Kaeser paved the way for the highest current efficiency gain, and thus reduced energy costs, when using variable-speed compressors. Following the ASD series, the CSD/CSDX series has now been equipped with this innovative drive technology.
Responsible use of resources is one of the key factors to which Kaeser Kompressoren owes its success. As a leading compressed air systems provider and a renowned industry trendsetter, the family-owned company proudly presented yet another technological milestone some time ago: the introduction of synchronous reluctance motors for its SFC variable-speed screw compressors. Following the ASD series, the CSD and CSDX series have now been equipped with this technology as well. This means significantly lower energy costs for customers, particularly in the crucial partial-load range, compared to the previous solution with asynchronous motors.
With Sigma Profile and innovative drive concepts, Kaeser’s rotary screw compressors already deliver outstanding performance and reliability, combined with energy efficiency and space-saving design, in keeping with Kaeser’s motto: More compressed air for less energy consumption. The roll-out of synchronous reluctance technology was the next step towards even greater efficiency. The major advantage of this complete solution, which was developed in partnership with Siemens, is an efficiency gain of approximately ten percent in the partial-load range. Thanks to the innovative motors and the top IES2 classification as per the new EN 50598 efficiency standard, this solution offers unprecedented efficiency. For example, in the case of an ASD SFC series screw compressor, this translates into average energy cost savings of around 450 euros per year, based on approximately 6,000 operating hours at a rate of 10 cents per kilowatt hour. Users therefore not only enjoy maximum flexibility for specific applications and varying environmental conditions, but also with regard to load response.
Variable-speed drive with high system efficiency
Compressed air stations are often constructed on a modular basis. Continuously running compressors with IE4 motors cover base load demand, whilst additional peak-load compressors respond flexibly to meet extra demand; the system is controlled by a Sigma Air Manager 4.0 to ensure maximum efficiency. With the Siemens synchronous reluctance drive systems, this will be performed with even greater efficiency in the all-important partial load range.
They were developed in response to the fact that the new EN 50598 eco-design standard applies not only to the efficiency values of individual drives, but represents a shift in regulatory emphasis to overall system efficiency and thus assesses the compliance of variable-speed drive solutions, based on their overall system efficiency. With its variable-speed version (SFC) of the ASD to CSDX series, Kaeser paves the way for customers around the world to embark on a path of minimal energy consumption and minimal operating costs.
Synchronous and asynchronous motor technology
This new and innovative series of general-purpose motors combines the strong points of both asynchronous and synchronous motors in a single drive system. No aluminium, copper or expensive rare earth magnets are used in the rotors. Instead they are made of electrical steel with a specialised profile and arranged in series, making the drive highly durable and maintenance friendly, the characteristic advantages of asynchronous motors.
On the other hand, the control properties of the new motors are comparable to those of synchronous motors. The special rotor design enables reluctance motors to deliver high speeds without additional rotor warming due to current flow. The key to this lies in optimised matching of the drive system elements, i.e. the motor and frequency converter. It is the perfectly harmonised interplay between these two components that facilitates maximum energy savings.
Unlocking the potential of connected packs
Solutions in connected packaging
With the support of SIG’s Connected Pack solutions, Brazilian dairy producer Languiru Cooperative has become one of the leading market players in the southernmost state of Rio Grande do Sul at a time of increasing competition and growing consumer demands. And to reaffirm its ongoing partnership with SIG, Languiru has commissioned another filling line from SIG.
Since implementing SIG’s pioneering digital solutions in 2017, Languiru has experienced a number of achievements. These include greater consumer trust and quality perception in their products, improvements in productivity, and now a market share growth that puts Languiru in the region’s top three largest dairy producers, according to Kantar WorldPanel. Before its traceability project with SIG, Languiru was the fifth largest dairy producer in Rio Grande do Sul.
Languiru operates in an environment where consumers are demanding more transparency in business, more product information, and more digital communication with their brands of choice. Alongside this, food and beverage producers like Languiru need to reliably manage products in their supply chain, and ensure visibility at all times to guarantee efficiency, control and safety.
As a response to these market challenges, Languiru set out to create a new dairy concept: Qualidade do início ao fim, which translates as “Quality from beginning to end”. But in order to realise this promise, the producer needed a solution that not only makes product data easily accessible, but can also drive consumer engagement, trust and brand recognition.
Quality from beginning to end
To technically realise its vision of “Quality from beginning to end”, Languiru turned to SIG’s integrated Connected Pack platform – a drive to deliver unique digital coding technologies and track-and-trace solutions that ensure 100% connectivity and transparency together with greater digital interaction and engagement.
“Languiru has always stood out for the quality of its products, and the use of SIG’s innovative Connected Pack technology has enabled us to strengthen this perception and show consumers that Languiru milk is truly differentiated,” said Languiru Cooperative president, Dirceu Bayer.
