Cost Savings for PET Blow Molding Machines By Technoplan Engineering. Energy Efficient Engineering. Sold Exclusively By Connell Industries

Transcription

1 Cost Savings for PET Blow Molding Machines By Technoplan Engineering Energy Efficient Engineering Sold Exclusively By Connell Industries

2 We are a Swiss company, based in Geneva, specializing in PET bottle manufacturing, with a Technical Service Team based in Mexico. About Technoplan Engineering 27 years experience in industrial machine design 17 years with ARS and ARS+ patents 4 years with ceramic TOEO 3 years with specific PARTS for Sidel and Krones blow molders 1 year servicing the Olicorp IRS and PWR Now launching the OVR10, a reliable replacement for Olicorp IRS & PWR Our range of cost-reducing solutions Reliable replacement for Modern-design valves Ceramic plates for the oven Air Recycling Systems Olicorp up to Saving up to Savings up to 2-year warranty 90% less air leaking 25% electricity on the lamps 40% High Pressure air

3 A Global Network with Local Support Khoi Quan

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5 OVR10 : a Reliable Replacement for Olicorp IRS and PWR A reliable solution to replace the Olicorp IRS10 and PWR Identical connectors Registered as Olicorp by Profibus on the Sidel SBO Universal PLC -> no need for software upgrade 2-year warranty Enhanced protection against short-circuits

6 Why are the OVR10 s More Reliable Than the Olicorp IRS10 and PWR-SDL? Compared to IRS PWR, the OVR10 s are protected by 10 fuses of 25 A, with an interruption capacity of A. Each OVR10 cabinet includes 3x spare fuses, for immediate replacement, to restart production ASAP. 3x spares included 10 fuses to protect the power card OVR10 power card The OVR10 is Warrantied for 2 Years

7 With the OVR10, the Electronic Power Card is Always Protected Against any Short-circuit. Olicorp OVR10 PROTECTION < 6000A only for short-circuits > 25A <6000A > 6000A Replace fuse ALWAYS PROTECTED The OVR10 is Warrantied for 2 years Breaker inside IRS cabinet Breaker inside PWR cabinet Breakers cannot withstand short-circuits > 6000 A

8 Which Blow Molders can use the OVR10? Original Equipment Manufacturer Sidel Manufacturing years SBO Universal Smi Group Tech-Long Chumpower ADS Serac Tecsor / Bosch Bottop

9 Who Already Uses the OVR10? Master Kong OEM : and others!

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11 For Sidel Series 2 : Reliable Valves with 3 years / 25 Million Cycle Warranty Valves Have up to 90% Less Air Leakage Than Original Sidel Series 2 valves Blowing valve V2VS2BVA Exhaust valve V2VS2EVA Compensation valve V3VS2CVA + 3 years or 25 Mo cycles guaranteed + No deviation in time-response after 1 year (machine blowing 8000h / year)

12 Pilot Valves V3E01NCA and V3E01NOA, for KHS Blomax IIIC, Krones and Kosme, Replacement for and , Guaranteed 30 million cycles / 3 years NC NO Krones V3E01NOA pilot on KHS Blomax 16 IIIC V3E01NOA 2x per station V3E01NCA 2x per station

13 Pilot Valves for Krones , Guaranteed 30 million Cycles/3 Years V3E02NOA 2x per station V3E02NCA 2x per station

14 Service Kits for Krones , That are 100% Identical to Original Krones Parts V2OC2PMA (1x per station) Krones ref : X-NOR V2OC2EMA (3x per station) Krones ref : X-NOR

15 Who Already Uses Our Pilots? and others!

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17 20% to 35% average electricity savings on the lamps Combined improvements are brought to the : - Ceramic reflectors - Shield design and ventilation resulting in a significant decrease of energy consumption Shield design and ventilation The shields are designed to improve the preform ventilation and achieve the right balance of air flow in the oven

