report

A Magazine for the Production Industry
report
Weaving the
fabric of success
Victorian Desalination
Project opts for
A label of quality
Bosisto’s relies on
Kaeser to deliver
The ‘jumping horse’
makes its mark
energy efficient Kaeser turn-key
compressor system
Narrow fabric weaving
in a place of tradition
High quality and dry
compressed air
Pferd brand tools
from Marienheide
2/15
report
Contents
Issue 2/15
Editorial
3
Introduction
4
Kaeser reaches a new milestone
celebrating 25 years in Australia
6
Textile Industry 4.0 in Milan
Kaeser Kompressoren at ITMA 2015
8
Victorian Desalination Project opts for
energy efficient Kaeser turn-key compressor system
11
A label of quality
Narrow fabric weaving in a place of tradition
14
Efficiently meeting demand
at the new Liebherr-Australia re-manufacturing
and warehousing facility
16
Compact and efficient
TE series refrigeration dryers with innovative
heat exchange system
17
Live and let live
Sustainability for gourmets
19
The ‘jumping horse’ makes its mark
From Marienheide to the world
22
Bosisto’s relies on Kaeser to deliver
high quality and dry compressed air
4-5
8-10
14-15
Imprint:
Publisher:
KAESER KOMPRESSOREN SE, 96450 Coburg, Germany, Carl-Kaeser-Str. 26
Tel. 09561 640-0, Fax 09561 640-130, www.kaeser.com
Editor:
KAESER KOMPRESSOREN SE
Photographer
Marcel Hunger
Printing:
Schneider Printmedien GmbH, Weidhausen
The editor accepts no liability for manuscripts and photos submitted without request.
Reproduction, including of excerpts, only permitted with written permission.
KAESER KOMPRESSOREN SE – Postfach 21 43 – 96410 Coburg
Tel. 09561 640-0 – Fax 09561 640-130, www.kaeser.com – E-Mail: [email protected]
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Report 2/15 – www.kaeser.com
report
Peter Eckberg,
Managing Director
Kaeser Compressors is currently celebrating its 25th anniversary in Australia! From just two employees in 1990 to a large network of branches and partners covering Australia, New Zealand and
New Caledonia, we have certainly come a long way!
Compressor technology as well as our customer’s
requirements have changed significantly in that time.
Where once a user was simply purchasing a piece of
capital equipment, today they are looking to purchase
an energy efficient solution.
The dawn of Industry 4.0 is now once again changing
this landscape. A term which encapsulates a number
of technologies and concepts, Industry 4.0 represents
the next phase in manufacturing, or the fourth industrial
revolution.
By utilising cyber-physical systems, Industry 4.0 brings
the real and virtual worlds closer together in order to
guide and optimise companies manufacturing processes as well as entire value chains.
Capable of seamless integration into an overall system and communicating with one another, all Kaeser
products are also ready to take advantage of the futureorientated benefits of Industry 4.0.
All elements of a Kaeser compressed air system can
be networked together from; production planning to
implementation and predictive maintenance, enabling
intelligent control, which allows for the automatic delivery of the compressed air volume and quality required
by each specific user. This strategy helps to maintain
availability and efficiency, and keeps lifecycle costs to a
minimum.
Kaeser Kompressoren is proud to present the future of
integrated compressed air supplies at the ITMA - the
global textile machine industry trade fair, taking place
from the 12th to the 19th of November 2015 in Milan.
You can find out more about this exhibition on page 6.
In this edition of the Kaeser Report you will also find a
number of local and international case studies which
demonstrate the diverse industry sectors and applications which rely on Kaeser equipment.
We hope you enjoy this edition!
Peter Eckberg, Managing Director
Report 2/15 – www.kaeser.com
3
The 30,000 ft2 purpose built factory in Dandenong, Victoria.
Kaeser celebrates
25 years in Australia
For over 52 years, the Manufacturers’ Monthly magazine has led and informed Australia’s manufacturing industries with its highly credible editorial and its acclaimed analysis of issues affecting
manufacturing. Alan Johnson, the Editor of Manufacturers’ Monthly, recently interviewed Peter
Eckberg regarding Kaeser Australia’s 25th anniversary…
Technology remains the backbone of
the company’s continuing success. Alan
Johnson reports. November will see
Kaeser Compressors Australia celebrating its 25th anniversary, and what a
journey it has been. From humble beginnings with just two employees, the company has exponentially grown with state
branches and a dedicated network of
partners throughout Australia, New Zealand and New Caledonia, yet remains in
the same location; Dandenong, Victoria.
Not surprisingly, Peter Eckberg, Managing Director of Kaeser Compressors
Australia since the company’s inception
in 1990, has seen major changes in the
industry over the past 25 years.
“Where once the user was simply purchasing a piece of equipment, today
they are looking to purchase a solution,”
he told Manufacturers’ Monthly.Eckberg
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Report 2/15 – www.kaeser.com
says the rising cost of electricity and
the growing environmental obligations
a company now has are two significant
factors that have contributed to this
change.
“As a result, the majority of compressed
air users today are not only interested
in the energy costs attached to running
a compressed air system, but moreover
its total life cycle costs.”
Looking back over the past 25 years,
Eckberg says the development of frequency controlled compressors has
probably been the standout advancement in air compressor technology.
“By precisely matching output to actual compressed air demand, frequency
controlled compressors can save energy for users with a fluctuating demand
for compressed air.
“As well, the revolutionary developments
in information and communication technologies have had a profound effect on
the control, monitoring, communication
and inter-connective abilities of air compressor technologies.”
Eckberg says it is now common place
for compressors to have an industrial PC-based controller with a display
which allows the user to see at a glance
key data such as load, operation and
maintenance hours as well as an operation history.
