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report
A Magazine for the Production Industry
Summer 2016
Time Travel
How Kaeser compressed
air technology is restoring
a golden age
Komatsu Mining: Huge excavators
and high-tech hydraulics
Liebherr: Compressed air
for cranes
Heat recovery in industrial
compressed air systems
Fürst:
Containing costs
report
Contents
report
Summer 2016
3
Editorial
4
Time Travel
Flyte Camp takes you back
8
The Big Scoop
Komatsu Mining: Huge excavators
12
Up, Up and Away
Liebherr: Compressed air for cranes
16
Heat Recovery in Industrial Compressed Air Systems
A Kaeser White Paper
19
IFAT 2016: Rotary screw power for blower air
Energy-saving aeration
20
Containing Costs
Fürst and SAM 4.0 foster sustainability
22
BAUMA 2016 Wrap-up
4-7
8-11
12-15
Mr. Frank Mueller,
President of Kaeser
Compressors, Inc.
Networked thinking and action as prerequisites for Industry 4.0 success
Industry 4.0 refers to the networking of machines and
people via the Internet. It also involves the digitalization, mirroring and processing of operational and
machine data in high-performance databases, coupled
with customer-focused applications. It represents an
enormous opportunity to boost the productivity and
efficiency of companies, which in turn will result in
increased competitiveness.
However, before these prerequisites for Industry 4.0
can be implemented, the established structures,
mindsets and approaches need to change. The fences
marking out rigid organizational structures must be
pulled down and, through project-based networking
across all hierarchy levels, companies need to implement open communications extending to all departments and areas.
Knowledge and skills should be passed on, and indeed
shared, without compromise. Mutual support increases
each individual’s intellectual performance as well as
that of the entire company. Mixed teams that communicate effectively contribute a variety of perspectives,
thereby boosting creativity and efficiency. Ultimately,
this form of networking yields benefits for everyone.
The result: a working environment shaped by collaborative thinking and activity that coalesces into a creative
and flexible center of cooperation. The shared goal
becomes a motivating factor driving the teams forward
to complete their common tasks.
Cooperation must always transcend departmental
boundaries with the goal of steering projects towards
success while never losing sight of the company as a
whole. This is the only way that the complex challenges posed by Industry 4.0 can be mastered. Additional
attributes are also necessary, however, such as curiosity, a desire for life-long learning, a drive to do exceptional things and the ability to identify fully with shared
objectives.
Change processes represent important challenges for
management that must not only be understood, but
also be subsequently implemented. Only in this way
will Industry 4.0 culminate in the revolutionary success
story that we anticipate it to become.
Publisher: Kaeser Compressors, Inc.
Phone: 800-777-7873
Editor: Angela Kelly
Photographer: Marcel Hunger
Reproduction, even in part, is only allowed with the written permission of Kaeser Compressors, Inc.
The Kaeser Report is distributed free of charge. To contact us about your subscription, please
email us at [email protected].
2
Kaeser Report – Summer 2016
Kaeser Report – Summer 2016
3
ing. It was during this time that features
such as warm birch interiors and quality,
custom hardware complemented sleek
aluminium exteriors.
Some collectors who locate an original
travel trailer opt to have Flyte Camp return the camper to mint, factory conditions. Many others choose renovation
where Flyte Camp incorporates modern
amenities that give the feel of a vintage travel trailer with customized conveniences. Timeless models such as
Bowlus, Curtis Wright, Airstream, Westcraft, Boles Aero, and Spartan make up
the majority of the units they restore.
Time Travel – Flyte Camp takes you back
Anna and Justin Scribner, creators and owners of Flyte Camp, turned their
passion into a very successful business.
Oregon has built an outstanding reputation as an outdoor adventure destination state, and Bend,
the largest city in central Oregon, is no exception. Situated on the eastern edge of the Cascade
mountain range along the Deschutes River, Bend is rapidly growing and has become a haven for
craft beer aficionados and outdoor enthusiasts. Tourism along with recreation and outdoor equipment are two of its top five industries. Enter Anna and Justin Scribner, the creators and owners
of Flyte Camp – a business dedicated to preserving the vintage camping experience by restoring
and renovating vintage travel trailers.
