Industrial Utility Efficiency    

System Assessments

A centralized vacuum system with three Mink claw vacuum pumps is used in each of the two Danish plants to generate the vacuum required for clamping. Both central vacuum system units have been in operation since July 2015 when they replaced the previously used dry-running rotary vane and liquid ring vacuum pumps. The rotary vane vacuum pumps required a lot of maintenance due to wear on the vanes. In addition, this vacuum generator gave off waste-heat directly into the production room. Its loud operating noise was also extremely uncomfortable for the employees. The water level of the liquid ring vacuum pumps had to be monitored constantly, and refilled or exchanged if the water became polluted with wood dust.

Blow-off Air

At Scholle IPN, Valley Packline’s engineering experience and JetAir’s drying expertise came together to deliver an automated, energy efficient solution. Ultimately, the new system eliminated 120 man-hours each week dedicated entirely to erecting and washing. The new system can be manned by just one employee as it pulls bins directly off delivery trucks, re-erects, washes, and dries them, and feeds them into the facility for refilling. Throughput at Scholle was improved by the system, while energy costs were kept to a minimum.

Vacuum Controls

Meat packaging plants have long used vacuum pumps as a way to remove air and reduce the amount of oxygen in their products’ plastic packaging. Vacuum packaging extends the meat’s shelf life while protecting its flavor and exposure to outside elements, such as freezer burn and bacteria.

Vacuum Generation

Air-driven Venturi vacuum generators have long been a viable option for fast-response, localized, vacuum-powered systems. Through the last decade, they were considered convenient and flexible solutions with quick response time. However, they were not regarded as energy efficient, probably due to their use of compressed air. Extensive product development with this equipment — particularly the crucial system accessories — often makes the selection of the most energy-efficient items difficult for many localized operations.

Pressure/Vacuum

Machine builders aiming to improve the energy efficiency of their machines tend to focus on using energy media other than pneumatics (typically electro-mechanical or hydraulic) since pneumatics, as traditionally applied, is viewed by some as inefficient due to factors like leakage and over-pressurization (i.e.: supplying a higher pressure in an actuator to accomplish a task which is endemic in practice). But they shouldn't, with its low cost of ownership, pneumatics when properly used remains a viable and many times preferable energy source for a given application.

Conveying

In open end pipe line suspension flow, or dilute phase pneumatic conveying, proper particle velocity is critical to continuing productivity and product quality. Until recently, measurement of actual particle velocity within the pipe has not been practical outside the laboratory. The plant operating personnel depend on a much less accurate metric - estimating the conveying air velocity in the pipe and relating that to particle velocity.

Blower Controls

The capacity and pressure requirements of blowers in a Water Resource Recovery Facility (WRRF) are determined by the aeration system. When systems are manually controlled blowers often operate at constant flow and pressure day in, day out. When the aeration system is automatically controlled to maintain a set dissolved oxygen (DO), however, the blower’s flow and system pressure vary constantly. Understanding these variations will help designers and suppliers optimize blower performance.
The market health is moderate. 2017 was a better year than 2016, which saw a slight decline. With that said, 2017 will be a good year for us. One major trend impacting the industrial vacuum market is industry consolidation. Busch employees and clients benefit against this dynamic market environment, from the strength and stability of our family-owned business- a business with over 3,000 employees in over 60 subsidiaries worldwide. The average tenure, for a subsidiary General Manager, is twelve years. This allows us to stay focused on managing for the long term benefit of customers and employees.
Most-Open-Valve (MOV) can be a cost-effective way to optimize aeration energy. It can also be a confusing and troublesome addition to a process automation project. In my experience MOV is the least understood aspect of aeration control. This article will shed light on MOV, the process and energy impacts and why it’s worth the trouble.
Meat packaging plants have long used vacuum pumps as a way to remove air and reduce the amount of oxygen in their products’ plastic packaging. Vacuum packaging extends the meat’s shelf life while protecting its flavor and exposure to outside elements, such as freezer burn and bacteria.
At Scholle IPN, Valley Packline’s engineering experience and JetAir’s drying expertise came together to deliver an automated, energy efficient solution. Ultimately, the new system eliminated 120 man-hours each week dedicated entirely to erecting and washing. The new system can be manned by just one employee as it pulls bins directly off delivery trucks, re-erects, washes, and dries them, and feeds them into the facility for refilling. Throughput at Scholle was improved by the system, while energy costs were kept to a minimum.
This article reviews two common pneumatic conveying system types and the importance for each operating plant to know their design and operating parameters particularly conveying air flow velocity and particle velocity profile.
The integrated process that leads to perfectly finished components begins in the plant’s new material store. “One way we’re staying at the leading edge in our market is by researching the latest innovations and choosing the best machine for each process,” Legere explains. “Our new material store, operational in June 2017, is one example. It combines a physical data base of sheet goods with a robotic arm that handles materials and presents them to a cutting machine for processing. After a few minutes, a finished part emerges. All of this occurs with zero human interaction.”
The capacity and pressure requirements of blowers in a Water Resource Recovery Facility (WRRF) are determined by the aeration system. When systems are manually controlled blowers often operate at constant flow and pressure day in, day out. When the aeration system is automatically controlled to maintain a set dissolved oxygen (DO), however, the blower’s flow and system pressure vary constantly. Understanding these variations will help designers and suppliers optimize blower performance.
In open end pipe line suspension flow, or dilute phase pneumatic conveying, proper particle velocity is critical to continuing productivity and product quality. Until recently, measurement of actual particle velocity within the pipe has not been practical outside the laboratory. The plant operating personnel depend on a much less accurate metric - estimating the conveying air velocity in the pipe and relating that to particle velocity.
If you want to understand vacuum systems, you have to get out of the ruts, and slog through the mud and bounce over the rocks a bit.  If you’re a “compressed air person”, think outside the box for a few pages with me.  I am going to borrow some terms from the “pump people” to explain how vacuum systems are similar, yet different from compressed air systems. There are several ruts to get out of.  Remembering what changes and what doesn’t, what is controlled, and how to design systems for optimal energy consumption.
Industrial process operating loads and optimal set points are not usually accurately known at the time of design, so often there is significant mismatch between equipment and the process it serves. To overcome this uncertainty, designers typically oversize equipment. Over time, process changes and equipment efficiencies decline, so equipment might be operating less efficiently than at start-up. Or, equipment can be undersized, thereby hampering the entire system and causing other inefficiencies to compensate. For instance, too much steam usage in the dryer section of a paper machine can occur because of inadequate vacuum at the wet end.