“Solutions such as our Sigma Air Manager 2 (SAM 2) PC-based master compressed air management system have
pushed the capabilities of this technology even further.“
He explained that the SAM 2 allows
compressed air users to manage all
of their compressed air production and
treatment components from one single
unit. “For optimum energy efficiency,
the SAM 2 uses Kaeser’s advanced
3-D Control to analyse the relationship
between three key factors; switching
losses, control losses and pressure flexibility.
“Based on this information and the specific pressure required by the user, the
SAM 2 then predictively calculates the
optimum achievable configuration and
adjusts the connected components accordingly.”
He said operating status, pressure history, free air delivery, power consumption, as well as maintenance and any
error messages can all be easily displayed and analysed on the SAM 2 in
both real-time and retrospectively from
the 12-inch colour touchscreen.
Common mistakes
While there have been major advances
in technology in the past 25 years, Eckberg says operators and owners are still
making mistakes regarding their compressed air systems.
“Most manufacturers still underestimate
the efficiency of their compressed air
systems, even though many are acutely
aware that it is a large energy consumer.
“An inefficient compressed air system
costs more to run, and with the energy
cost of a compressed air system accounting for around three quarters of its
lifetime costs, knowing the efficiency of
the system is paramount in keeping this
cost to a minimum.”
Eckberg says compressed air is one of
the safest and easiest technologies with
which to generate relatively quick and
significant energy savings.
“By undergoing a simple compressed
air energy audit, users can identify
where the opportunities exist within their
compressed air system and what the
savings potential may be.” As well, Eckberg is surprised to see some manufacturers still neglecting the maintenance
requirements of their compressed air
equipment, or see price as the key consideration in selecting a maintenance
provider.
“When you look at the lifetime costs of
a compressor, maintenance only accounts for around 6%, and this drops
to around 3% for an optimised compressed air system.
“It therefore pays to follow the manufac-
turer’s prescribed maintenance schedule which will maximise the lifetime of
the compressed air equipment, ensuring
it operates optimally, efficiently and at its
peak performance at all times.”
Eckberg says opting for the cheapest
service provider or the cheapest spare
parts is often false economy.
“Only genuine OEM spare parts have
been rigorously tested by the OEM for
their durability, performance, efficiency and safety with the compressed air
equipment. Inferior parts or service may
lead to inferior compressor performance
and may be considered a safety hazard.”
Incorporating a back-up system is another area Eckberg, says manufacturers
tend to overlook.
“This can be a costly oversight. Whether
it be for maintenance or due to a system
failure, whenever a business relies on its
compressed air system, it is imperative it
has a back-up system in place.
“Some manufacturers believe they cannot afford to have a back-up system,
however the more pertinent question is
how can they afford not to have one?
“Once you start to weigh up the costs of
lost production, the necessity of having
a back-up system becomes clear,” Eckberg said.
Technology advances
As a leading innovator in air system
technology, Eckberg says Kaeser places great importance on developing
progressive system solutions with optimised performance and energy efficiency at their core.
“Developing technology that delivers
‘more air with more savings’ remains
a driving force at Kaeser and perfectly
encapsulates what manufacturers can
continue to expect to see from the company in the future.
“One of the world’s largest manufacturers of rotary screw compressors, many
readers might be surprised to hear that
Kaeser Compressors remains owned
and operated by the same Kaeser family with all products still manufactured in
Germany.”
From 2.2 to 500kW, Kaeser Compressors manufactures a wide range of
compressors and associated auxiliary
equipment
Eckberg says Industry 4.0, the collective
term for technologies and concepts of
value chain organisation, is playing a
key role in both new product and service
developments as well as the company’s
manufacturing capabilities.
“By utilising cyber-physical systems,
Industry 4.0 brings the real and virtual
worlds closer together in order to guide
and optimise companies manufacturing processes as well as entire value
chains.”
He explained that two new “innovative”
factories are currently being constructed at Kaeser’s head office in Coburg,
Germany.
“The manufacture of compressors and
compressed air equipment in these
futuristic production halls will be networked with internal and external logistics, as well as their sales and marketing
arms.
“By taking advantage of all that Industry 4.0 has to offer, the new production
halls will allow Kaeser to build new and
innovative products whilst optimising
productivity and minimising lead times.”
Capable of seamless integration into an
overall system and communicating with
one another, Eckberg said all Kaeser
products are ready to take advantage of
the future-orientated benefits of Industry
4.0.
“All elements of a Kaeser compressed
air system can be networked together
from; production planning to implementation and predictive maintenance, enabling intelligent control, which allows
for the automatic delivery of the compressed air volume and quality required
by each specific user.
“This strategy will help to maintain availability and efficiency, and keep lifecycle
costs to a minimum,” Eckberg said.
Peter Eckberg, Managing Director of
Kaeser Compressors Australia since the
company’s inception in 1990.
Report 2/15 – www.kaeser.com
5
Kaeser Kompressoren at ITMA 2015
Textile industry 4.0
It was a long road from the inception of the textile industry to
the start of the industrial revolution when Sir Richard Arkwright
established his spinning mill in Cromford, England in 1771.
At that time, Cromford was at the forefront of a massive expansion in the cotton trade, with Arkwright’s cotton mill inspiring
countless industrial centres around the world to take up textile
manufacturing. Whilst the first cotton mills ran on water power,
modern systems make use of compressed air technology to
accomplish the same goals. The very latest advances in the
industry are showcased every four years at ITMA, the world
exhibition for textile technology. This year, Milan hosts the world
of industrial textile production.
All technical textile applications share a
common reliance on a dependable and
plentiful supply of premium quality compressed air. The most important criteria
are the purity and dryness of the compressed air, since modern air-jet looms
use it to guide the weft thread reliably
across loom widths of some four metres. At full load, this process repeats
at a rate of 700 times per minute, at a
blinding speed of approximately 160
km/h. The interplay of mechanical and
pneumatic precision is as dizzyingly impressive as it is fascinating.