Justin grew up fascinated by travel trailers, especially those made by aircraft
companies such as Airstream. Their
sleek lines and styling appealed to him
as he enjoyed his family’s long‐standing tradition of trailer camping. Anna’s
family grew up tent camping. So while
her love of the outdoors was built‐in,
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Kaeser Report – Summer 2016
her perception of trailer camping included visions of mildew and cheap
paneling. “Imagine my surprise when I
stepped foot into what was to become
our first trailer, a 1958 Shasta Airflyte.
I was blown away by the hardware and
the adorable appliances,” recalled Anna.
The opportunity to have a vintage “tiny
home” won out, and the Scribners quickly established their own family tradition.
Over the next decade, Anna and Justin
continued to enjoy restoring and camping in vintage travel trailers. “We owned
and restored 5 trailers before we came up
with idea of Flyte Camp. Other than my
“There are a lot of vintage trailers available. Every time you get outside city
limits, you see them wasting away in
the back of fields. The challenge is finding one that justifies a full restoration,
either in condition or desirability. Plus,
each manufacturer had their own construction methods so finding or replacing these custom pieces is a challenge,”
said Anna. “Our hope is that generations
to come will have the opportunity to enjoy the feeling of simpler times and the
craftsmanship so often missing today.”
Still other customers opt for the best
of both worlds with Flyte Camp’s latest approach: new, handcrafted retro
travel trailers. This specialty product
allows each end user to work with Anna
and Justin to fully customize the travel
parents, our friends and family thought
we were crazy for the most part,” Justin remembered. With his background in
homebuilding and general contracting,
Justin began spending more and more
time on trailers. Realizing the opportunity to combine their personal passion for
outdoor life and existing skill sets – Flyte
Camp was born in 2010!
The Scribners gained some significant
notoriety from their appearance on the
reality TV series Flippin’ RVs on the
Great American Country Channel. However, Anna and Justin are truly committed to preserving the vintage camping
experience every day off camera. Flyte
Camp specializes in trailers from the
1930’s through to 1964 – which they
consider the Golden Age of trailer camp-
Real wood and vintage fixtures harken back to the golden age of travel trailer camping
Kaeser Report – Summer 2016
5
equipped to provide paint and body
work, woodworking, appliance restoration, plumbing, electrical and running
systems. The shop is powered by a
Kaeser SK15 AirCenter which combines a compressor and dryer with an
appropriately sized storage tank and
condensate filter. It also includes a
complete SmartPipeTM installation.
Flyte Camps’ 8400 sq ft facility is
powered by an SK15 AirCenter.
trailer for their particular use. While
using all new parts, the design and
finishing gives a classic, timeless feel.
Flyte Camp has built two units so far in
2016, and hopes to have 10 completed
by the end of 2016. “We decided to go
into custom manufacturing because we
were practically doing so with the vintage units – sometimes using very little
of the original vehicle. With our new offering, we offer the vintage experience
for a controlled cost, taking some of the
‘surprise’ out of the build,” said Justin.
Flyte Camp handles all restoration and
renovation as well as custom trailer fabrication from their new 8,400 square
foot facility. Flyte Camp’s twelve‐person crew handles virtually every aspect
of building and design. They are fully
The Scribners are very clear: the
Kaeser air system is crucial to their
business. “The loop system is fantastic,” they agreed. “It delivers constant
dry air to every part of our building.
Even with all the guys working away in
the shop, we never have an air shortage. We also use it to run our paint
booth and it works better than any system we’ve had!” Their facilities manager agrees and appreciates the quiet
operation which provides a comfortable
work place. “We really can’t say enough
good things!”
