Initial start-up
Condensate treatment Confi guration ...with KAESER KOMPRESSOREN Contact i
Data management and security: Wort concentrates for the 120,000 shipments per day: Good fortune and glass: QITS – Document processing 4.0 world: Döhler brewery 4.0 Compressed air for Witt Safety glass from Glasprofi Contents Issue 2/17 Editorial
3 Editorial
4 Guardians of digital data management and security The courage to embrace change QITS – Document processing 4.0
8 Wort concentrates for the world: Döhler brewery 4.0 Change can be an unsettling experience for everyone – especially since it often comes when we least expect it. 8-11 12 120,000 shipments per day: We may believe that we’re losing control, which is rarely a Witt is the place for… compressed air! welcome feeling. The mind begins to spin webs of doubt as soon as we come to the realisation that our success de- Jason Morgan 16 Good fortune and glass... pends on our ability to change: Managing Director Safety glass: just-in-time delivery by Glasprofi HPC Compressed Air Systems What will happen if I make a mistake? 20 Good for the Mosel Kaeser screw blowers in wastewater treatment What if I’m not up to the challenge of change? Yet, as humans, we are remarkable: we are resilient and What lies ahead if I can’t successfully adapt? continuously strive to master the process of change. 22 More compressed air for less energy When we believe in the outcome and ourselves, we will 12-15 TE/TF – The energy-saving dryers Most changes in life bring about stress and uncertainty. Any attain the goal of adapting more quickly and more suc- path that leads us away from familiar territory and into the cessfully than those who never dare to make the attempt 23 DBS series screw blowers unknown is fraught with difficulty and often, we’re simply not at all. Quiet and efficient used to it. Yet what is life, but change? Nothing remains the Our new reality, Industrie 4.0, demands intense and rapid way it is forever. Those who do not embrace change are left change from us all; change that many today cannot even behind and miss-out on the opportunities that the future has imagine. Nevertheless, we must succeed in order to reap to offer. the rewards that the future holds, namely: increased fle- xibility, greater efficiency, new business models and, last, Therefore, to be able to achieve change successfully, we but not least, a significantly enhanced competitive edge. need to move out of our comfort zone. We have to under- We wish everyone who chooses to take up the challenge 16-19 stand and accept our vulnerability and even the possibility of walking this necessary and exciting path much coura- that we may not initially be able to adapt to the new circum- ge, inspired enthusiasm – and all the success in the stances. world.
Imprint: Publisher: KAESER KOMPRESSOREN SE, 96450 Coburg, Germany, Carl-Kaeser-Str. 26 Tel. +49 9561 640-0, Fax +49 9561 640-130, www.kaeser.com Editor: KAESER KOMPRESSOREN SE Photographer: Marcel Hunger Printing: Schneider Printmedien GmbH, Weidhausen The editor accepts no liability for manuscripts and photos submitted without request. Reproduction, including of excerpts, only permitted with written permission. KAESER KOMPRESSOREN SE – Postfach 21 43 – 96410 Coburg Tel. +49 9561 640-0 – Fax +49 9561 640-130, www.kaeser.com – E-Mail: [email protected]
2 | KAESER report KAESER report | 3 An innovative IT service provider is making the dream of a paper- less office a reality – particularly for customers that work with large volumes of invoices or other transaction documents. With headquarters in an industrial park in Ratingen, near Dusseldorf, QITS provides output manage- ment, real-time tracking and electronic forwarding with great speed, reliability and above all, data security.
Guardians of digital data management and security – Document processing 4.0
At the heart of QITS...