Kaeser Kompressoren at ITMA
Weaving mills all around the world, particularly in Asia, are increasingly using
air-jet looms – a technology in which it
is not uncommon for the cost of compressed air that drives the machines
to account for some 85 percent of total
system costs. The aim of reliably supplying these machines with a source of
cost-effective compressed air is therefore compelling. The path to achieving this goal involves the increasingly
important trend toward the “Internet of
Things” (IoT) in which networking of the
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Report 2/15 – www.kaeser.com
production process’s compressed air
supply is becoming ever-more widespread – even in the textile industry. It follows therefore, that Kaeser
Kompressoren has chosen to highlight the subject of “Industry 4.0”
at this year’s ITMA (12th - 19th of
November, 2015, Fiera Milano Rho,
Milan, Italy, Hall 6, Stand H6-G122).
The focus is expected to be on compressed air supply systems for applications requiring large free air
deliveries, such as those needed by
air-jet looms. Kaeser Kompressoren
is proud to meet this demand with
its latest range of ESD series rotary screw compressors featuring the
Sigma Control 2 controller. The comprehensive networking capability of
this controller enables both straightforward integration of individual units
into larger stations, as well integration with master controllers, such as
the advanced Sigma Air Manager 2.
Visitors to the Kaeser stand in Milan
who value dry-running compressor
technology will be able to see sophisticated air-cooled units capable
of delivering a dependable and efficient supply of quality compressed
in Milan
air even under extreme operating conditions. Moreover, these machines are
able to provide efficient and effective
drying in combination with the optionally
integrated iHOC rotation dryer.
Kaeser Kompressoren is also setting
new standards in the area of master controller technology: The Sigma
Air Manager (SAM 2) with innovative
3D-Control can coordinate operation of
up to 16 compressors. At the same time,
Sigma Air Control (Plus) documentation
software is specifically tailored to work in
tandem with the SAM 2, delivering crystal-clear transparency of compressed air
costs by simplifying the once arduous
processes of operational data gathering
and processing.
That’s not all though: The Sigma Air
Manager 2 provides direct connection
to the Kaeser Data Center which allows
continuous energy efficiency optimisation and also lays the foundation for Predictive Maintenance to ensure maximum
compressed air availability.
A brief history of ITMA
The members of CEMATEX (Comité Européen des Constructeurs de Machines
Textiles / European Committee of Textile
Machinery Manufacturers), established
on the 20th of October 1952, had a revolutionary idea: to create a trade fair that
would bring together all of its members’
products in a single forum. These efforts
were inspired by an initial attempt to
hold an international textile machine exhibition in 1951 in Lille, France. Although
the exhibition area at this first textile machine exhibition was relatively modest
at 12,000 m², it still managed to attract
some 280 exhibitors.
However, this was just the beginning.
The first true CEMATEX-ITMA held four
years later in Brussels in 1955 boasted
almost double the exhibition area at
20,000 m² and attracted 453 exhibitors.
Since then, the exhibition has enjoyed
irrepressible success. Since its establishment, ITMA has been held every
four years at various locations in Europe
and consistently attracts growing numbers of exhibitors and visitors alike. The
17th ITMA exhibition will be held from
the 12th to the 19th of November 2015
in Milan, a city that has not hosted this
international trade fair for some twenty
years.
Constructed in 2006, the new Milan convention centre now boasts one of the
world’s largest exhibition grounds, with
a total area in excess of 400,000 square
metres. The new lofty exhibition halls
are connected by impressively unique
architectural elements that resemble sails, made from glass and steel,
and are perfectly suited for all kinds of
technical exhibitions. The complex is
composed of eight fully independent
exhibition halls (total area: 345,000 m²)
that house some 20 restaurants and 57
bars, a host of conference rooms, an
auditorium, VIP entrance and helipad,
to name just a few facilities. In addition,
automatic moving walkways provide
fast and convenient visitor mobility within the complex, which spans some 1.3
kilometres from the first to last hall.
Bookings received by the 4th of July
2014 submission deadline already indicated that this year’s exhibition will
surpass all previous attendance figures:
around 1,300 exhibitors from 43 countries have registered and rented exhibition space for ITMA 2015. With such
an impressive facility and compelling
exhibits, no one with an interest in the
latest technology and innovations in this
sector can afford to miss ITMA 2015.
Hall 6
Stand H6-G122
Visit us from the 12th -19th of November 2015 in Milan
Report 2/15 – www.kaeser.com
7
Victorian Desalination Project opts for
energy efficient KAESER
turn-key compressor system
In constructing the Victorian Desalination Project, AquaSure chose to install four Kaeser DSD 238
SFC series frequency controlled rotary screw compressors to meet the plants’ requirements for
an energy efficient source of compressed air. Ready for action in times of drought, the Victorian
Desalination Project can produce and supply up to 150 billion litres of water a year to Melbourne
and Geelong.
In June 2007, the Victorian Government
announced its intentions to construct a
desalination plant as part of its Water
Plan, which would create a droughtproof supply of water for Melbourne and
Geelong.
The contract to finance, design, construct, maintain and operate the Victorian Desalination Project (VDP) was
awarded in July 2009 to the AquaSure
consortium. Located near Wonthaggi,
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construction commenced in September 2009 and was completed in 2012
by AquaSure and its contractors, which
included design and construction contractors Thiess Degrémont and operations and maintenance contractors Degrémont Thiess Services (Watersure).
The VDP comprises; a reverse osmosis
plant, marine structures which include
two underground tunnels located 15
metres below the seabed, a two-way
underground 84 km water transfer pipeline and 87 km underground power supply. With a production capacity of up to
150 billion litres of water a year, the VDP
provides a rainfall-independent source
of water to communities throughout
Melbourne, South Gippsland and Westernport.
