Maximising production efficiencies in food and beverage processing plants

By selecting, maintaining and monitoring critical components and inside rotating plant and machines such as gearboxes, electric motors, pumps and fans, food and beverage processing companies can improve their plant efficiencies, eliminate production downtime and increase the operating life and reliability of plant equipment, says Dr Steve Lacey, Engineering Manager at Schaeffler UK. In food and beverage processing, production is typically based on highly automated, fast moving processes and systems, where every second of production counts. In these operating environments, the cost of production downtime can equate to hundreds of thousands of pounds per day. Total maintenance costs for a typical food or beverage manufacturer are around 15-20% of total costs. Although maintenance departments are set up to deal with problems like these, often, because of time and resource constraints, maintenance becomes reactive, with problems around the plant dealt with as they occur rather than in a proactive, planned manner. Condition monitoring (CM) prevents the unnecessary replacement of components and the subsequent introduction of possible new and unrelated problems. Maintenance teams can benefit from the use of CM technology to predict when failures are likely to occur and plan replacement during production shutdowns. In too many companies, components are replaced on a time basis rather than on a condition basis because this is considered to be the safest option. However, there are numerous technology safeguards available which, when compared to the cost of lost production, are relatively inexpensive. These safeguards use the latest CM technologies and predictive maintenance systems, including vibration monitoring, wear monitoring and automatic lubrication to protect plant and machines. Intelligent monitoring FAG SmartCheck is an extremely...

WEG’s new synchronous motors are tough and dynamic

WEG, a leading global manufacturer of drive technology, has introduced a new series of robust and efficient synchronous motors, the SM40 series, for the power range from 5 to 35 MW. The motors provide exceptional reliability in demanding applications with extended maintenance intervals, enabling users to reduce servicing costs and increase process uptime.With shaft and rotor made from a single piece of forged steel and high starting torque, the new SM40 is ideal for high-inertia applications including centrifugal compressors in air separation plants or the oil and gas industry, large fans in the steel industry or power plants, and high-power pumps and pulp mills. The SM40 motor has a robust rotor construction with high mechanical strength and stability, and has been designed to eliminate the risk of detachment of individual pole shoes or pole mounting screws. The stator consists of high-quality, low-loss silicon steel laminations and top-grade bobbin windings insulated using a special vacuum/pressure impregnation (VPI) process while an optimised thermal design ensures uniform temperature distribution along the stator, prolonging the service life of the winding insulation.   The motors have a high starting torque and low starting current enabling users to achieve significant energy savings, which is particularly important in energy-intensive applications. The low starting current also minimises the impact of the motor on the power supply network and means starting aids such as starting chokes, autotransformers or variable speed drives become unnecessary, thus bringing costs down further. M40 motors can also help plants reduce power costs and improve the efficiency of the power network to which they are connected because the deliver high efficiency over a wide...

Bonfiglioli helps Technowrapp achieve greatness with Runner Arm

Technowrapp is a firm specializing in the design and production of automatic stretch wrap film pallet wrappers and pallet movement systems. Technowrapp has made a name for itself on the international scene by developing an innovative and creative solution. The new Runner Arm is exclusively equipped with Bonfiglioli motors. Through their close collaboration with Bonfiglioli, Technowrapp has created Runner Arm, a perfect combination of high performance and simplicity of operation and maintenance. Bonfiglioli´s comprehensive and reliable motor solutions have ensured that Technowrapp is the trusted partner of leading firms in the packaging and logistics sectors.

Technowrapp faces new technological challenges by supplying the market with cutting-edge solutions, such as the Runner Arm that improve quality, performance, and production. In the Runner Arm automatic rotary arm pallet wrapper, Technowrapp engineers have succeeded in combining the high performance of a ring wrapper with the simplicity of operation and maintenance typical of an arm type wrapper. Thanks to two specific patents that make it possible to speed up the wrapping process, Runner Arm can achieve the unrivalled result of wrapping 136 pallets/hour with 10 turns per pallet, stabilising a pallet with just 76 grams of stretch wrap film (value achieved with 15 µm film). These two patents have produced the fastest arm pallet wrapper in the world. The rotary arm with centripetal contrast ring contains and guides the arm as it moves and makes it possible to reach a speed of rotation of 45 revolutions per minute, combining this with low structural stress. The cutting and welding pliers operate on the moving load, contributing to the increase in speed and efficiency of the...
WEG motors drive efficiency in gas compressors for food processing and pharmaceuticals

WEG motors drive efficiency in gas compressors for food processing and pharmaceuticals

Gas compression is commonly used across a range of industries where refrigeration is required, including food processing and pharmaceuticals. In such contexts, this technology can play a key role in enhancing productivity and energy efficiency. Therefore, it comes as no surprise that ensuring the smooth running of gas compressors is top of the agenda for global manufacturers such as Mayekawa. The company turned to WEG technology to equip its latest packaging compressor units with reliable and highly efficient motors. Mayekawa is a leading provider of freezing and compressor technologies with 3,500 employees worldwide. The company offers a comprehensive range of gas compressors to meet the needs of a variety of applications requiring refrigeration. One of Mayekawa’s key goals is to supply its customers with highly efficient and energy-saving solutions for line engineering processes including material acceptance, thawing, heating, cooling, freezing, packaging, boxing, and product storage.   At its Belgian operations, Mayekawa specialises in the production of packaging compressor units for food processing, pharmaceutical and petrochemicals industries. This equipment plays an important role in thermal management processes, which are key to ensuring the quality and safety of products such as freeze-dried medicines or even the flavour, quality and taste of foods. Ensuring reliability and efficiency With compressors playing a major role in vital thermal management processes, efficiency and reliability are top the agenda for Mayekawa. For example, its SCV-Series of standard screw compressors is a thoroughly reliable and easy to maintain oil injected screw compressor package which delivers the highest performance during its lifetime of operation. The use of the SCV-Series in thousands of refrigeration installations worldwide is testimony to...
How efficient are your motors… really?

How efficient are your motors… really?

Around the world, legislation relating to electric motor efficiency is tightening in an attempt to reduce carbon emissions and damage to the environment. However, far less attention is paid to some of the practicalities. Here, Lucie Hodkova of Exico looks at how best to determine the efficiency of an installed motor. Motors are the greatest consumers of electricity in the world, with about 70% of all power generated being used by them. Since the Rio Earth Summit a generation ago, there has been a continuous effort to improve motor efficiency, with much effort being put into drafting efficiency standards and new testing methods for newly manufactured motors, which get gradually tighter over the years. However, this approach misses the point that there is a huge number of motors already in use around the world and their efficiency does not come under anything like so much scrutiny. So, a review of the motors in your place of work may well lead to the identification of significant improvements to your energy efficiency, carbon footprint and – perhaps most importantly – saving on your utilities bill. If you use machine tools, automated manufacturing systems, conveyors, or other ‘technical’ equipment, each of these is likely to use a number of motors. If you have air-conditioned offices, there will be motors driving pumps and fans. Medical equipment, displays, test stands, lifts, escalators, extractor fans in kitchens and laboratories are all motor-driven and, typically, their efficiency may never have been checked! All motors should have their efficiency checked and it may be best to start with those motors that are used a lot; if a...
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The one leading voice for the Fluid & Power Transmission Industry - Saturday, December 16th 2017
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