PC-JUN09-PGS16.OK:PC-JUN09-PGS16.OK.qxd 05/06/2009 12:50 Page S16
Focus Food processing & packaging
Air management generates energy savings
Precise caramel control for biscuit maker
Problem: One of the world’s largest Problem: Throughput speed of the pro- or slowing down in synchronism.
snack food plants needed help in duction line for Rocky chocolate bars at “The new system is much more opera-
achieving its target of a 10% reduc- Fox’s Biscuits’ Kirkham plant was limited tor friendly,” said line manager Stephen
tion in overall energy usage. by the caramel depositing station which Acker. “Much of the jargon has been
Solution: An EnergAir com- needed upgrading. taken out and pictorial representation of
pressed air management system Solution: Depositing systems company the line makes it easier and quicker to
combines the supply for two pro- Wymbs Engineering has supplied a pres- access information, diagnostics and new
duction operations on one site, surised multi-head manifold with 2-axis set-ups for a different product. Our down-
integrating two retrofit variable movement and fed by metered pump, time has reduced – it takes a matter of
speed drives, reducing system which has increased throughput. Three minutes to change the manifold and
pressure and fine tuning com- variations of Rocky bars, chocolate, select a new ‘recipe’ on the HMI – and
pressor usage. Energy bills have control included on both sites is caramel and orange, and several ‘own waste is kept under control.”
been reduced by £27,000pa. an EnergAir SX control unit – a brand’ biscuits for retail chains, can now Control Techniques
Energy savings were achieved specialised supervisory and con- all be produced on this one line. T: 01686 612900 Enter 241
by applying a combination of trol module designed to provide The precision control of the depositing www.controltechniques.com
system pressure optimisation optimised pressure and sequence manifold and the metering pumps is the
principles, matching air genera- management of all the air com- duty of four Control Techniques Unidrive
tion closely to demand, ensuring pressors on each site. SP 2.2kW AC drives operating in servo-
compressors work at their opti- There are seven compressors mode and working in conjunction with
mum speed/efficiency, and oper- on site: three 160kW units and Control Techniques FM servo-motors with
ating compressors only when four 200kW with production run- resolver feedback.
needed. The central element of ning 24 hours a day. Based on the Two control the manifold positioning,
overall cost of installing the one the dispensing pump into the mani-
system balanced against the fold and the fourth, a separate pump that
reduction in energy that could be dispenses caramel into ‘tote’ bins for
achieved, the payback period transfer to other production plants.
was estimated at 18 months for The first of the drives is designated a
the entire project. This payback ‘master’ and is fitted with a second encoder
period was achieved module for the feedback from the conveyor
EnergAir Solutions shaft encoder. The whole depositor system
T: 01932 343638 Enter 240 is geared to actual line speed, speeding up
www.energair.co.uk
Transferring · emptying · circulating · mixing · dosing
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ENGINEERING SERVICES
Enter 110 Enter 111
S16 JUNE 2009 Process & Control
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