Anna and Justin’s passion for preserving these rolling pieces of art shines
through with each build. “We never
know what we will encounter in a project. Much depends on the year, make,
model and current condition of the trailer. As individual as all of our clients are,
so too are their needs. Desires vary with
regards to finishes and amenities. Each
project presents its individual challenges and opportunities,” they concluded.
“However, we are committed to solving
these challenges, creating a superior
finished product that is both aesthetically beautiful and functional, and preserving the travel trailer experience for
generations to come.”
Flyte Camp specializes in trailers from the 1930’s through to 1964. Timeless models such as Bowlus, Curtis Wright, Airstream,
Westcraft, Boles Aero, and Spartan make up the majority of the units they restore.
6
Kaeser Report – Summer 2016
Kaeser Report – Summer 2016
7
Komatsu Mining: Huge excavators
The Big
Scoop
Capacity is everything...
South Düsseldorf’s Benrath district, located along the Rhine has a long history as an established site for heavy industry. Part of the construction machinery factory formerly operated
by the Demag company is still used to produce large-scale excavators for open-pit mines
throughout the world.
8
Kaeser Report – Summer 2016
...when it comes to removing enormous
quantities of overburden as quickly
and efficiently as possible and to then
forward the extracted raw materials for
further processing equally as effectively.
The sight that greets first-time visitors
to the assembly halls is somewhat unusual. Although the elements awaiting
installation are strikingly familiar, the incredible scale of the excavator buckets,
arms, chain wheels, hydraulic cylinders
and rotating assemblies, is far removed
from any machinery or equipment seen
on “most” construction sites. After all,
open-pit mining involves an entirely different magnitude of overburden.
The PC 300 Komatsu Mining Excavator – the “baby” of the family, weighing
in at just over 275 tons – is capable of
removing an impressive 20 cubic yards
of excavated material in a single pass.
Impressive, that is, until compared
with its big brother, the PC 800 (weighing some 825 tons), which boasts an
55 cubic-yard capacity and is capable of
moving almost three times as much.
Back in Benrath, modular assembly of
the giant buckets is underway. Undercarriages and superstructure assemblies are produced separately, as are
the arms equipped with deep buckets
or folding buckets. Similar to automotive
production, the various assemblies are
integrated into a whole at the end of the
Kaeser Report – Summer 2016
9
production process. In this case, however, the finished product isn’t ready for
delivery just yet. The first “trip” taken by
every new Komatsu mining excavator is
just across the courtyard from the testing hall where it has to prove its ability
to perform exactly as required in every
aspect. After all, the excavator will have
to perform its heavy-duty work in the
harshest environments day in, day out,
for many years. To ensure this happens
with maximum dependability, the excavator’s inner workings are equally durable and sophisticated. The highly complex hydraulic control of all functions is
every bit as intricate as any microprocessor controller – aside from the size
of the control units and line diameters.
Once the excavator has proven and
flexed its functional ‘muscle’, it is disassembled into transportable elements
– in their fully assembled state, these
titans can move only under the power of
their own engines.
Essential compressed air
Compressed air plays a pivotal role in
the production processes as work air
for plant and lifting tools – making it the
most crucial energy source throughout all assembly phases. Updated in
SFC variable frequency drive rotary
screw compressor with an integrated refrigerated dryer. Additionally, a TF
173 refrigerated dryer replaced another
older, defective dryer. For coordination
of the new and existing equipment in
Station 1, a Sigma Air Manager (SAM)
4/4 equipped with a Sigma Air Control
plus software package coordinates the
new and existing equipment and also
provides visual remote monitoring of the
entire air system. One year later, growing compressed air demand resulting
from increased production prompted
installation of yet another Kaeser rotary
screw compressor with refrigerated dryer (ASD 57 T), which is also managed
by the SAM master controller.
Then in 2012 and 2013, the remaining
rotary compressors were replaced with
modern rotary screw compressors in a
two-stage process: a CSDX 140 series
rotary screw compressor was installed
first, and then a CSDX 140 T (with integrated refrigerated dryer) was installed
following renovation of the station structure. The SAM’s capabilities are now
being put to full use and the compressor system has been optimized to accommodate current and future demand.