After registering and passing through a spondence of a sensitive nature requiring a to specific target audiences; especially for security check, visitors are led to the inner high level of data security and strict adher- communications containing myriad different sanctum, located in the middle of an ex- ence to delivery times. rates and offers. The mailings are produced pansive, modern, temperature-controlled From bank statements to loan agreements, using single-sheet digital printing on laser conference room: an imposing, square electricity and gas bills to the latest spe- printers, or in continuous rolls on high- monolith identified as the “QITS DataSafe” cial offers from vineyards in Burgundy and speed colour inkjet systems, in both black in large letters against the “QITS grey” sur- Champagne: the QITS DataSafe process- & white and colour. The mailings are bound face. This is the company’s beating heart es and prepares all of this information with either mechanically or by hand, including and its true working capital – safeguarded such detailed precision that each one of individual enclosures and individualised re- by countless backups and redundancies, the annually 40 million deliveries is both sponse elements. to assure maximum security. This powerful addressed to the correct recipient and also In addition to simply addressing the mail- data centre stores and processes customer tailored to the specific content. ings, QITS therefore provides a range of and accounting data from a huge number The specialists at QITS provide not only services for individualising them for each of customers, ranging from major banks to processing of transaction documents but specific purpose. The company’s decision energy utilities companies through to wine also individual design of marketing mail- to use more modern printing techniques, shops and consignors. ings tailored to the requirements of each rather than offset printing templates and What they have in common is years and customer: QITS manages the printing and forms, not only reduces storage costs and decades of reliance on QITS for depend- distribution processes for complex mail- able forwarding of correspondence to the ings. Experienced pre-press and IT spe- The compressed air station adjacent to the respective addressees – especially corre- cialists develop custom solutions geared exterior wall of the high-rack warehouse
4 | KAESER report KAESER report | 5 ...paper handling...
Colour management and... outlay, but also enables exceptional receiver with a volume of one cubic metre – responsiveness whenever up-to-the- at 6 m³/min, 8 bar. And true to Industrie 4.0 minute offers and conditions need to The output management at QITS is truly a principles, the entire system is efficiently be sent out. managed by the Sigma Air Manager 4.0 Highly individualised offers can be vibrant example of Industrie 4.0 at its best and fully integrated into the company’s pro- produced quickly thanks to customer duction control system. ...IT-controlled... databases compiled from online shop- QITS also opted for a Kaeser air-main ping records, CRM and customer loy- charging system (AMCS). The AMCS re- alty cards. Imagery as well as individual discounts and response the volumes currently being processed. These onboard systems liably prevents the surge of compressed elements to be redeemed at the POS increase repeat business were the weak link that brought the “system” of decentralised and air rushing through the dryers, filters and SIGMA AIR MANAGER 4.0 4 Automatic 10.04 bar and turnover. non-redundant compressors to its knees – increasingly frequently. distribution network without resistance, Station Station Status The decision to update the printer and processing systems to work which otherwise occurs when the system Compressors Power 165.51 kW Messages Volumetric fl ow rate 27.60 m³/min C1 Everything networked – even the compressed air with a state-of-the-art centralised compressed air supply, complete is started up again following an interruption C1 - BSD 75 Monitoring The output management at QITS is truly a vibrant example of with system integration (and demand-based expansion options) for in production. It additionally ensures that C2 - BSD 75 Energy & costs C2 D1 F1 C3 - BSD 75 Maintenance R1 Industrie 4.0 at its best: without seamless networking of the con- both process as well as control air, was therefore both logical and compressed air of the required quality and C4 - CSD 105 SFC DHS1 Control
C3 D2 F2 Dryer stantly updated customer and service provider databases, the com- obvious. pressure is available immediately following SAM 4.0 Logic