Reverse osmosis is the desalination
technology used at the VDP to turn
seawater into freshwater. It is also the
most energy efficient method of desalination. This is not the only energy
efficient measure implemented at the
VDP. AquaSure introduced a number of
innovative systems to ensure the plant
operates as energy efficiently as possible. This included; incorporating systems within the plant to minimise power
consumption during the reverse osmosis processes and the plant’s compact
modular design which reduces pipework and eliminates inefficient energy
use.
The compressed air system was another area where AquaSure opted for
equipment that possessed energy reducing features such as variable speed
drives and high efficiency motors.
Compressed air is used to power a
number of processes within the VDP.
One of the main requirements for compressed air on the plant however, is to
actuate a number of the 17,000 plus
automated valves!
To maximise energy efficiency while
meeting these requirements, AquaSure
chose to install a Kaeser turn-key solution consisting of; four Kaeser DSD 238
SFC series frequency controlled rotary
screw compressors, four air receivers
along with four instrument air treatment
skids which include pre- and post- duplex filter sets as well as a desiccant
dryer.
Manufactured in Germany, the DSD
SFC series frequency controlled rotary screw compressor packages from
Kaeser provide the ultimate energy efficient solution.
Every Kaeser rotary screw compressor is equipped with a large, efficient
screw compressor block featuring high
performance Sigma Profile rotors. Powered by a direct drive system, the screw
compressor blocks in the DSD series
compressors eliminate the transmission losses associated with gear driven
systems. This significantly increases
reliability and service life. The benefits
speak for themselves; efficient power
transmission, optimal power consumption, reduced servicing and downtime
costs along with significant energy savings. In addition, further and considerable energy savings are achieved with
Report 2/15 – www.kaeser.com
9
One of the main requirements for compressed air on the VDP is to actuate a number of the 17,000 plus automated valves.
the inclusion of the Sigma frequency
control (SFC) module.
With the SFC module (variable speed
drive) air delivery can be matched to
actual air demand, according to the required system pressure, by continuously adjusting drive motor speed within its
specified control range. This can lead to
significant savings, as only the required
compressed air at any one time is produced, with a 1 bar reduction in pressure amounting to a 7 percent reduction
in energy consumption.
From construction completion in December 2012 to the end of the contract
in 2039, Watersure will operate and
maintain the plant, seawater tunnels,
pipeline, and ecological reserve surrounding the plant site.
The contract with AquaSure provides
for flexible water ordering of between
0GL and 150 GL a year in set increments, enabling the State Government
to order water if required. When the
VDP is not producing water, there is a
comprehensive maintenance program
in place which guarantees that the VDP
is available to produce water when the
need arises, making an important part
of Melbourne’s water security in times of
future drought and to support its growing population and economic prosperity.
Efficient and reliable, the DSD SFC series frequency controlled rotary screw
compressors from Kaeser are available
with drive powers up to 160 kW, working
pressure 7.5, 10 or 13 bar and with free
air deliveries from 3.6 up to 30.60 m³/
min.
The VDP utilises 4 Kaeser DSD 238 SFC series frequency controlled rotary screw compressors, 4 air receivers and 4 instrument
air treatment skids which include pre- and post- duplex filter sets as well as a desiccant dryer.
10
Report 2/15 – www.kaeser.com
Narrow fabric weaving in a place of tradition
A label of quality
Re-established approximately ten years ago, the Bornemann-Etiketten GmbH company in the
Ronsdorf district of Wuppertal is continuing an enduring, local industrial tradition using the very
latest technology. Rotary screw compressors from Kaeser play an instrumental role as the company continues to weave a colourful and exciting future.
The Duchy of Berg, a territory in eastern Rhineland that formed part of the
German-speaking Holy Roman Empire, granted the cities of Barmen and
Elberfeld a monopoly for bleaching
and selling thread in 1527. The bleach-
ers and dyers that settled around current-day Wuppertal attracted weavers
and clothiers, who were then followed
by mechanical engineers and dye manufacturers. In the late 18th century, all of
these elements combined to provide the
impetus of the first industrial revolution.
By the 19th century, up to 80 percent
of the local residents earned their living
through the weaving mill industry and its
suppliers.
Report 2/15 – www.kaeser.com
11
Of course, this industrial transformation
did not take place overnight. Until well
into the 17th century, the local narrow
fabric weavers supplied ‘tapes’, for example, made individually on special
tape looms for decorative or liturgical
uses – generating a healthy source of
income. By the end of the 16th century,
the first multi-tape looms had appeared
and, as the name suggests, were able
to simultaneously produce several tapes
at a time. Unsurprisingly they had their
detractors, mainly luddites who, not unreasonably, viewed such technological
innovation as a direct threat to their livelihoods.
Ultimately though, technology moved on
apace and soon new ribbon mills clattered noisily in many a weaver’s house.
Since they were quite expensive, the
new machines were primarily purchased
by merchants who employed the weavers as “independent wage workers” in a
putting-out system. This system, used,
for example, in the Duchy of Berg and
Silesia, eventually resulted in grave social inequalities.
By the end of the 18th century, the looms
had been further mechanised and water
power had established itself as the main
source of drive power. It was only then
that business owners started to change
their production model by concentrating
large numbers of machines in manufacturing houses and later large factories,
where they were operated by employees.
The first such factory is now considered
to be Richard Arkwright’s cotton mill that
Bornemann’s looms produce miniature works of art
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was founded in Cromford, Derbyshire,
England. Furthermore and somewhat
brazenly, the first true “factory” in Continental Europe was named “Cromford”.
It was constructed in Ratingen, near
Dusseldorf (the capital of the Duchy of
Berg since the 14th century), by Johann
Gottfried Brügelmann. He was an entrepreneur who, in what may be the firstknown case of industrial espionage,
had Arkwright’s “Waterframe” (the first mass
production water-powered spinning machine)
reverse-engineered and
used the ‘borrowed’
technology to line his
own pockets.