Komatsu Mining: Huge excavators and
XXL high-tech hydraulics
stages since 2010 with Kaeser rotary
screw compressors, the compressed
air system also makes a valuable contribution to the company’s overall energy efficiency with its
heat recovery capabilities.
As part of the upgrade process, several outdated reciprocating compressors were
replaced with a CSDX 137 T
10
Kaeser Report – Summer 2016
Compressed air for cranes
Up, Up and Away
The Liebherr Group’s plant
in Ehingen produces vehicle
and crawler cranes with load
capacities ranging from 38 to
3300 tons – all with support
from a full complement of
Kaeser rotary screw compressors.
Founded in 1949, Liebherr’s corporate
headquarters is located in Bulle, Switzerland. Although the group’s activities
span the globe, it is still a family-run
company managed by descendants
of the founder. The broad-based production program includes first-class
engineering and technology products
in a wide range of fields. The high degree of commitment and technical
qualifications among the firm’s more
than 40,000 employees ensure the
consistently high quality of Liebherr
products and services. Since its inception the group has maintained a decentralized organizational structure, composed of well-defined, independently
operating company units. This yields
dual benefits: better proximity to customers, enhanced global competiveness, and the ability to respond to local
markets.
Liebherr products have become well-established favorites both for construction and excavation projects around
the world. The construction machinery
range includes complete model lines of
revolving tower cranes, vehicle-mounted cranes, crawler cranes, hydraulic excavators of all sizes, dump trucks, duty
cycle crawler cranes, wheel loaders,
crawler tractors and crawler loaders,
pipelayers, concrete mixing plants and
truck mixers. Yet Liebherr’s comprehensive product lines extend to many
other areas as well, such as ship, container and loading cranes used for cargo handling. In the field of mechanical
and plant engineering, Liebherr offers
an impressive array of machine tools,
interlinked machine systems, aviation
equipment and transport technology.
For residential and commercial needs,
the company also offers a complete
selection of refrigeration and freezer
equipment. Furthermore, Liebherr plans
Kaeser Report – Summer 2016
13
Compressed air is used for tool cooling in this advanced Škoda processing center.
It is also essential for blasting (above right) and painting (below) large components.
environment for Liebherr employees
safer and less physically demanding –
and compressed air plays a key role in
making this possible. Compressed air is
used to drive impact wrenches, torque
and impulse drivers, fills tires, serves
as control air for the gantry robots used
for axle installation and powers turning equipment that positions the workpieces and components as needed.
By deploying several new Škoda processing centers for large steel components, Liebherr is trailblazing new territory for compressed air applications.
The cutting tools dispense with the
specialized cooling emulsion conventionally used to protect against overheating; instead they’re cooled using
compressed air. Not only is this solution more cost-effective in terms of both
materials and application costs, it also
eliminates the not insignificant effort of
recycling, treating and disposing of the
cooling fluid.
and implements industrial projects, from
manufacturing cells to complete production plants. The company is even active
in the tourist sector, with hotels in Ireland, Austria and Germany.
The Liebherr plant in Ehingen has been
operating since 1969 and is located
just a few miles upstream of Ulm on the
Danube. Here some 3300 employees
produce mobile cranes with load capacities ranging from 38 to 3300 tons on
wheeled and crawler chassis: all supe-
14
Kaeser Report – Summer 2016
rior quality products are developed inhouse and feature the very latest crane
technology. Key components such as
diesel engines, hydraulic pumps and
motors, winches, slewing gears and rotating assemblies, as well as the basic
modules of the digital control systems,
are all proprietary products developed
by Liebherr.
Air for every need
Modern assembly infrastructure on all
production lines makes the working
For some time, the recently installed
Kaeser compressed air station has
delivered compressed air to the new
large-component surface coating systems, such as the blasting system, as
well as to the paint shop and countless
pumps and stirrers in numerous paint
and lacquer applications.