Filter pany’s trademark speed and individualisation of such huge volumes Once QITS had decided in favour of Kaeser Kompressoren, the restart of the compressed air station. Once Time control C4 CT1 Air receiver of postal material would be impossible to achieve. In particular, the next step was to determine the most suitable installation location the system was up and running, Niclas Alm- Initial start-up Condensate Confi guration processes tasked with putting the data onto paper and then, in turn, for the centralised compressed air station. In the end, the decision stadt, Head of Sales, reported that the de- treatment Contact i the paper into the appropriate envelope, require compressed air to was made to install it adjacent to the exterior side of the rear wall cision in favour of Kaeser was a very good be supplied with maximum precision – and at the necessary qual- of a high-rack warehouse, which is flanked by two production halls. one, particularly from the perspective of ity and volume. Most of the company’s existing printing, binding & Three Kaeser SK 22T type rotary screw compressors (with inte- compressed air station efficiency and avail- sorting machines and systems came with “onboard compressed grated refrigeration dryers) now supply both halls with compressed ability, not to mention the excellent Kaeser air supplies”, however they merely performed adequately directly air – treated according to the needs of the respective application Service. following their installation – eventually they couldn’t keep up with – via three F22KE units from the Kaeser Filter range and an air ...by an advanced master controller
6 | KAESER report KAESER report | 7 of needing to “do it all themselves”. They are increasingly leaving the production of individual ingredients, including complex preliminary products, to specialised suppli- ers whose products are closely coordinat- Wort concentrates for the world ed with customers. And they deliver them when and where they are needed, and in a variety that would be virtually impossible to maintain in-house without massive vertical integration efforts. Among the top suppliers of the global Döhler brewery 4.0 food industry is Döhler GmbH, with headquarters in Darmstadt, Ger- many. It is a leading global man- ufacturer, seller and supplier of technology-based natural ingre- dients, ingredient systems and integrated solutions for the food and beverage industry. Döhler’s integrated approach and broad product portfolio offer an optimal foundation for innovative and safe food and beverage applications. Its wide range of natural ingredi- ents extends from natural flavours, natural colours, health and nutrition ingredients, cereal ingredients, dairy and dairy-free ingredients, speciality ingredients, dry ingredients, and fruit and vegetable ingredients through to complex special purpose blends (ingre- dient systems). Döhler is active in more than 130 countries and has 30 production facilities as well as sales offices and ap- plication centres on every continent. More than 5,000 dedicated employees provide integrated food and beverage solutions It is – from the concept to the implementation not only in phase, true to the company’s motto: “We such high-pro- bring ideas to life” – words that perfectly file industries as capture the company’s versatility, with the car manufacturing nuanced sense of both creating new ideas that the rise of globalisa- and, conversely, applying those ideas to tion has led to ever-increas- life’s needs. ing speciali- sation in pro- duction and to more and more parts and mod- Gleaming: ules being purchased from global the brew kettles for brewing the mash suppliers. In fact, these suppliers are so closely linked online to their customers in “just-in- time” supply chains that they are practically integrated into the customers’ production processes – the beginnings of Indus- trie 4.0, in a sense. Neuss-Holzheim – From the early 1990s, this was the main production site of a former brewery that Much less obvious is the fact that a shopping trolley filled to the produced “Altbier”, a beer variety popular in the Rhineland. Built in 1991, the facility is still used for malt brim at the local supermarket is comparable to a modern car, at least in terms of its contents, with “ingredients” that come from a processing: as a branch plant of the major international food ingredient supplier Döhler, it supplies malt wide range of sources from many different countries. The big in- concentrates on an industrial scale to the food industry and breweries around the world. ternational food producers have also moved far beyond the stage
8 | KAESER report KAESER report | 9 Here in the southern building, the computers are also keeping an eye on things. Until the beer wort – customised to each customer‘s specifications – is ready for filling, large volumes of highly treated air have to flow through the pipe network. A “super-silenced” cold air outlet from the compressor station is shown below.