As of May 2017, Brazilian consumers of five different Languiru milk products can access quality data, brand information and interactive quizzes directly on their smartphones by scanning a unique on-pack QR code. This QR code system was unprecedented in the food industry when it launched and proved SIG’s early commitment to the connected packaging trend.
“We have no doubt that with SIG we have a greater competitive advantage within the market compared to many other brands,” added Languiru’s Bayer. “SIG understood our demands and developed a tailor-made solution for Languiru that demonstrates quality and therefore adds value to our brand.”
Adding value throughout the supply chain
With a direct link to consumers, Languiru also has the opportunity for digital marketing activities, such as games, quizzes and promotions. In addition to this, in-line monitoring capabilities and vast data collection in the product journey has enabled Languiru to optimise production and logistics, and manage quality risks more proactively. The process of product traceability in the supply chain has now been reduced from five hours to five minutes, making recalls significantly easier. And in 2018, Languiru recorded a productivity improvement of more than 5% at its dairy plant, resulting in less waste and improved costs.
Languiru has also commissioned a third SIG filling machine. This new line ensures that 100% of Languiru’s long-life milk and chocolate milk product Chocolan has surgical traceability with unique QR codes securing end-to-end traceability for consumers and Languiru.
“For SIG, our greatest achievement is the success of our customers. Being part of the growth of Cooperativa Languiru and its consolidation as a market leader in long-life milk in Rio Grande do Sul is very gratifying and shows SIG’s commitment to be not only a supplier but a solution partner,” said Ricardo Rodriguez, CEO of SIG Combibloc Americas.
Traceability from the start for Origem
In August, Languiru launched a new premium milk called Origem. The milk is produced by only five farms, which all have the Good Practices of the Farm seal – a local initiative recognising dairy farms with best practices and processes – and are filled within 24 hours. The originating milk doesn’t have stabilizers, which maintains its purity, freshness and flavour characteristics.
With SIG’s Connected Pack technology, consumers can obtain information about the milk and the farm where it was produced, as well as information from producers, time of collection and satellite images of the farms.
Unique QR codes tied to the originating milk, as well as Languiru’s regular line, offer detailed information on factory quality tests and support traceability all the way to the shelf. This means Languiru can offer consumers an even more premium product with differentiation for those seeking a product of proven quality.
SIG’s Connected Pack is one of three value-adding segments that are part of its Value Proposition to help food and beverage producers meet increasing industry demands. Other solution-driven segments available include Product Innovation & Differentiation, and Smart Factory.
Conveying & Filling, Packaging, Labeling & Storage Food & Beverage Measurement, Instrumentation, Control & Automation Plant Construction, Engineering & Components Videos
Transmitter for Compressed Air
Conveying & Filling, Packaging, Labeling & Storage Food & Beverage Measurement, Instrumentation, Control & Automation Plant Construction, Engineering & Components Trade shows
The DNA of Better Packaging and Processing
At interpack 2020 in Düsseldorf Multivac will be presenting itself as a supplier of integrated solutions in packaging and processing. International visitors to Multivac’s five exhibition areas will be able to learn all about the company’s comprehensive range of solutions as well as the expertise of the Multivac Group in all applications. The company will also be focusing at the trade fair on concepts for producing sustainable packaging solutions, as well as on the digitalisation of processes and business models.
The main stand in Hall 5 (E 23) will focus primarily on the food processing industry. Here Multivac will be showing four fully automated packaging lines to demonstrate its far-reaching expertise in line automation, as well as exhibiting a wide range of different packaging technologies. Concepts for producing sustainable packaging solutions will also be featured, as well as aspects of digitalisation in processes and business models.
Utilising an outside area (between Hall 5 and 7), Multivac will be showing a fully integrated solution in live operation for the slicing and thermoforming packaging of a wide range of products. The fully automated line consists of Multivac’s highest-output slicer model and a thermoforming packaging machine.
Exhibiting on another outside are (in front of Hall 5), Multivac will be giving an insight into its wide range of semi-automatic and fully automatic packaging solutions for small and medium-sized processors. This includes chamber machines, traysealers and compact thermoforming packaging machines.
Trade fair visitors to Fritsch (Hall 3, C 04) can find answers to their questions on all aspects of dough forming and processing as well as details of the company’s comprehensive product range – from solutions for hand-crafted producers right up to industrial-scale manufacturers.
In addition to this, Multivac will be presenting in Hall 16 (Stand B 72) a range of solutions for packing medical and pharmaceutical products. The exhibits include solutions for the automatic packing of sensitive products and small batches, as well as marking and automation solutions, which are specifically designed for the high demands of this sector.