18 Ceramic reflectors Using high performance ceramic material, with treated surfaces, the Infra-Red light reflection is enhanced, allowing the optimisation of the preforms heating. Before After An average decrease in oven power consumption by a minimum of 20% up to 35% Significant financial savings due to the reduced electricity consumption of the oven Easier profiling and better process window : better heated -> easier to blow Lower maintenance costs : - no maintenance costs on the ceramics - reduction of lamp intensity greatly expands their operating life minimizing lamp expense - lamps from the shut down ovens can be recovered Quick return on investment (< 18 months) Usually Qualifies for Utility Energy Efficiency Rebates Further Lowering the Payback Time (< 12 months)

19 EXAMPLE - SIDEL 2 Before Optimisation After Optimisation Same bottle production rate and quality Rapidly installed without any major modification to the oven (only the process is modified) Based on a proven and reliable technology

20 TOEO Can be Applied on:

21 After Optimisation Before Optimisation EXAMPLE - SIDEL 2 SBO kw/h -> 74.5 kw/h : 40.8 kw/h spared, or 35%

22 Proven results 7 months after installation 30.5 kwh saved per hour If blow molder runs 6000h / year: 183,000 kwh saved per year Or $18,300 USD per year (with 1 kwh = 0.10 USD)

23 2 Identical Sidel 14 Universals, Supplying Same Filling Machine

24 TOEO Efficiency on Sidel Series 2

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26 Benefits Same production rate and quality of your bottles = we only save air No modification of the software No major modification of the blow molder Mechanically & electrically independent of the blow molder = Production possible with the ARS switched OFF (normal blowing) Return On Investment <18 months Rapidly installed : 3 to 5 days possible Can run production during nightshift Measurements All ARS installations are measured for final results by our technician. Control Your Usage We also offer FlowMeters as option

27 Recovery % Compressing 1 Nm3 at 40 bar requires 0.25 kw Released to atmosphere, this money is lost. 50% Up to 50% of the discharged air flow can be directed into a recovery tank, before a final exhaust.

28 3 Possible Air Recovery Systems : ARS Machines targeted : Sidel serie 1, 2 ; Sipa SFL, SFR ; Krones ; Krupp Blomax II No recovery P1 supplied by 40 bar Stretching air supplied by 7 bar or reduced 40 bar P2 ARS : patented 2002, 45% to 50% discharged air recovered 1 recovery P1 and stretching air supplied ARS Excess of recovered air returned to LP line EXH P1 Nestlé France : 5 blower molders, all equipped with ARS : one HP and two LP compressors on hold.

29 3 Possible Air Recovery Systems : ARS+HP Machines targeted : KHS / SIG Blomax, small Kosme 4 or 6 cavities No recovery P1 supplied by 40 bar ARS+HP : patented 2006, 25% to 30% HP air net savings 1 recovery, controlled from exhaust signal P1 supplied by ARS+HP Intermediate Blowing step, supplied by ARS+HP P2 P2 I.B. EXH P1 REC Exh P1

30 3 Possible Air Recovery Systems : ARS+Full Machines targeted : Sidel Series 2, Universal ; Krones ; Sipa SFR No recovery P1 supplied by 40 bar ARS+Full : patented 2006, 35% to 45% HP air savings! 2 successive recoveries P1 and Intermediate Blowing step supplied by ARS+Full Stretching air supplied ARS+Full P2 P2 REC 1 X I.B. EXH P1 REC 2 P1 EXH Stretching Technoplan SA

31 Potential Air Flows From Initial 1000 m3h Blowing Air 1. No recovery HP line : Nm3h 30% Savings 2. ARS HP line : 900 Nm3h Str: 150 Recovery : 100 Nm3h 50% Recovery P1: % Savings LP line : 250 Nm3h Nm3h Nm3h = 500 Nm3h Machines : Sidel Series 2, Sipa SFR, Krones Hot-Fill 3. ARS+HP HP line : 700 Nm3h 4. ARS+Full Savings : P1: 100 HP line : 550 Nm3h IB: Nm3h Machines : Blowmax IIIM, IIIC, Kosme Str: 150 Savings : P1: Nm3h IB: Nm3h = 450 Nm3h Machines : Sidel Series 2, Sipa SFR, Krones

32 ARS Standard Can be Installed on: Rotary SFR 1, 2, EVO SBO Series 1 SBO Series 2 SBO Universal ARS recovers 40% to 50% of discharged air, supplying : - Preblow air for ~10% net HP air savings - 100% service air - Any excess of the recovered air is returned back to the utility line Also available on KOSME linear and other machines Linear ECS, FX, SF, SFL