Hops and malt… Especially when it comes to the latter, more and more customers all plant for such functions as conveying of the large volumes of spent is housed in a large room with sufficient space for an additional over the world are relying on the malt concentrates from Döhler’s grains to fill the waiting waste disposal transports. compressor-dryer combination should one be needed in the future. Neuss-Holzheim plant. These basic ingredients, based on mashed The solution was developed by the Kaeser compressed air experts in And finally there are two other small but noteworthy details that cereal malt, are a decisive factor in the taste of beer. They are close cooperation with Guido Weitz, Technical Director at the plant, underscore the thought that a genuine compressed air system pro- produced on an industrial scale, but at consistently high quality who also has extensive experience with compressed air systems. vider puts into an installation: the cooling air from the compressors standards and according to individual customer recipes. To pro- It almost completely separates the delivery of high-volume bursts is exhausted via the roof. This is achieved without the need for duce the wort, Döhler of compressed additional fans and, in consideration of the nearby residential are- has adapted the brew- air for the ster- as, a specially designed and highly effective ery’s process, using ile tank from silencer cassette module is also used. Even four brew kettles. In When partnering with a true compres- what is hap- when standing right next to the air outlet port an additional step, the pening in the on the roof, the only way of telling whether beer wort is then con- sed air systems provider, everything is compressed the compressors are running is to put up a centrated to produce air network: hand to feel the “draft”. There is practically malt extract. considered down to the last detail compressed no sound. This adaptation re- air is delivered quired the recently by two CSG- completed full mod- 70 oil-free ro- ernisation of the compressed air supply. This was necessary main- tary screw compressors to two Kaeser Secotec TE 91 refrigeration ly to ensure that one of the key requirements for compressed air in dryers before passing through two Kaeser F83 KEA filter combina- a brewery setting could be met reliably and without impacting other tions for final purification. Within the station, network air is stored in operational areas: before bottling, the finished malt extract is placed a 3000-litre air receiver. in a sterile container for intermediate storage. Once emptied, this Outside the compressor room there is also a 5000-litre compressed container must be cleaned and sterilised with hot steam and then air receiver on hand at all times whose contents are used to cool cooled to ambient temperature as quickly as possible. This cooling the sterile tank; it is immediately refilled following this process. requires compressed air – plenty of it, ready at all times, with no The compressor station, managed by a Sigma Air Manager mas- reduction in the working and control air required elsewhere in the ter control system and networked with the plant control system,
10 | KAESER report KAESER report | 11 120,000 shipments per day: Witt is the place for... compressed air!
“Witt is the place for linens”. Back in the 1950s and 1960s, that was one of the best-known slogans in the mail order business, and “Witt Weiden” was truly a household name. Today the company, located in the Upper Palatinate region of Germany, has rejoined the ranks of the leading European mail order fashion and textile companies for its target group.
Boxing clever with the roller conveyor
The fully IT-integrated facility is the core of hub motors as generators, converting the Naturally, to protect the control elements Witt’s shipping logistics. Calling it an “all- braking energy into electric power that is and actuators, this air must meet high – round” facility is an understatement: the fed back into the grid... and above all consistent – quality and purity goods go back and forth, up and down, standards. For this rea- and sideways. The conveyors – set up with son, the Witt logistics rollers or belts (with barriers in curved lo- experts decided upon cations) – extend for many kilometres. All A company with tradition construction of the movements are monitored and controlled high-rack warehouse, by computer, and are subject to visual mon- and advanced logistics that this was the per- itoring via two large control consoles. The fect time to replace the system uses state-of-the-art conveyor tech- This perfectly organised chaos, the setting entire compressed air supply system. nology and is so advanced that containers of the many switches, and the reposition- The result is a streamlined, modern com- can be individually braked on downslopes ing of entire conveyor sections is almost pressed air station in which three CSD 85 using multiple rollers, which then use their entirely performed using compressed air. series rotary screw compressors deliver Conveyor belt ballet – choreographed by compressed air
