efficiency, Sacmi Filling chose the Danfoss VLT® FlexConcept drive system for the high-performance and optimized management of new bottling lines designed
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fiThis project has a challenging objective,fl said Giorgio Frosi, Sacmi Filling Beverage Engineering Department. fiWe aim to meet the strict requirements for both productivity and processing speed, as well as energy efficiency, so we can be the most competitive over time.fl 2Over 100,000 bottles per hour, equivalent to a potential of 400 million per year, distributed in 25 countries, from Belgium to Russia, from the United States to Australia, from New Zealand to Japan and from China to Kuwait. This is Tavina, a bottling company for four mineral waters, Tavina, Linda, Allegra and Novella, who made automation 4.0 their own in a new plant in Salo (BS). The water that ˜ows from the ancient glacial basin of the Lombardy foothills, inside the Natural Park of Alto Garda, then ˜ows into a highly automated process. It is put into bottles (PET or glass), which are molded, labeled, packaged and stored in an automated warehouse ready to be dispatched all over the world. The two new automatic bottling lines, which were designed and produced by Sacmi Filling, a Sacmi Group company, are PET leaders. Key to achieving these results was the use of the Danfoss VLT® AutomationDrive FC 302 and the high-e˚ciency VLT® OneGearDrives installed at the end of the line. Sacmi Filling technicians have used the technological combination, known as the VLT® FlexConcept , to the best of its abilities for the planned objectives. Bottling is more competitive if it is sensorless Maximum-level efficiency fiThere are two twin bottling lines Œ explained Frosi Œ and they are interchangeable. One is for the production of 0.5 L bottles and the other is for 1.5 L bottles.fl The journey begins with the initial separate sourcing of caps and preforms, which then ˜ow into the blower (that transforms the preforms into bottles) and ˛nally go to the ˛ller and capping machine. The next step involves the labeling of every single bottle before proceeding to the transport system. At this point, there is a split along a bu˝er. fiOnce the bottles have left the labeling machine Œ continued Frosi Œ they are sorted into alternate groups down two contiguous channels. These ˜ows are then spaced out and distributed onto various pathways, where the bottles are ready to be put into bundles for ˚nal packaging.fl By following the path of the bottles, the other 40 VLT® OneGearDrives (per line) meet, that is to say highly e˚cient permanent magnet, three-phase synchronous motors (equal to 96%, superior to the IE4 standard), combined with optimized bevel gear boxes that help to improve plant productivity and reduce energy costs. To satisfy the demand for higher productivity and energy efficiency, Sacmi Filling chose the Danfoss VLT® FlexConcept drive system for the high-performance and optimized management of new bottling lines designed and installed at the new headquarters of the Brescian company, Fonte Tavina. This system has added value thanks to its almost non-existent use of sensors and/or photocells, thus guaranteeing long-lasting services.
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fiWith only one motor type and three available gear ratios available,fl explained Fabio Galletti, Sales Account Manager Danfoss Drives, expert in the Food & Beverage sector, and Emilia Romagna, Sacmi Filling client administrator, fithis product covers all typical versions of conveyor drives commonly used in the food and beverage industry.fl 3The reduced range of the physical con˛gurations for these drives slashes costs and simpli˛es spare-part storage. Uniform mechanical dimensions reduce engineering and installation time and costs. The drive comes in two versions: Standard for dry and humid production areas (like the Fonte Tavina success case); Hygienic for humid and aseptic environments that require intense cleansing and sterile production areas. fiFurthermore,fl added Galletti, fithe design that characterizes these gear motors allows them to be joined, head to head, without mechanical interference, as their diameter is only 76 mm and they are reversible.fl Parallel bottling lines Flexible and modular for versatile, high-performance control As previously highlighted, each line is equipped with 40 VLT® OneGearDrives positioned along the transport system. Likewise, these correspond to the Danfoss VLT® AutomationDrives, which are suitably positioned in the automation cabinet. They were designed for variable speed control of all asynchronous motors and permanent magnet motors, both with closed and open loop (the latter have been chosen and adopted by Sacmi Filling speci˛cally for this application), and to increase the ˜exibility and
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4fiWhen we chose to use VLT® OneGearDrives,fl added Frosi, fithis was undoubtedly something di˛erent in terms of the technology, as it provides both high energy savings and increases the corresponding sensorless system™s performance, which was fully developed by us.fl The sensorless system, used by the Sacmi Filling technical team, has the capacity to manage almost all bottling lines without using control sensors and/or photocells, and can be used in a conventional manner for these applications. This was made possible thanks to a synergetic mix between Sacmi Filling know-how and skills, along with the services provided by the Danfoss VLT® FlexConcept drive system. optimize the control of processes on any industrial machine or production line. The robust structure guarantees maximum functioning time. The items are also ˛tted with a large range of the sector™s standard characteristics, which can be expanded with other fiplug- and-playfl options. The user-friendly and quick-use graphical control panel ensures the drive is easy to set up and operate, also saving commissioning and operating costs. These drives are used in Tavina, not just for the transport system, in combination with gear motors, but also to optimize the control of the process of various machines in the line. For example, on the blower, in the ˛ller, on the mixer, for the labeling machine and, partially, on the palletizers, where there are no axis controls. fiThe application of the sensorless system,fl added Frosi, fiwas made possible thanks to the accurate and timely feedback from the VLT® OneGearDrive permanent magnet motors, with respect to current absorption and torque. This information, interpolated from our control algorithm, based on the calculation of the current and torque that the motor is absorbing in certain conditions, allows for optimized process management by facilitating maximum productivity. The information also facilitated the layout during the device design phase.fl Moreover, the system, for example, is authorized to control the entrance of the bottles into the shrink wrapper in a limited space of no more than three linear meters, where, normally, it would be necessary to have almost triple the distance for the bottles to be fed in a correct, homogeneous and balanced process.