An endless supply
of compressed air
To accommodate its constant growth,
Bornemann-Etiketten GmbH relocated
its operations to a new, larger building in 2011. Following installation of a
compressed air ring main made from
aluminium piping (DN 80), the compressed air station – which had been
expanded several times to meet the
Fine labels for fine
textiles
Wuppertal remains a
hub for the narrow fabric The compressed air station keeps growing to meet
weaving industry to this ever-increasing demand
day – but to a somewhat
lesser extent than in the middle of the growing demand – was also relocated
last century. The Bornemann name there. It comprises a BSD 62, a BSD
was already well-known in the industry 72 and a CSD 102 T-SFC Kaeser rotaat that time, although the company he ry screw compressor, as well as two refounded was later incorporated into the frigeration dryers and numerous filters
Paxar conglomerate at the beginning of – all masterfully coordinated by Sigma
this century and afterwards continued Air Manager 4/4 to ensure optimum
to operate under the corporate name efficiency and availability. The compaonly. Then, around ten years ago and ny now saves even more energy since
like a phoenix from the ashes, Sandra installing a heat recovery system three
and Georg Bornemann decided to res- years ago.
urrect the family business under the
Bornemann name, went into business
for themselves and re-established the
Bornemann Etiketten company. As their
track record of success testifies, this
was a smart move. Since starting with a
dozen employees in 2005 in Ronsdorf,
their payroll has now grown to nearly 70
employees who produce high-quality
labels for clothing by pre-eminent fashion customers, such as Gerry Weber,
Schöffel, Schiesser and Basler. In fact,
every garment comes with a quality label that is designed by Bornemann’s
professional design studio, in close
cooperation with customers, to ensure
that it aligns precisely with the specific
Author: Klaus Dieter Bätz
brand’s corporate design and identity.
Contact: [email protected]
Report 2/15 – www.kaeser.com
13
Efficiently meeting demand
In building its new re-manufacturing facility in Adelaide, Liebherr-Australia chose
Kaeser equipment to deliver an energy efficient supply of compressed air on demand.
Since 2004 Liebherr has re-manufactured used components from its own construction, handling,
maritime and mining equipment. Built to the same quality standards as original new parts, the
Reman Program allows Liebherr to deliver high quality components whilst saving energy and
material – good for the environment and good for customers!
In 2012 Liebherr-Australia began building a re-manufacturing and warehousing facility at its Adelaide head office
complex. With a number of Liebherr
sites worldwide already satisfactorily using Kaeser compressors, Stefan
Stübiger, Industrial Engineering Project
Manager at Liebherr-Australia, called
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upon local Kaeser distributor Mobile
Compressed Air to design and supply
the compressed air system for the new
warehouse.
This complete Greenfield site required
large quantities of compressed air at
varying locations across the extensive
factory floor. From the dismantling area
to the reassembly area, compressed
air would be required, to power large
torque and rattle guns, grit blasting as
well as the painting booth. It was anticipated that the demand for compressed
air would vary significantly throughout
the working day. Liebherr-Australia
therefore required a system that could
rapidly scale up or down to match
demand in the most energy-efficient
manner.
To meet these requirements, Mobile
Compressed Air recommended installing; a CSD 125 series rotary screw
compressor, a CSD 105 SFC series
frequency controlled rotary screw
compressor, a BSD 83 series rotary
screw compressor and a Kaeser Sigma Air Manager Master Controller.
Manufactured in Germany to exacting
quality standards, the Kaeser CSD series of rotary screw compressors provide the user with significant energy
savings. Every CSD rotary screw compressor incorporates a premium quality screw compressor block equipped
with Kaeser flow optimised Sigma Profile rotors. Developed by Kaeser and
Kaeser equipment is delivering LiebherrAustralia with an energy efficient supply
of compressed air on demand
would further allow Liebherr-Australia
to enjoy considerable savings. Able to
control up to 16 compressors, the SAM
controller precisely adjusts the loading
and operation of all compressors within
the system to achieve optimum station
energy efficiency, whilst its patented 3-D
control allows a significant reduction in
air network system pressure resulting in
further savings!
The Kaeser equipment was subsequently installed along with large compressed air distribution manifolds. Designed and manufactured by Mobile
Compressed Air, these manifolds provided Liebherr-Australia with the compressed air equivalent of a power board.
With seven outlets installed at different
points throughout the facility, compressed air would be highly accessible
when and where required. The project
completed in December 2014. Mr Stübiger said, ‘The compressed air system
is providing us with a reliable source
of energy efficient compressed air and
we have since chosen to install Kaeser
compressors in four further nationwide
warehouses.’
Since installation, Liebherr-Australia continues to rely on Mobile Compressed Air for its on-going compressor
and maintenance requirements.
The CSD / CSDX (SFC) rotary screw
compressors from Kaeser are available
with drive powers up to 90 kW, working
pressure 7.5, 10 or 13 bar and with free
air deliveries from 1.07 up to 16.16 m³/
min.
For more information visit www.kaeser.
com.au or phone 1800 640 611.
From the dismantling area to the reassembly area, compressed air is used to power
large torque and rattle guns, grit blasting as well as the painting booth.
continually enhanced ever since, the
Kaeser Sigma Profile can deliver power
savings of up to 15 percent compared
with conventional screw compressor
block rotor profiles. All Kaeser rotary
screw compressor blocks feature this
energy-saving rotor profile and are designed to ensure maximum energy efficiency.