In 1907, Josef Witt (1884-1954), a car- linen offering excellent value for money, In 2005 an automated container centre for penter by trade, took over his sister’s co- and for decades was produced almost ex- processing returns went into operation in lonial goods shop in Reuth bei Erbendorf clusively in-house. nearby Ullersricht. Since 2008, the logis- and began a textile mail order business. Economic and demographic transforma- tics centre in Weiden-Brandweiher, on the In 1913 he relocated his expanding com- tions resulted in the takeover of the com- outskirts of town, has been shipping up to pany to Weiden, about 30 kilometres away, pany in 1987 by Schwab AG, a member of 350,000 articles a day at peak periods. At then and now the business centre of the the Otto Group. This led to a resurgence in the beginning of 2015, Josef Witt GmbH ex- northern Upper Palatine region. The move Witt’s core business – women’s outerwear, panded the logistics centre with the open- gave rise to the term “Witt Weiden”, which underwear and home textiles – that has ing of Distribution Centre III. It features an has remained synonymous ever since for continued to the present day. automated high-rack warehouse and an in- high-quality apparel, home textiles and bed tegrated goods-in facility. Helping hands are also needed Ceiling-suspended conveyor Collation of orders
12 | KAESER report KAESER report | 13 ity while maintaining communication between the compressed air station and the production management sys- tems. In both operational areas, the Kaeser installations went above and beyond meeting all expectations of the project manager, Mattias Schnurrer, right from the start. He is also pleased to confirm that the new equipment has delivered substantial energy and main- tenance cost savings com- The compressed air is pared to the previous system. fully integrated
All paths lead to the customer
Compressor The logistics centre in Weiden-Brandweiher room at the Ullersricht site... air at 8.5 bar(g). Each is matched with an An integrated compressed air supply is also energy-saving TF 174 Secotec refrigeration important for Witt’s Ullersricht facility. This dryer and an FF221 filter combination that is the location of the company’s almost ful- dry and purify the air at the required stand- ly automated return management system, ard. The air then flows to a 3000-litre com- which also operates highly complex, com- pressed air receiver, ready to be released pressed air-based conveyor technology. into the compressed air network, designed At this Witt site, the hall used for receiving as a loop supplying the entire logistics cen- returned goods stands opposite an impos- tre. Furthermore, a Sigma Air Manager 4/4 ing former factory now listed as a histori- master control system is installed to ensure cal building. The compressed air station optimised compressed air station efficiency has two ASD 40 and BSD 65 Kaeser ro- and reliability and also provides seamless tary screw compressors (each delivering connection to the logistics process control- 8.5 bar(g)) paired with two TE 121 refriger- ler. The Sigma Air Manager’s planned up- ation dryers. Before being fed into the net- ...and the compres- grade to Version 4.0 will bring about even work, the compressed air passes through sed air station in the high-rack warehouse closer integration of all operational process- two FF138 filter combinations. Here, too, a in Distribution Cent- es as envisioned for Industrie 4.0 produc- Sigma Air Manager 4/4 ensures exception- re III, Weiden-Brand- tion environments. al compressed air efficiency and availabil- weiher
14 | KAESER report KAESER report | 15 Safety glass: just-in-time delivery by Glasprofi Good fortune and glass…
…soon break, alas! At least that’s what the proverb says. Glasprofi, a glass manufacturer in Luhe, in Germany’s Upper Palatinate region, begs to differ – at least when it comes to glass. Its products make a convincing argument – in no small part thanks to Kaeser compressed air technology.