Since the first installation of Kaeser
compressors back in 2001, the plant
has almost doubled in size. Naturally,
the compressed air station has kept
pace with this growth. It now includes
three independent stations which
house a total of 15 Kaeser rotary screw
compressors of various sizes and
ranges, as well as Kaeser refrigerated dryers and other treatment components. Everything is managed, controlled and monitored by the innovative
SAM master controller, which meets all
of the technical requirements necessary
to accommodate future expansion and
to ensure energy-optimized operation of
all compressed air system components.
Where beneficial and possible to implement at a reasonable cost, heat recovery systems have also been integrated.
These systems utilize the recyclable
heat from cooling fluid or exhaust air
to help minimize the energy costs associated with space heating and water
heating required for employee showers.
Heat Recovery from Industrial Compressed Air Systems
BBy:
y: Michael
Michhaell Camber
Cambber andd Werner
Werneer Rauer,
Rauer Kaeser
Kaeser Compressors,
Compressors Inc.
Inc
The rise in energy prices is an unwelcome reality in today’s manufacturing and business environment. And while the rate of price increases for natural gas, heating oil and electricity may
vary from year to year, the upward trajectory is clear. Energy cost reduction strategies are vital
to staying competitive.
Compressed Air as an Energy
Source
Up to 100 %
total electrical power
consumption
Approx. 5 %
heat dissipation
from the drive
motor
Approx. 2 %
heat dissipated
by the compressor
into the ambient air
Approx. 76 %
heat energy
recoverable
through
fluid cooling
Approx. 2 %
Approx. 15 %
heat energy recoverable through
compressed air
cooling
Approx. 96 %
recoverable heat energy
heat remaining in the
compressed air
One important way operational efficiencies can be increased is by harnessing
heat from compressed air systems,
which make up a significant share of
industrial energy consumption. In fact,
nearly all (96%) of the electrical energy
used by an industrial air compressor is
converted into heat. Too often, that heat
is simply ejected into the ambient environment through the compressor cooling system. But here’s the good news:
Nearly all this thermal energy can be recovered and put to useful work and significantly lower a facility’s energy costs.
Some uses of recovered energy from
compressed air systems:
•
•
•
•
•
Supplemental space heating
Makeup air heating
Boiler makeup water preheating
Industrial process heating
Water heating for showers,
bathrooms, etc.
• Heating proceed fluids
• Heating food and beverage products
• Heat-driven chillers
Heat Recovery with Rotary
Screw Compressors
The most common compressor equipment found in manufacturing plants is
the air-cooled, lubricated rotary screw
design. The amount of heat recovered
using these systems will vary if the
compressor has a variable load. But
in general, very good results will be
achieved when the primary air compressor package is an oil-injected rotary
screw type design.
Oil-less rotary screw compressors
are also well-suited for heat recovery
activities. As with other compressors
systems, the input electrical energy is
converted into heat. Because they operate at much higher internal temperatures than fluid injected compressors,
they produce greater discharge temperatures (as high as 300 ˚F or even
greater).
Warm Air Applications
Capturing warm air is easily accomplished by ducting the air from the compressor package to an area that requires
heating. The air is heated by passing it
across the compressor’s aftercooler
and lubricant cooler. This extracts heat
from the compressed air as well as the
lubricant, improving both air quality and
extending lubricant life.
By integrating standard HVAC ductwork
and controls, warm exhaust air from
compressors can be channeled to remove or provide heat in the compressor
room and adjacent areas. Typical uses
include:
• Heating for warehouses or
storerooms
• Heating for production areas and
workshops
• Drying air for paint spraying
• Air curtains
• Pre-heating combustion air to
improve efficiency
Nearly all current models have cabinets that channel airflow through the
compressor, and many current designs
exhaust warm out the top of the unit.