In addition, the CSD 105 SFC rotary screw compressor includes sigma
frequency control. Kaeser SFC compressors are able to directly match the
required air demand by continuously
adjusting the compressor block speed
within the given control range. The result is significant reductions in energy
consumption. The inclusion of a Sigma
Air Manager (SAM) station controller
Re-manufacturing and warehousing facility at Liebherr-Australia’s Adelaide head
office complex
Report 2/15 – www.kaeser.com
15
TE series refrigeration dryer with innovative heat exchanger system
Compact and efficient
Representing the cutting-edge of energy-saving innovation, Kaeser refrigeration dryers with their
latent-heat thermal mass storage system require just half the footprint of their predecessors, yet
provide the same output.
When it comes to compressed air treatment, refrigeration dryers are the first
choice for the majority of applications,
which is why improvements in their design are so significant and have such
wide-ranging effects. The goals when
redesigning the TE refrigeration dryer
series were therefore similarly far-reaching: namely, to achieve at very least the
same high, absolute capacity for thermal
storage with tangibly reduced energy
requirement and significantly reduced
footprint. The newly developed thermal
mass system with an integrated latent
heat storage systems takes advantage
of the phase-change effect – demonstrated when a material changes from
one state of matter to another (solid to
liquid). This effect therefore allows an
astonishingly high thermal storage capacity some 99 percent better than that
of conventional storage systems.
The exceptional capacity of the
Secopack LS latent heat storage system
makes it possible to implement efficient
cycling control for the dryer’s internal
refrigerant compressor. Together with
minimal pressure loss (<0.15 bar), this
results in exceptional energy efficiency
(specific power consumption < 100 W/
m³/min), which translates into significant
energy savings. Furthermore, Sigma
Control Smart, a newly-developed dryer
controller, continuously ensures reliable and energy-saving compressed air
delivery with a pressure dew point of
+3 °C. It also enables easy and seamless connection to master controllers
such as the Sigma Air Manager via an
Ethernet module.
Read more about the astounding energy saving potential of this refrigeration
dryer on page 19 of this issue.
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Live and let live
Sustainability for gourmets
Extracting caviar without harming the fish is an innovative and gentle method that’s recently been
made commercially viable by a company based near Bremerhaven. It’s all made possible thanks to
a team of Kaeser rotary blowers that aerate the fish pools and the on-site water treatment.
In the past, gourmets around the world
had to accept an unpleasant compromise in order to enjoy the popular delicacy of caviar: unfortunately, up until
now, it has not been possible to collect
the roe without also killing the fish from
which it is taken. Now though, there’s
hope for both gourmets and sturgeon
alike: a new, patented method has been
used since 2014 to produce high-quality
caviar from separated eggs.
The idea of extracting caviar from living
sturgeon has long been a focus in the
sector. In both the wild and in fish farms,
female sturgeon require many years
before they can produce roe – up to 26
years for some species. Furthermore,
the conventional method currently used
to produce caviar will likely lead to the
extinction of all 27 known species of
sturgeon in the relatively near future.
Even under optimal feeding and care
conditions in aquaculture, sturgeon take
five to eight years before they produce
the coveted delicacy and, until recently,
it would be both the first and last time
they did so, since the conventional approach for producing caviar from premature roe involves killing the fish.
The problem that has cost female sturgeon their lives (up until now), is that
mature eggs, though they can be removed from a living fish, are unsuitable
for eating since they become gelatinous
and soft in water and burst and clump
when exposed to salt. The mature, unfertilised egg is highly unstable and cannot tolerate the rigours of processing.
The Vivace process
Enter Prof. Dr. Angela Köhler and the
Alfred Wegener Institute for Polar and
Oceanic Research (AWI) in Bremerhav-
Professor Dr. Köhler ensures that all is well with the sturgeons
en. Köhler, a marine biologist, sought to
develop a method by which the separated, mature – but unfertilised – eggs
obtained from living fish could be processed for eating. Five years of research paid off, as she finally identified
the essential, naturally-occurring active
ingredient for treating the eggs. She
found that – in simplified terms – certain enzymes essentially trick the egg
into thinking that it has been fertilised.
When freshly separated roe comes into
contact with these signal molecules
(extracted from the sperm of male sturgeons), they stabilise the highly sensitive eggs. Upon fertilisation, various
biochemical messengers signal the cell
to grow a new, harder protective wall
around the mature egg in order to prevent multiple fertilisation, which would
kill the embryo.
The more robust wall around the eggs
obtained through the Vivace process
developed by Prof. Dr. Köhler therefore protects them from damage and
from the growth of harmful bacteria.
The clean, stabilised eggs can be salted and packed immediately without preservatives, including those with questionable health effects, such as Borax
(E 285), which is approved as a preservative only for caviar. With the support of the Alfred Wegener Institut, the
private investor Wecken & Cie. and the
German Reconstruction Loan
Corporation
(KfW),
Prof. Dr. Köhler
Report 2/15 – www.kaeser.com
17
Photo credit: Rolling Pin
Large volumes of dependable blower air are vitally important for fish and water
established Vivace GmbH in Bremerhaven in 2010 in order to market the
exclusive rights, to employ the globally
patented process and to grant licenses
to suitable partners.
Reliable blower air – an absolute
necessity
Vivace’s first product site for “sustainable caviar” is located just south of the
Bremerhaven city limits in a commercial
district in the town of Loxstedt, within
the regional municipality of Cuxhaven.