Toughened glass (single-pane safety glass) tolerances in drill holes and may result in gan investing in the safety glass segment. is produced by pre-stressing plate glass. slight buckling. In 1994, with the first “Tamglass” tempering The process generally starts with a flat Upon breaking, the release of the stored oven, it began producing single-pane safe- pane. It is heated to its transformation point energy in an internally stressed sheet of ty glass. Business soon took off. Glasprofi (approx. 500-700 °C) and is then abruptly toughened glass causes it to shatter into steadily expanded its range of equipment, cooled with sharp blasts of compressed air. small, rectangular fragments. This greatly investing in modern glass processing facil- The glass is then in a state of internal stress, reduces the risk of serious cuts. The typi- ities and innovative software. This made it with the body possible to manufacture customised and and surface mass-produced sheets of glass of the very under tensile highest quality – and to deliver them just-in- and compres- Tailor-made safety glass for just- time. Consequently, the company was soon sive stress, in-time delivery to the customer supplying several renowned shower cubicle respectively. manufacturers. This increas- The next step in the company’s expansion es the tensile bending strength (to values cal blunt-edged fragments from toughened came in 2000, when Glasprofi acquired the over 200 Nm/mm²) of the glass without glass stick together and are smaller than plate glass factory in Luhe (now part of the making it harder. At the same time, the 1 cm². Toughened glass is found in all kinds municipality of Markt Luhe-Wildenau), built pre-stressing raises its thermal shock re- of interior and exterior glass applications in in the 1950s by Schöniger, a Weiden-based sistance to around 200 K. residential and commercial architecture. manufacturer. The plant’s production facili- Following pre-stressing, the internal stress- ties were subsequently expanded and up- es in the glass and the resulting stored Just-in-time shower cubicles from graded. In today’s modern factory, equipped internal energy greatly limit the ability to Luhe with computer-controlled glass manufactur- perform work on it. For that reason, all drill- The company Glashandelsgesellschaft ing machines, the company can produce ing or edging work on glass intended for Profi mbH – Glasprofi for short – was estab- customised toughened glass components shower enclosures, etc. must be performed lished in Wiesau in 1986. In the beginning quickly and cost-effectively. Since 2005, prior to the pre-stressing process. In the it operated purely as a glass wholesaler. Glasprofi has operated as an independent planning stage it is also important to bear Three years later the company expanded, unit within the Flachglas-Wernberg Group. in mind that the heat treatment will affect acquired production halls in Weiden and be- A large toughened glass component There are still tasks...... where skilled professionals are needed
16 | KAESER report KAESER report | 17 Lots of power and compressed air In addition to the large electrical (heat) energy input required for unworked glass sheets to reach the required aggregate state, between solid and liquid, toughened glass manufacturing requires a sufficient supply of compressed air for the rapid cooling needed to produce the internal stresses. This means that, together with kilometre-long bundles of thick copper ca- bles in the plant floor, the facility is fitted with large-diameter compressed air piping to carry the cooling medium to where it is needed – along with control and working air for the highly mechanised conveying and processing equipment. The compressed air supply at the Luhe plant is designed for the especially demand- ing applications there, posed by a product portfolio that includes safety glass with a thickness of just 3 mm: this requires mas- Cool air for tensile strength sive amounts of compressed air to be de- livered “all at once”, which in turn demands total storage capacity of 35 cubic metres, distributed across several compressed air tanks. To keep pace with the manufactur- ing process, these have to be recharged at a pressure of 10 bar every two and a half minutes. This task is performed by six compressors from various model series (1 x ESD 441, 1 x DSD 202, 2 x BSD 81, 1 x ASD 57 and a tried-and-true veteran: the CS 91), two large refrigeration dryers (TE 121, TF 173) and, to protect the sen- sitive surface of the glass, the appropriate combinations and configurations of Kaeser filters. A Sigma Air Manager master controller ensures optimum compressed air supply efficiency and availability at all times and also ensures seamless integration into the manufacturing process, where the defining Drilling for hardware and other cutouts comes before the tempering process Three of six – the Glasprofi compressed air station features of Industrie 4.0 are already very much in evidence. In the shower cubicle business – a key seg- ment for Profiglas – this a very welcome de- velopment, given the ever-increasing focus on just-in-time delivery of customised glass components. The innovative and com- prehensive IT integration of the Glasprofi manufacturing operations makes it possible to ship installation-ready glass within two days of receiving the order. That is today’s performance benchmark for true glass pro- fessionals – like the dedicated “Glas-Profi” specialists in Luhe.