This simplifies adapting compressors
for space heating to the installation of
ducting and (sometimes) a supplemental fan to handle duct loading and eliminate back pressure on the compressor
cooling fan.
Space heating can be regulated easily
using thermostatically controlled, motorized louver flaps for venting, thereby
maintaining consistent room temperature by making continuous adjustments
to the heating air flow. This also means
that when heating is not required, the
hot air can be ducted outside the building to reduce cooling costs.
Water/Fluid Heating
Rejected heat can also be used to heat
water or other process fluids. It can
be done with either air-cooled or water-cooled compressors, although the
best efficiencies are usually obtained
from water-cooled compressor installations where discharge cooling water
is connected directly to a continuous
process heating application such as a
heating boiler’s return circuit for yearround energy savings. Some compressor manufacturers offer built-in heat re-
covery heat exchangers as options. In
some cases, they are fully integrated inside the compressor cabinet and require
very little onsite engineering.
Energy Savings … and More
Most process applications in production
facilities can benefit from heat recovery
from compressed air systems throughout the year. In most space heating applications heat is required during three
seasons. During the warmer months,
removing the heat of compression will
make the compressor room much more
comfortable. Maintaining proper ambient conditions will also improve compressor efficiency and facilitate air treatment. Moreover, controlling operating
temperatures will extend equipment life.
Beyond energy savings, heat recovery
activities benefit the environment. After all, substantial energy savings also
mean a reduction in the carbon footprint
of a plant. As energy policies and regulations continue to evolve in the United
States and other countries, these considerations are only expected to become more important.
Heat exchanger
(Internal)
Air-cooled
rotary screw compressor
Hot wate
r
Cold w
ater
Hot water tank
Hot water heating
Shower
18
Kaeser Report – Summer 2016
IFAT 2016: Rotary screw power for blower air
m the 30th of
A1.143/242 fro
of June 2016
d
3r
e
th
to
May
n
Messe Münche
Energy-saving aeration
Kaeser further expands its range of screw blowers designed for lower flow rates with the new
DBS series. These screw blowers are ideally suited to municipal and industrial water treatment
applications.
Kaeser’s new DBS screw blowers deliver unparalleled efficiency by combining
the proven Sigma rotor technology used
in Kaeser’s rotary screw compressors
with the innovative non-slip direct drive
with speed transmission integrated into
the airend. Together, these features
make DBS blowers true energy-saving masters and the most efficiency
gains are realized under continuous
operation conditions. The integrated
Sigma Control 2 blower controller ensures precision control at all times by
connecting each individual component
within the network and with comprehensive monitoring. Thanks to a variety of
interface options, the blowers can be
seamlessly integrated into systems with
master controllers and/or centralized
control networks at any time.
Depending on the model and with
available motor drive powers from 20
to 50 hp, DBS blowers deliver flow
rates between 282 to 777 scfm at a
maximum pressure of 32 Hg. These
units are also exceptionally quiet with
sound emissions of only 72 dB(A).
DBS blowers can be delivered with an
integrated frequency converter for variable speed control (Sigma Frequency
Control, SFC) or a wye-delta starter
(STC). Plus, DBS series units are designed with “plug and play” features in
mind. They are extremely space-efficient and both the STC and SFC versions can be installed side-by-side.
Total installation costs are minimized
as the blowers and frequency converter
form a perfectly matched single unit –
direct from the factory – and are ready
for immediate connection and operation
without any additional work.
chine controller offers various operating
modes, such as speed control, pressure
control, or control based on an external
process value. And of course, the new
DBS blowers are Industry 4.0-compatible. All relevant operating data and
component-related maintenance, warning and fault messages are exchanged
in real time with corresponding networks
via bus connection (various bus adapter
modules are available as an option).
See the new DBS screw blower for
yourself at the Kaeser booth at IFAT
2016 (Munich May 30th-June 3rd).
A whole host of innovative Kaeser
solutions for greater efficiency and
availability in water management
applications awaits (A1.143/242).