It is home to more than 7,000 sturgeon
living in 77 pools. They follow their natural lifecycle and produce their roe under
simulated natural temperature and light
conditions during reproduction. The valuable eggs can be separated from the
abdominal cavity in just a few minutes
by giving the fish a gentle massage; it’s
a straightforward process used routinely
in all fish farms. The basic requirement
for fish farming is to supply a continuously consistent level of oxygen to the
fish pools, so absolute reliability of the
rotary blowers is one of the most important requirements. The same goes for
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Report 2/15 – www.kaeser.com
the air used in the on-site wastewater
treatment plant that supplies the active bacterial cultures with oxygen. The
company therefore chose to install seven “Compact” class rotary blowers from
Kaeser Kompressoren. Each is installed
next to its particular area of use, whilst
two Sigma Air Manager master controller systems coordinate operation in the
fresh water and wastewater areas respectively. The turnkey “Compact” blowers installed at Vivace were delivered
ready for immediate connection complete with all sensors, star-delta switch
(or OFC variable-speed control), the
industrial PC-based Sigma Control 2
blower controller, emergency off switch
and full certification. Opting for the complete package greatly reduced the work
effort and time – and therefore also the
cost – required for the planning, installation, documentation and commissioning processes. The Kaeser blowers are
quiet and efficient, so it seems that the
experience of one satisfied customer
who declared “Nothing’s as dependable
as Kaeser blowers – if only all systems
were so reliable!” is being repeated in
Loxstedt.
We wish the inventors and users of
the Vivace process every success, so
that both caviar gourmets and sturgeon
stocks can enjoy a long and sustainable
future.
Vivace
has
installed
the
following blower equipment: three EB 421 C,
two EB 291 C, one DB 166 C and
one DB 236 C. The units for aeration of the fish tanks and clarifiers
are each coordinated for optimum
efficiency in continuous operation
by a single Sigma Air Manager master controller.
From Marienheide to the world
The “jumping horse” makes its mark
Leonardo da Vinci, Italy’s famous Renaissance man, was not
the first to sketch drafts of tools, recording them on paper for
posterity. We know that files and similar tools were used as far
as back as ancient Greece. Farther north, in the former Duchy
of Berg, however, the history of a company dedicated to manufacturing tools began towards the end of the 18th century – an
enterprise that grew from a one-man operation into a company
with global reach.
The Rüggeberg ridge, also known as the
“Rauer Bergrücken” (“rugged mountain
ridge”), lies on a mountain ridge along
the border between the Sauerland and
territory of the former Duchy of Berg and
is now part of the city of Ennepetal. At the
end of the 18th century, the village was
a tiny agglomeration focused on homebased work (craft-like work produced for
sale by residents in their homes) whose
streets, laid out in a star-pattern centred
on the church, housed many smithies
even then. They were the harbingers
of the impending transformation of this
Rhine-Westphalian region, located between the Wipper/Wupper and Emscher
rivers, into a major production centre –
first European, now global – dedicated
Report 2/15 – www.kaeser.com
19
The new refrigeration dryers featuring the Secotec latent heat thermal mass
technology deliver significant savings
tories in cities as part of the social and
economic changes brought to the Ruhr
Valley by industrialisation.
So it was only logical that Johan Friedrich’s son August Rüggeberg and his
own sons Alfred, Emil and Robert began to seek an alternative location, finally settling in the small town of Marienheide that lies some 40 kilometres to the
south. The location offered many welltrained and highly skilled home workers,
as well as steel mills in close proximity
to supply the required raw materials.
All of this culminated in the founding,
in 1897 in Marienheide, of the company that continues to bear the name of
August Rüggeberg (August Rüggeberg
GmbH & Co. KG), whose first production building remains intact and now
forms the inner core of the modern production facility.
to the iron and steel industries. It was
in one of these smithies that Johan
Caspar Rüggeberg produced the first
files and graters toward the end of the
18th century. His son, Johan Friedrich,
went one step further by having local
home workers apply the cut to raw files.
The brand logo also dates from this
time: a horse jumping through a hoop.
Eventually, these activities developed
into a lucrative manufacturing business
– the only problem was that the home
workers ended up migrating to the fac-
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Report 2/15 – www.kaeser.com
Coming round
The period between the World Wars
brought both growth and diversification.
The product range grew, in terms of
quantity and quality, yet the end of the
1930s brought another major change:
the realisation that manual filing was
becoming irrelevant and that industry
would increasingly rely on mechanically-driven tools. But instead of losing
heart, Rüggeberg rose to the challenge
and made an important breakthrough,
which resulted in a revolution in metal
processing: he transformed linear filing motion into rotating motion. This
resulted in the rotary miller, which was
designed for freehand use and worked
using geometrically optimised tooth
shapes and angles of twist. The machines that developed from this rotating tool (patented in 1942) during the
post-War period and on to the present
day are now essential to industrial and
craft processes; the company’s current
product catalogue contains thousands
of choices.
With its grinding and cutting discs
strengthened with fibre-reinforced artificial resin, the Pferd brand conquered
the market in the early 1950s. Today, the production and sale of elastic
discs are the areas with biggest sales.
Rüggeberg’s high level of vertical integration, however, means that tool
manufacturing isn’t oriented exclusive-
August Rüggeberg GmbH & Co. KG is a German tool manufacturer based in Marienheide whose products are distributed under
the Pferd brand name. The company is one of the world’s leading providers in the international tool industry.
ly to large unit quantities, but rather is
able to flexibly serve customers and
meet their individual needs with customised solutions. For instance, the
Marienheide company offers its highly
complex shapes for diamond mills with
very reasonable minimum order quantities – like “1” for example!
Pferd goes to school
Yet even in the realm of conventional
products, the broadly diversified selection of tools for sanding, filing and
milling offers the right tool for virtually
any application. There’s no limit to the
shapes that can be imagined as well
as drive systems, which can be customised if requested by the customer.
The company’s product range even
goes one step further: Pferd Academy
provides a forum for users and customers to gain not only theoretical knowl-
edge about the premium quality tools.
Practical skills and operation are also
demonstrated and practiced at specially equipped workstations, under expert
guidance.
