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Energy-Saving Measures Are Worth the Candle

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Energy-Saving Measures Are Worth the Candle TECHNICAL WINDOW - GREEN BOTTLING LINES ENERGY-SAVING MEASURES ARE WORTH THE CANDLE Electricity prices continue to cre- use of more energy-efficient hea- that are already helping custo- ep up in most countries of the ters - and also indirectly, via fea- mers reduce their utility bills. world. That’s despite the price of tures that, say, reduce the need to On the redesigned blowing valve oil being at levels not seen so low compress air. block, dead air volume has been for some 13 years and natural gas reduced by 35% and air con- for power stations increasingly BOTTLE BLOWING sumption can be as much as 25% available. But even if prices were A major consumer of energy less, depending on bottle design. to fall, if there were cost-effective in reheat stretch-blow molding SIPA has also replaced pneumatic ways to cut energy consumption machines is the ovens. With its compensation with mechanical in industrial production, it would “green” ovens on the SFR EVO3, compensation, so high-pressure still make sense to use them. SIPA has succeeded in making blowing air is now used only on Well, there are ways, and SIPA major savings. Compared to ear- the final 0.2 mm of the stroke. offers many of them in areas all lier generations of oven, electri- This leads to a massive reduction along its lines for producing and cal consumption is down by up in air consumption, particularly filling bottles, through to shrink- to 40%, thanks to the use of new with smaller bottles. wrapping them. SIPA has identi- lamps and special materials and An optional feature on the SFR fied four areas in particular where coatings for the reflectors. EVO3 is the ARS Plus system. energy consumption can be made There are also plenty of ways to This recovers air for re-use as more efficient: in stretch-blow cut down air consumption in primary air and machine service molding, in filling and mixing, the blowing section. SIPA’s high- air. Tests on an SFR 24 model in conveying, and in shrink speed SFR EVO3 rotary stretch- fitted with ARS Plus showed it wrapping. Savings can come di- blow molding unit, for example, was possible to reduce the total rectly - for example through the incorporates several new features amount of high pressure air nee- _50 _51 TECHNICAL WINDOW - GREEN BOTTLING LINES times. Use of isolator technology energy consumption for such cooling tunnels after the filling and automatic COP (Clean Out procedures in half; water con- operation can capture as much as of Place) means that run times sumption goes down by a similar half of the heat that would other- between separate CIP (Clean In amount. Hot-fill lines obviously wise be lost, and channel it into Place) procedures can be exten- offer potential for energy savings. other process areas. ded to 120 hours, cutting overall Thermal recovery systems in the ded by 16%, and cut overall air in SIPA’s Flextronic range can be CO2 by 10%. A further advan- consumption in half. As a result, configured in the XFILL version, tage with XFILL is that the ex- the SFR EVO3 can be fitted in which the carbonating or tra product stability it provides with a much smaller air com- mixing unit tank can be used as enables carbonated soft drinks pressor, which obviously uses a buffer tank for the filler, which to be filled at higher temperatu- less electricity. then has no need for an on-board res than before – around 18°C or product tank. more – which reduces the need FILLING AND MIXING XFILL makes it possible to redu- for energy-intensive product Big energy savings can also be ce electrical power consumption chilling. Still more savings are made in the filling station. Fillers and can also cut consumption of achievable through increased run _52 _53 TECHNICAL WINDOW - GREEN BOTTLING LINES CONVEYING AND WRAPPING In the filling section itself, the There is even energy to be sa- MASSBLEND “liquid ring” va- ved once the bottles have been cuum pump with closed-circuit blown and filled. In the bottle water circulation can cut wa- conveying system, for example, ter consumption by as much as a high-end gearbox, may use as 95%. And for filling operations much as 40% less energy than a where a bottle base cooling sy- conventional gearbox, and requi- stem is required (for carbonated re less maintenance. soft drinks and pressurized pro- The gearbox will clearly cost ducts for example), an optional more upfront, but in most if fully draining stainless steel ba- not all cases, it is an investment sement with liquid recovery can worth making. cut consumption by up to 95% Energy-saving shrink-wrapping here too. systems can also help reduce elec- tricity bills. Latest equipment has improved hot air channeling systems that direct more heat to the shrink film and less to the conveyor belt, and thermal po- wer and cooling fan speed can be adjusted in real time, according to product output. The shrink tunnel can also be fitted with automatic doors at both ends to reduce heat loss. LESS WATER There are numerous opportuni- ties to save water on filling lines. For example, SIPA’s Sincro Bloc units, which combine blowing, filling and capping into a sin- gle unit, have no need for a rin- ser between blowing and filling. _54 _55.
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