All auxiliary systems, including fans, are
connected and monitored. All sensors
and limit devices are connected to the
Sigma Control 2, which stores operating parameter programming. The maKaeser Report – Summer 2016
19
Containing Costs
Conserving resources and fostering sustainability
The main production site of Fürst GmbH,
a third-generation family company, is located in Hallerndorf, Franconia. Fürst
is a major producer of plastic food containers and recently introduced an ISO
50001-compliant energy management
system which has since been certified.
One of the many positive aspects of this
process was that it presented the perfect opportunity to put all internal processes to the test – including the compressed air system – to review, evaluate
and improve them. The results were
encouraging: significant energy saving
potential was identified in the company’s overall energy costs, including the
compressed air system. The subsequent modifications, adjustments and
new equipment introduced in this area
are helping to make energy usage more
efficient and are also ensuring that the
company is ready and equipped to meet
all future challenges and opportunities –
including those associated with Industry
4.0 implementation.
Quality is the top priority
Fürst produces packaging for the food
industry using injection-moulding processes. Both the final product and the
entire production process itself are subject to the most stringent quality standards. The international packaging market is a highly competitive sector, so as
a company with production based in
Germany, it is that much more important
to use optimized production processes
to maintain and enhance competitiveness in the global market. Nadja Fürst,
daughter of the current company owner,
is responsible for quality management.
“Quality is our top priority and sustainability is also incredibly important,” she
says. “Not only with regards to our products, but also to the manufacturing process itself. Just as we ensure that our
containers are leak proof, dishwasher
safe and reusable, so that they provide
as a long a service life as possible, we
also place great emphasis on resource
conservation in our manufacturing process.“
Reliability and efficiency
From material transport, through to
blowing out and removing the finished
products, compressed air features
prominently in all production activities
and is a key energy source in every
stage of the process. Plus, it is an important cost factor, since it provides
the main form of drive energy. So
it’s only logical that Fürst wanted the
company’s compressed air supply not
only to meet the highest quality standards applicable to the food industry, but
to also be as energy-efficient and reliable as possible. Following an in-depth
compressed air audit to document the
company’s compressed air consumption in detail, Fürst’s compressed air
system was planned and designed to
take advantage of the very
latest compressed air engineering technology.
Installing a compressor
precisely matched to compressed air demand has
significantly
increased
compressed air production efficiency. The addition of air main charging
systems and new dryers has also resulted in a
compressed air system permanently
supplying the required compressed
air quality at all times. Prior to modernization, Fürst’s air system did not
have a master controller. Installing a
Sigma Air Manager 4.0 (SAM 4.0) was
a milestone opening up additional potential for enhancing energy efficiency
and easy maintenance, as well as networking and control capabilities within
the scope of Industry 4.0. Compressors and compressed air treatment
components with integrated controllers
are able to transmit their data to other controllers and form the basis for
this industry-changing approach. The
SAM 4.0 master controller simultaneously monitors all compressed air production and treatment components and
precisely matches production to actual
demand. In other words, this advanced
controller is able to automatically adjust air delivery to accommodate fluc-
Quality and efficiency are top priorities at Fürst. Nadja Fürst and Robert Peters carefully inspect a
Qu
newly
finished product.
ne
tuating air demand, while also ensuring comprehensive energy efficiency
optimization by minimizing control and
switching losses. It also prepares the
compressed air system for additional future services, such as predictive
maintenance for example, which can
be easily managed and coordinated by
continuously transferring machine data
to the manufacturer’s Machine Operation Center for permanent compressed
air system monitoring. This central data
center independently analyses the current situation and, as necessary, sends
a message via the service team directly
to the on-site service technician. Operators benefit considerably from increased
operational reliability and availability.
Network and integrated into Industry 4.0
associated concepts. Additional savings
are available in the area of heat recovery, the benefits of which Fürst is enjoying for the first time. The exhaust heat
from the compressors generated as a
result of the compression process can
be used to heat the entire office complex, resulting in additional annual savings of roughly $6300 worth of heating
oil. Nadja Fürst is more than happy with
the new system, “Ultimately, it is our decision as to how we use a product and
the resources that are available to us.