Going into the tempering oven Shower cubicle elements...... ready for shipping
18 | KAESER report KAESER report | 19 FBS screw blower: “I’m new around here. Dependable blower air for supplying oxygen The result: pure Mosel water... You’re going to be seeing a lot of me...” to two aeration tanks
The wastewater treatment plant in Tre- key systems: they are equipped with an in- cess management systems. Networking is is-Karden is a sequencing batch reactor – tegrated, network-enabled Sigma Control 2 carried out via conventional or floating con- a variant of the activated sludge process. controller together with all of the necessary tacts, or by Profibus/Ethernet. This process uses two basins, which han- power electronics, such as the frequency Although designed as a turnkey system, dle batches in a cycle (filling, mixing, filling, converter. Pre-programming of the frequen- the FBS screw blower had to be delivered aerating, settlement, decanting) that takes cy converter and the fact that the entire sys- and installed as individual components at around five hours to complete. The water tem undergoes a trial run in the plant makes the Treis-Karden site: the retrofitted sludge levels are approx- installation far easier press, which cannot be deactivated while imately 5.5 me- and more economical the plant is operating, restricts access to tres, with physical The water is in most cases. the “blower cellar”. Here the typical Kaeser pressure of about The Kaeser Sigma modular design of the screw blower came 570 mbar during pure Control 2 blower con- to the rescue – it was a quick and easy pro- operations. There troller monitors all op- cess to dismantle the blower, reassemble it is also consid- erating parameters in the cellar and flip the switch to start it up. erable seasonal variation in the wastewa- within the bower system, keeps them within The new blower was soon proving its worth ter throughput: the many day-trippers and the optimal ranges, and can be integrated with up to 25 percent energy savings. long-term visitors who come to the region in easily and cost-effectively into existing pro- the summer months result in substantially higher volumes than in the winter, for exam- ple. Correspondingly, the water pressure in the tanks against which the aeration equip- ment has to operate also fluctuates and is typically between 480-570 mbar, depending on the water level. The system operators were already more than happy with the installed rotary blowers that had been in use beforehand. However, they were also interested in the prospect of further significant energy savings for the Kaeser screw blowers in wastewater treatment aeration process, and agreed to install a Kaeser FBS screw blower with a flow rate of 67 m³/min on a trial basis to replace the existing equipment. The blower is equipped with highly efficient Sigma Profile rotors developed from the proprietary technology Good for the Mosel used in Kaeser’s rotary screw compres- sors, which are world-renowned for their The regional municipality of Cochem in Germany operates a highly innovative network of wastewater efficiency. Depending on operating conditions, Kaeser treatment plants and is always looking for new ways to improve efficiency and reduce costs, whilst also screw blowers are up to 35 percent more respecting the environment. One such example is at the wastewater treatment plant in the district of efficient than conventional rotary blowers. They also provide significantly greater en- Treis-Karden, where, with help from a new Kaeser screw blower, purified water flows into the Mosel River ergy efficiency compared with commonly at a rate of approximately 350 litres per second. available screw and turbo blowers on the market, since they dispense with auxiliary equipment such as oil and vacuum pumps. The Treis-Karden wastewater treatment facility (at left; above: Karden district with the Kaeser screw blowers are supplied as turn- St. Castor collegiate church) tried out a new Kaeser screw blower with excellent results
20 | KAESER report KAESER report | 21 More compressed air for less energy DBS series screw blowers TE/TF – The energy-saving dryers Quiet and efficient Through innovative technology, the Secotec TE and TF refrigeration dryers from Kaeser Kompressoren For applications requiring maximum energy efficiency in continuous operation – for example in the aeration demonstrate that improved performance can indeed go hand-in-hand with significantly reduced energy of wastewater treatment tanks – then there’s no better choice than a screw blower from Kaeser. The new demand and space requirement. DBS series completes the lower output range of our screw blower portfolio.