33 ARS+HP Systems Can be Installed on: Blomax IIIM Blomax IIIC KSC 6H ARS+HP supplies : ARS+HP supplies : - 25% to 30% net HP air savings - 25% to 30% net HP air savings - Preblow, Intermediate Blowing air - Service, Preblow, Intermediate Blowing air

34 ARS+Full Systems Can be Installed on: SBO Serie 2 SBO Universal Krones Krones ARS+Full supplies : ARS+Full supplies : - 100% of service air (LP air) - 35% to 45% net HP air savings - 25%-30% net HP air savings with Preblow air - Service air, Preblow air, Intermediate Blowing air and Intermediate Blowing air Also available on Sipa SFR blow molders

35 ARS+Full : Blowing Curve Study on Krones Zoom x5 Normal size P2 } I.B. P1 } } Zoom x5

36 ARS+Full : 2 Successive Recoveries Before ARS+Full With ARS+Full 3. Final Exhaust 1. First Recovery With ARS+Full 2. Second Recovery P2 IB P1 X REC 1 REC 2 EXH

37 ARS+Full : 2 Recovery Volumes High-Pressure Recovery tank Low-Pressure Recovery tank

38 ARS+Full : Intermediate Blowing Intermediate blowing air 40 bar air With ARS+Full P2 IB P1 X REC 1 REC 2 EXH Valve blocking the 40-bar line

39 Standard ARS Installed in 2008 Controlled in 2014 Energy saved 100 High-Pressure air 105 x 0.25 kw = kw/h 6.5 Low Pressure air 681 x kw = kw/h 42.5 Total = kw/h If blow molder runs 6000h / year: 668,250 kwh saved per year Or $66,825 USD per year (with 1 kwh = 0.10 USD)

40 ARS+Full Energy saved High-Pressure air 576 x 0.25 kw = 144 kw/h If blower works 6000h / year: 864,000 kwh saved per year Or $86,400 USD per year (with 1 kwh = 0.10 USD)

41 FlowMeter FM-DN25 and FM-DN40 + Monitor the High-Pressure and Low Pressure air flows + Check in real time if your ARS systems are correctly set Standard ARS : monitor the Preblow savings and air returned to LP line ARS+HP : monitor 25% to 30% HP air savings ARS+Full : monitor 40% to 45% HP air savings HP line : 900 Nm3h Serv: 150 HP line : Nm3h Serv: 150 P1: 100 P1: 100 IB : 200 LP line : 250 N

42 Flowmeter DN25 set : Key Components FlowMeter DN25 or DN40 Screen Power Transformer Pressure Sensor

43 FlowMeter FM-DN40 for High-Pressure air RIA 290 Cabinet in plastic material, transparent. Dimension: 290 x 390 x 140 mm Protection Index IP66 Wire length 15 m RNS22 socket FlowMeter DN40 Pressure sensor PMP131 Wire length 15 m 22 Pipe Ø 48.3 x 2 Fitting for manometer Ø 3 Ø 1000 Oring EPDM type Xorella Flange to weld DN40 PN40

44 FlowMeter FM-DN25 for compressed air 290 Cabinet in plastic material, transparent. Dimension: 290 x 390 x 140 mm RIA16 Protection Index IP66 Wire length 15 m RNS221 bornes FlowMeter DN25 Pressure sensor Power wire, 230 Length 15 m Pipe Ø 33.7 x 2 mm Raccord pour manomètre 1/2" Ø Ø ±2 Oring EPDM type Xorella Flanges DN25 PN40 DIN 2635 Form C

45 What to Do? 1. Air steel pipe To blower 2. Cut the steel pipe 3. Procure and weld the flanges DN25 / PN40, leaving a precise distance between the 2 flanges of /-2mm 1006 ±2 4. Install the DN25 or DN40 flowmeter Example of 2 flanges fitted together FlowMeter Flange to weld PN40 DIN 2635 Form C ±2

46 For More Information Please Contact Us or Visit Our Website Connell Industries, Inc. 13 Fairfield Avenue West Caldwell, NJ Phone (877) x1 - Fax (305) Website: