Pfeiffer Vacuum, provider of vacuum technology, is presenting the new and innovative Roots pumps of the Hi Lobe series which can be used for numerous industrial vacuum applications such as electron beam welding, vacuum furnaces or freeze drying. The pumps of the Hi Lobe series are of particular interest for fast evacuations (load-lock chambers or leak detection systems). Furthermore, they are suitable for use in coating applications.
Compact and powerful Roots pumps
The compact Roots pumps offer a wide nominal pumping speed range of 520 – 2.100 m³/h. This is made possible through the new drive concept in conjunction with frequency converters. Thanks to their individual speed control, the pumps can be precisely tailored to customer-specific requirements. Thanks to this powerful drive concept, the Hi Lobe achieves approximately 20 percent shorter pump-down times than conventional Roots pumps. Rapid evacuation reduces costs and increases the efficiency of the production system.
Process-reliable and cost-efficient vacuum
The maintenance and energy costs of the Hi Lobe are >50 percent lower compared to conventional Roots pumps. The reason for this is a drive with energy efficiency class IE4 and the special rotor geometries of the pumps. The sealing concept also contributes to this. The pumps are hermetically sealed to the atmosphere and have a maximum integral leakage rate of 1 · 10-6 Pa m³/s. Dynamic seals are eliminated and, as a result, maintenance is only required every four years. Due to the innovative sealing concept in the suction chamber, the use of sealing gas is superfluous in most applications, which also has a positive effect on the operating costs. Since the operation of the Hi Lobe Roots pumps is possible even at ambient temperatures of up to +40°C with flexible air cooling, cost-intensive water cooling is unnecessary.
Control and communication are the essential factors for increasing system availability. The intelligent interface technology of the Hi Lobe allows very good adaptation and monitoring of the processes. This facilitates anticipatory and efficient work. By integrating such condition monitoring, information about the condition of the vacuum system is always available. In addition, condition monitoring increases system availability allowing users to plan maintenance and repair measures in a useful and anticipatory way and prevent cost-intensive production downtimes. These advantages lead to a long service life and maximum operational safety. Depending on their suitability for the existing system, the Hi Lobe vacuum pumps can either be aligned vertically or horizontally. This allows maximum pumping speed and a more customized and efficient use of space at the customer’s production site.
Fresh fragrance on feminine hygiene products
Smallest quantities sprayed continuously but flexibly
A new project of Visctotec Asia at the end of 2019 was the application of a fragrance on top of feminine hygiene products. Before implementation, dosing tests were carried out for the customer. A preeflow Eco-Spray dispenser was employed for this. The aim of the tests was to check the dosing accuracy and repeatability of the Eco-Spray for the small quantities. A particular challenge was to achieve precise results for various different products. Various quantities were to be tested for several products in the customer portfolio: 1.5, 1.8 and 2.5 mg per part – to allow flexible automated production. The in-depth dosing tests consistently demonstrated the accuracy and consistency of the small volumes required for the process. With the preeflow spray dispenser, Visctotec Asia is able to spray with less than 1 % deviation from the nominal value.
An example from the customer’s portfolio: The parts to be dispensed run in a roll form under the Eco-Spray. The speed of the roll is over 1,500 parts per minute. At the final stage, the customer wants to apply a small amount of <1.6 mg of fragrance to each product. The material is gravity fed from a container suspended about 2.5 meters above the floor. The method used up to now could not precisely dose such a small volume in each part and had poor repeatability. In conclusion, the customer decided to purchase the Eco-Spray from preeflow to integrate the spray dispenser into the existing line.
The key to success: The dosing tests proved that the customer required volume accuracy and consistency for product model could be achieved. In addition, the change from a pressure tank or gear pump tank, which was previously used, to product being fed by a gravity tank was convincing. An analog signal with PLC now also makes it possible to link the speed of the production line with the flow rate of the dispenser. This means that the amount of liquid to be sprayed can be dynamically adjusted according to the speed of the roll.