The Secotec name has long been syn- under partial load conditions without us- terial. With its far higher thermal storage Like their big brothers, the EBS and FBS, The low energy consumption of the Sigma Air Manager 4.0 (SAM 4.0) mas- onymous with quality, industrial-standard ing additional energy. The rapid-response capacity compared with conventional heat the new Kaeser DBS screw blowers deliv- Kaeser screw blowers makes them the ter controller – which has proven its worth in Kaeser refrigeration dryers that ensure sta- Secopack LS heat exchanger system en- exchangers, it requires 98% less heat stor- er unparalleled efficiency. They are up to perfect choice for supplying compressed the compressor sector – is also available for ble pressure dew points, meet the highest sures that quality, dried compressed air is age material. The storage capacity required 35 percent more efficient than convention- air to water treatment plants – because it’s blowers, entire blower stations can be inte- reliability standards and which assure low- available whenever it’s needed. to assure pressure dew point stability can al rotary blowers and also provide energy especially in continuous operation that their grated easily into Industrie 4.0 production est possible total life-cycle costs. The electronic Sigma Control Smart con- therefore be achieved with hugely reduced savings in the double digit range compared outstanding energy efficiency comes to the environments. With the innovative Secopack LS latent heat troller is simple and intuitive to use. The space requirement. Optimised flow chan- with many commonly available screw and fore. They require little maintenance and storage / heat exchanger system equipped message memory, operating hours counter nels reduce pressure losses and further turbo blowers. can be installed side by side. Upon request with the Sigma Control Smart controller, for individual components, and the main- enhance dryer energy efficiency. The dry- These benefits are made possible by the they can be delivered with an integrated the new generation raises the bar yet again tenance timers allow efficient monitoring ers are also exceptionally durable thanks proven Sigma Profile rotor technology used frequency converter or a star-delta starter. when setting the standard for energy effi- and analysis of the operating data. Float- to corrosion-resistant air piping and the in the rotary screw compressor sector. An- The screw blowers are delivered as turn- ciency, compact design and ease of use. ing contacts and the optional Modbus TCP aluminium heat exchanger (condenser and other key factor is the durable, non-slip di- key systems (including power electronics The TE and TF series of refrigeration dry- communication module make networking SECOPACK LS). rect drive with almost 100% transmission and the Sigma Control 2 controller) that are ers (10.5 to 34 m³/min) require less than 97 with master controllers such as the efficiency. ready for commissioning straight “out of the watts of power per m³/min of compressed Sigma Air Manager 4.0 simple. Kaeser DBS series screw blowers are avail- box”. The Sigma Control 2, based on an air (ISO 7183 A1). Thanks to their innovative The storage module of the able in four versions with drive motor rated industrial PC, delivers more than just ener- energy-saving technology, the excess cool- innovative Secopack LS heat capacity of 22 to 37 kW. They come in two gy-efficient system control. It also provides ing output stored in the thermal exchange exchanger system is filled pressure ranges (650 and 1000 mbar(g)) a wide range of interfaces to integrate the system can be retrieved for drying purposes with a phase-change ma- and with flow rates of 18 to 23 m³/min. blowers into IT networks. Moreover, since
22 | KAESER report KAESER report | 23 HPC Compressed Air Systems, Victoria Gardens, Burgess Hill, West Sussex RH15 9RQ Tel: 01444 241671 Fax: 01444 247304 E-Mail: [email protected] www.hpccompressors.co.uk
Compact, but powerful! Portable compressor KAESER MOBILAIR 50 Smart and strong Corrosion-proof enclosure made from impact-resistant rotomoulded polyethylene SIGMA PROFILE Electric version Maximum energy efficiency The electric-powered M50E and availability version is whisper-quiet and assures zero on-site emissions
Flexible Tool protection Can be towed by car even with the Even at low temperatures optional compressed air aftercooler Exceptional endurance with the patented Also weighs-in at under 750 kg (weight < 750 kg) KAESER Anti-Frost Control even with a full 80-litre tank
KAESER Kompressoren – More compressed air for less energy www.kaeser.com