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5HMI for transporter automation where Sacmi replicated the LCP programming of the frequency converters to potentially modify the parameters of each device without needing to open the electrical cabinet. Distributed, constant and continuous performance fiIt was certainly a huge challenge to be able to compress the layout in this manner, without a sensor or photocell to restore information required for the process, such as the number of containers at that line section,fl underlined Frosi. The operational approach is carried out both on the transport section of the unpackaged bottles and on the entire conveyor section of the packages that are ready. The evolved automation system that Sacmi Filling was able to implement, thanks to the Danfoss VLT® FlexConcept drive system, not only avoided the direct use of sensors and related wiring, but provided even more signi˛cant added value with respect to competitiveness. Bottling line for the production of 1.5 L bottles >89 %global system output
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6The Danfoss VLT® AutomationDrives, with suitable dimensions for the requirements of the transporter type installed on the cabinet, are designed to control the variable speed of all permanent magnet synchronous reluctance motors and made to increase flexibility and optimize the process control for any industrial machine or production line. fiThe sensorless systemfl Œ observed Frosi Œ figuarantees services that are equivalent, if not superior, to those obtained by managing ˜ows in a more conventional manner, using sensors and photocells. There is added value in the ability to guarantee maximum e˝ciency and continuity for the services provided. Indeed, you no longer need to deal with sensors and photocells that require maintenance and, if you accidentally tamper with or decalibrate them, you can signi˚cantly damage the process and create ine˝ciency. Especially on complex lines, for example, in the bottling industry.fl As there had been requirements for a ˛eld inverter rather than a panel inverter at the end of the line, Danfoss provided the VLT® Decentral Drive FCD 302 frequency converters to be positioned near the motor, thus eliminating the need for long cables. fiThis option,fl explained Galletti, fidoes not require any change to control and management communications. This means the system is modular and will remain so for future operational integrations or new devices, and it always maintains its global output (Drive+motor+gearbox) that is greater than 89%.fl Key automation 4.0 Other than the aforementioned Danfoss products, Sacmi Filling technicians also used other drives on these bottling lines, namely the VLT® Micro Drive FC 51, for the ˛nal part of the line, the palletization. At this stage, the wrapped bottle packages then go to shuttles, in a fully automated manner, are conveyed by the pallet to the storage warehouse (20-m high and able to store 11 thousand pallets) and are ready to be dispatched.
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© Copyright Danfoss Drives | 2018.06 ITDD.PC.712.A1.02 A better tomorrow is driven by drives Danfoss Drives is a world leader in variable speed control of electric motors. We offer you unparalleled competitive edge through quality, application-optimized products and a comprehensive range of product lifecycle services. You can rely on us to share your goals. Striving for the best possible performance in your applications is our focus. We achieve this by providing the innovative products and application know-how required to optimize efficiency, enhance usability, and reduce complexity. From supplying individual drive components to planning and delivering complete drive systems; our experts are ready to support you all the way. You will find it easy to do business with us. Online, and locally in more than 50 countries, our experts are never far away, reacting fast when you need them.You gain the benefit of decades of experience, since 1968. Our low voltage and medium voltage AC drives are used with all major motor brands and technologies in power sizes from small to large. VACON® drives combine innovation and high durability for the sustainable industries of tomorrow. For long lifetime, top performance, and full-throttle process throughput, equip your demanding process industries and marine applications with VACON® single or system drives. Marine and Offshore Oil and Gas Metals Mining and Minerals Pulp and Paper Energy Elevators and Escalators Chemical Other heavy-duty industries VLT® drives play a key role in rapid urbanization through an uninterrupted cold chain, fresh food supply, building comfort, clean water and environmental protection. Outmaneuvering other precision drives, they excel, with remarkable fit, functionality and diverse connectivity. Food and Beverage Water and Wastewater HVAC Refrigeration Material Handling Textile
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