Whether we discard or reuse products,
how we manufacture products and use
resources, sustainability is all about
mindset.”
Transparent and cost saving
The savings potential of the new air
system includes both the direct energy
consumption costs as well as the overall
system life-cycle costs. The measures
implemented in this particular case resulted in annual direct energy savings of
some $16,000. Plus, procurement costs
for planned future expansion are also
easy to manage, as the master controller is already designed to accommodate
potential air system expansions. All
that’s required is a straightforward software update, with no need for further
hardware. The new components can be
simply connected to the SAM 4.0 master
controller via the Ethernet-based Sigma
Verfasser: Daniela Koehler
Kontakt: [email protected]
daniela.koehler@ka
@ eserrr.c
.c
com
om
Kaeser at the world’s largest trade show:
BAUMA 2016 Wrap-up
The International Trade Fair for Construction Machinery, Building Material Machines, Mining
Machines, Construction Vehicles and Construction Equipment – also known as BAUMA – was held
on April 11-17, 2016 in Munich. Covering a staggering 6.5 million sq. ft. Bauma has more exhibition
area than any other trade show in the world. As usual, Kaeser had a substantial open-air display
complete with the distinctive multi-colored M31 compressor tower to highlight our comprehensive
portfolio of compressed air solutions for the world’s construction sites.
A wealth of exciting new products were
available to customers at Bauma and
Kaeser once again was proud to raise
the bar in energy efficiency and reduced
emissions.
Kaeser “Low emission zone”
Construction machinery is now subject to the low emissions thresholds.
Kaeser has long accommodated these
requirements and at this year’s Bauma,
presented all Mobilair models compliant
with Stage IIIB and Tier 4 interim standards. These were joined by other new
products, such as the M 125 and M 171
whose SCR catalytic converters and
diesel particulate filters ensure compliance with the Stage IV and Tier 4 final
emissions standards – currently the
most stringent in effect. In addition to
delivering flow rates from 350-600 scfm
and pressures from 125 to 200 psi,
these new models are equipped with
the Sigma Control mobile compressor
controller and energy-saving fans as
standard.
The phenomenon popularly known as
Industry 4.0 has also been referred to as
the “fourth industrial revolution”. Based
on advanced networking with machines and humans, and the real-time
availability of all relevant information,
Industry 4.0 won’t just be limited to factory floors. Increasingly, construction
and excavation sites, as well as raw
materials mining operations, will benefit
from the many opportunities presented
by global networking capabilities. So it’s
good to know that portable compressors
from Kaeser’s Mobilair range can be
equipped with the necessary technology. For instance, the M 500-2 Mobilair
delivers almost 1765 scfm and comes
standard with the GPS/GSM module.
Because this large compressor is predominantly used within rental fleets, its
advanced networking capabilities allow
it to be precisely located at any time
while also transmitting operational data.
This allows the next scheduled service
to be coordinated and scheduled in order to enhance operational reliability. All
Mobilair units with Sigma Control are
available with the GPS/GSM module as
special equipment.
USA/Canada
Legislative authority: Environmental
Protection Agency (EPA) and Environment Canada
Basis: 40 CFR Part 1039 (CFR = Code
of Federal Regulations)
Applicable emissions levels are Tier 3,
Tier 4 interim and Tier 4 final, by motor
output class. The EPA currently has no
plans to implement stricter emissions
standards.
© 20
2016
16 b
bauma,
auma, Mü
aum
M
München
nchen
© 2016 bauma, München
Fleet management for
Industry 4.0
Kaeser Compressors, Inc.
P.O. Box 946 Fredericksburg, VA 22404
COMPRESSORS
kaeser.com
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866-516-6888 • us.kaeser.com
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©2016 Kaeser Compressors, Inc.
[email protected]
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