As such, the modern training centre is
also one of the consumers of the compressed air – that indispensable energy
carrier, especially at Pferd – produced
in large quantities by the central compressed air station. For example, compressed air is used to power the motors
for the high-speed rotating tools at the
Pferd Academy. Compressed air also
fulfils the important roles of process
and, crucially, control air for the many
highly complex CAD/CAM production
units, each of which is specially produced by the in-house mechanical
engineering department to precisely
meet the given requirements. Günter
Schmittler, responsible for mechanical
engineering and maintenance, is quite
rightly proud of this “factory within the
factory” – which simply wouldn’t be possible with standard machines.
At Pferd, everything meets the very
latest standards in terms of technology and productivity, so it’s no wonder
that the same attention to detail has
been paid to the compressed air supply. During the most recent renovation,
the existing compressed air dryer was
replaced by three TF 280 series thermal
mass refrigeration dryers from Kaeser,
which save space in the compressed
air station and also improve overall efficiency of this area. Compared to the
previous supply system, energy consumption for compressed air drying has
fallen by an impressive 80 percent and
the approximate 9,000 euro annual saving speaks for itself.
Report 2/15 – www.kaeser.com
21
Bosisto’s relies on KAESER to deliver
HIGH QUALITY and
FGB Natural Products, the
manufacturer of the renowned
Bosisto’s ‘Parrot’ brand Eucalyptus Oil, recently chose to
install a Kaeser CSD 105 rotary screw compressor, along
with a DC108E desiccant dryer
at its manufacturing facility, to
ensure a reliable and efficient
supply of high quality and dry
compressed air.
An independent Australian owned and
operated pharmaceutical company,
FGB Natural Products (FGB) specialises in manufacturing natural; over the
counter pharmaceuticals, nutritional
supplements, household products, personal care products and medical devices which can be found in pharmacies
and supermarkets throughout Australia.
The largest fully integrated producer
and manufacturer of eucalyptus oil and
eucalyptus oil based products, FGB
manufactures such well-known and
much loved Aussie brands as; Bosisto’s
‘Parrot’ brand Eucalyptus Oil and Euky
Bear range, from its modern facility in
Oakleigh South, Victoria. Compressed
air is used to power a number of functions across the facility from; the automatic capping to the high speed labeller
and shrink wrapping machines.
Larry Michaud, the Maintenance Officer
at FGB recently called upon Kaeser
Compressors to replace their ageing
22
Report 2/15 – www.kaeser.com
DRY COMPRESSED AIR
compressed air system. Requiring reliable, high quality and dry compressed
air, FGB chose to install a Kaeser CSD
105 rotary screw compressor along with
a 1000 litre air receiver and DC108E
dessicant dryer.
The CSD series rotary screw compressors from Kaeser deliver premium
quality compressed air and superior
efficiency. At the heart of every CSD
rotary screw compressor lies a lowspeed Sigma Profile screw compressor
block equipped with flow optimised rotors. Developed by Kaeser, the Sigma
Profile achieves power savings of up to
15 percent compared with conventional
screw compressor block rotor profiles
for a highly energy efficient solution. In
addition, all Kaeser rotary screw compressor blocks are powered by premium efficiency IE3-rated drive motors
(that comply with, and exceed, prevailing Australian MEPS regulations for 3
phase electric motors), for maximum
performance and reliability.
The internal component layout in the
CSD series rotary screw compressors,
not only ensures even greater efficiency, but it also allows direct access to all
service and maintenance points from
the front of the unit. This saves both
time and money when it comes to servicing. A long service life is also achievable thanks to the inclusion of only high
quality components.
Producing exceptionally dry compressed air is paramount for FGB in
the manufacturing process, where any
moisture contamination to the compressed air supply could cause product
spoilage.
As a result FGB chose to install a Kaeser DC108E heatless dessicant dryer
with Eco Control. This desiccant filled
air dryer has an exceptionally high adsorption capacity and its regeneration
capability provides sustained low pressure dew point performance with minimal pressure and energy loss. For maximum energy savings, the DC E models
are equipped with “Eco Control” an intelligent control system which features a
highly effective purge air savings mode.
Robust, compact and reliable the DC
series desiccant dryers from Kaeser, incorporate a meticulous design and high
quality durable components for minimal
operating and service costs.
Installed and operating for over 12
months, Michaud commented: ‘We are
very happy with the performance of the
Kaeser equipment which has proven to
be very reliable in operation.
We are also impressed with the long
service life of the equipment which has
created cost savings for us.’
The CSD / CSDX series rotary screw
compressors from Kaeser, are available
with fixed or variable speed drive and
with an integrated refrigeration dryer.
Drive power 45 to 90 kW, working pressure 5.5 to 15 bar with free air deliveries
from 1.07 to 16.16 m³/min.
Kaeser compressed air is used to power the high speed labeller at FGB; FGB chose to install a Kaeser CSD 105 rotary screw
compressor along with a 1000 litre air receiver and DC108E dessicant dryer
Report 2/15 – www.kaeser.com
23
KAESER COMPRESSORS Australia Pty. Ltd.
Locked Bag 1406 – Dandenong South – Vic. 3164
45 Zenith Road – Dandenong – Vic. 3175
Phone: +61 39791 5999 – Fax: +61 39791 5733
www.kaeser.com – E-mail: [email protected]
More air, more savings…
Screw blowers with SIGMA PROFILE
Intelligent controller
SIGMA CONTROL 2
SIGMA PROFILE
blower airend
Whether for standalone units
or team players – the SIGMA
CONTROL 2 delivers optimal
energy efficiency and flexible
communication for every
application
More air and more savings are
now also possible with blowers
Compact design
Intelligent component layout
enables space-saving design and
optimum maintenance-relevant
access
Plug and play
Made in Germany
KAESER screw blowers represent the
very best in German engineering
and durability
Blower air –
dependable, efficient, KAESER
Complete packages delivered
according to the “Plug and Play”
principle: simple installation,
minimised installation time
and costs