vacon case study. optimized vacuum pump operation at glass bottle plants

VACON CASE STUDY OPTIMIZED VACUUM PUMP OPERATION

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Photo courtesy of STX EuropePHOTO BY PNEUMOFORE

OPTIMIZED VACUUM PUMP OPERATION AT GLASS BOTTLE PLANTS

CLIENT NAMES: Pneumofore, Hindustan National Glass IndustriesSEGMENT: Glass bottle and container manufacturingPRODUCTS USED: VACON® NXP, VACON® MULTIMASTERLOCATION: HNGI’s new plants in India


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KEY FACTS OF CLIENTS:• Pneumofore in Rivoli (TO), Italy, provides solutions for industrial vacuum and compressed air applications around the world.• With a 65% share of the Indian market, Hindustan National Glass Industries (HNGI) is the largest manufacturer of glass bottles and containers in the country, and is also aiming to become a global industry leader.


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CHALLENGE:• HNGI decided to utilize vacuum pump technology at the new production lines in Nashik in Maharashtra and in Naidupeta in Andhra Pradesh.• Both contain six production lines with twelve sections, with each line capable of producing thousands of bottles a minute. • HNGI wanted the twelve production lines at the Nashik and Naidupeta plants to have: • sufficient vacuum levels required for high speed and precise molding of hollow glass containers • automatically adjustable production capacities.


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SOLUTION:• Pneumofore decided to install six UV50 VS90 vacuum pumps, each driven by a 90 kW motor operating at variable speed. • The VACON NXP AC drives controlling the pump motors enable the rotational speed to vary between 950 and 1750 rev/ min and the flow rate between 1890 and 3240 m3/h.• The VACON NXP AC drives permit optimized power consumption according to changing needs, depending on the rate of production, number of personnel working or seasonal changes. • Operating at lower revolutions reduces energy consumption.


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SOLUTION:• Reduced wear on the moving mechanical parts results in less need for maintenance and extends the life of the vacuum pumps. • The VACON NXP drives help keep the pressure constant, which is essential for consistent quality and strength in the glass bottles and containers. • VACON Multimaster, special software to improve reliability and efficiency, keeps as many vacuum pumps as possible at their optimum operating point and enables the pumps to alternate to balance the working hours and load.

PHOTO BY BOTTERO S.P.A.


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SOLUTION:• The VACON NXP drives in the vacuum pump system communicate with each other and are able to judge how many pumps are needed at any particular time and the speed the pumps should operate at, and notice if there is a fault in one of the motors, pumps or AC drives. • If the demand exceeds the maximum capacity of the leading pump and more capacity is needed, auxiliary pumps are connected as required. The leading pump and the auxiliary pumps run in parallel, which saves energy and reduces wear on the pumps.


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TESTIMONIAL:“The vacuum pump systems react within a few seconds to changes in production. It normally takes much longer for changes to be activated. The VACON NXP with the VACON Multimaster software provided the best possible solution to the needs of this application. In Vacon we found a partner with whom we can make changes to the software to make it more efficient in a specific application. This approach would have been difficult with other AC drive suppliers.”

Mauro Ferrero, Commercial Director, Pneumofore

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vacon case study. optimized vacuum pump operation at glass bottle plants

Engineering