For consumers and the government, a maximum of safety and quality in the production of food is essential. In order to ensure the highest standards of hygiene, food producers and processors are obliged to clean their machinery regularly via washdowns. To guarantee that vacuum pumps are effectively protected from the used aggressive cleaning media, Leybold has developed a series of Hygienic Enclosures. The vacuum specialist offers users these stainless steel housings in seven different sizes, tailor made for each vacuum pump.
Risk of contamination eliminated
In the food industry, vacuum pumps are often placed directly next to the processing and packaging lines and thus not implemented in the equipment. On the one hand, this leads to a higher vacuum performance because, losses in pumping speed over longer pipelines are avoided. A direct positive consequence of this, are shorter process cycles and a better product quality. On the other hand, unprotected pumps are directly exposed to aggressive cleaning media during the rinsing processes. Over time, this leads to corroded vacuum pumps, shorter life cycles, higher costs and ultimately even to food contamination.
Effectively protected in stainless steel enclosures
In order to counteract these risks, Leybold has developed a new protection concept with the Hygienic Enclosures. Encased by these stainless steel enclosures, the vacuum pumps can be positioned near machines and systems without any problems. „On the basis of the protected Leybold vacuum pumps we can create better and more robust solutions for the demanding food applications“, emphasizes the responsible product manager Niels Gorrebeeck. „Of course, this applies all the more to applications such as stuffers, tumblers and of course packaging machines, where the machines and systems are cleaned and disinfected particularly frequently and intensively,“ the product manager explains.
Tailor made & easy to install
Gorrebeeck explains that these stainless steel enclosures are tailor made for each vacuum pump. As a result each enclosed pump can run constantly on every working pressure. The only limitation is the maximal ambient temperature for the enclosure. Nevertheless, the normal working temperature in F&P environments are around 10 °C, we qualified most enclosures up to 25 °C. Further all the enclosures are offered as a Do It Yourself kit and can be as well installed as commissioned by the user themselves without great effort. „These properties make of the Hygienic Enclosures a cost-effective, sustainable solution. In the end, Hygienic Enclosures makes investments in expensive piping obsolete and at the same moment they offer a better pumping speed performance“, argues Niels Gorrebeeck.
Incidentally, this also applies not least with regard to future packaging concepts. Gorrebeeck believes that the industry is also well equipped for this with the new enclosures: „Regardless of which solutions will prevail, food applications can be operated from today more hygienically, ergonomically as well as flexibly. Leybold can successfully accompany these processes into the future with our holistic solution approaches.“
Compressed air for jet milling applications
When it comes to generating compressed air, operators of jet milling equipment for the production of very fine powders can achieve significant energy cost savings through the skilful use of heat recovery. It is for this very reason that Kaeser has recently expanded the options palette for its range of oil-free compression rotary screw compressors from the CSG, DSG and FSG series.
Aside from steam, jet mills are most commonly operated using nitrogen or compressed air. In the case of the latter, heat energy can be recovered from the compressed air inside the jet nozzles and subsequently reused for the milling process. Exhaust heat arises as a by-product of compressed air generation, which essentially makes it a cost-free source of energy.
With the specific needs of jet milling applications in mind, Kaeser has now extended the options palette available for its two-stage, oil-free compression rotary screw compressors to include such features as compressed air discharge temperature control. Operating via flexible, controlled adjustments to the intercooler, this option can lead to a clear reduction in specific energy consumption per tonne of the final product, depending on the type of material being processed.
Kaeser offers the option of compressed air discharge temperature control on compressors from the CSG, DSG and FSG model range, featuring a power output from 37 – 355 kW and pressure from 4 – 11 bar. Both air-cooled and water-cooled versions are available.
Furthermore, Kaeser also offers compressors specially adapted for operation with nitrogen, in which the compressor can be individually configured to the specific nitrogen circuit.