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SEW-EURODRIVE has modernised the PET transport line for Coca-Cola Hellenic in Vienna, reducing energy use by 75%
educing energy consumption is one of the most important requirements today when mod- ernising machines and systems. Often, there is great potential for saving energy – which, in the end, means saving money. While retrofitting a transportation system, Vienna-based Coca-Cola Hellenic Austria used the MOVIGEAR mechatronic drive system from SEW-EURODRIVE. This reduced energy consumption by 75%, which is equivalent to an
annual reduction of 41 tons of CO2. Even Controlling is pleased: the pay- back time is less than one year. Coca-Cola Hellenic is the licensed Coca-Cola in Austria.
bottler of
When the company decided to mod- ernise a transport line in its bottling plant in Vienna, reducing power
consumption and reducing CO2 emissions were the main priorities. Additional requirements included standardising the drive variants that are used in order to simplify the stocking of spare parts and facilitat- ing a fast restart of the system after the conversion. The final goal of the retrofit was to simplify maintenance. SEW-EURODRIVE and Coca-Cola Hellenic have long shared a close partnership which isn't just due to the fact that the companies are located near one another in Vienna. The companies have long engaged in regular business contact with one another regarding standard geared motors and frequency inverters. It was because of this that the SEW Vienna were able to recognise the numerous benefits that the mecha- tronic drive system would have to offer the client, Coca-Cola Hellenic. With detailed energy consumption calculations, SEW-EURODRIVE was able to show that the transport system could attain the highest level of energy efficiency using MOVIGEAR. SEW sector manager Tobias Nittel presented this innovative product to the customer in Austria. He explains: “The individual components may be a bit more expensive than the conventional solutions, however, these products provide the customer with clear additional advantages that quickly translate into financial benefits: lower energy consumption, reduced installa- tion costs, shorter startup times as well as simplified maintenance and diagnostics. MOVIGEAR offers clear advantages for the end customer. It is also easy to clean and saves on water
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Technology of the transport line In less than six months, the leaders of the beverage company managed to organise the changeover of their bever- age line – from filing the budget and taking care of the technical planning, all the way to fully utilising the narrow time window for the conversion. By the beginning of 2010, it was time: the company was ready to modernise transport line 2a. This line links the bottling plant for Coca-Cola, Fanta and Sprite to the palletising system via the packaging machine. PET bottles holding 0.5 to 2.5 litres are handled in this area. Previously, the line was driven by standard line-powered geared motors. As part of the mod- ernisation, the company replaced a total of 39 geared motors – some with inverters, but most without – as well as the controller for the drives.
PROFIBUS interface
Instead of using 24V switch contactor technology for line-powered motors, the company opted for PROFIBUS interfaces. This allows the operator to change the speed as required and adjust it precisely to suit the process. In addition, the PROFIBUS interface optimises the system's ability to shut down the line in case of a jam and minimises idle times. These measures result in a noticeable reduction in power consumption.
The PROFIBUS transmits the con- trol signals from the PLC to the drive and transmits cur- rent diagnostic and status signals from the drive to the controller. The use of PROFIBUS also offers com- pletely new diagnostic options. The operator now
Modernised bottle transfer line saves energy R
and cleaning products. This is an obvious advantage in a bottling plant.”
Vienna-based Coca-Cola Hellenic Austria used the MOVIGEAR
mechatronic drive system from SEW-EURODRIVE
has much more than an I/O display: the speed and current are displayed on a keypad, allowing the operator to check whether mechanical compo- nents are moving freely, and, should service be required, the fault type is displayed. Bus operation also allows the operator to record the current for general monitoring purposes and serves as an indicator of capacity utili- sation. From a service perspective, MOVIGEAR, in combination with PROFIBUS, offers a wide range of additional options.
Results With the MOVIGEAR system solution, power supply and communi- cation are handled using SNI technology (Single Line Network Installation). This allows energy and communication transfer in one shielded cable, thereby decreasing the number of components required while significantly reducing the installation cost. The actual mechani- cal conversion of the system took place over an extended weekend, from Friday morning to Sunday evening. In this short period of time, the old drives were disconnected and mechanically removed and the new drives were mechanically mounted, electrically installed and started up. On Monday morning, production started up again in the bottling plant. With the complete system solution, Coca-Cola Hellenic Austria was able to reduce the power consumption of the transport line by a sensational 75% (in comparison with the technology previously in use). This means that the investment pays for itself in less than one year. Extrapolated from a five-day measurement of the amount of energy consumed, the new system will generate an estimated savings of 41 tons of CO2 annually.
Thanks to these amazing results, upon the start of the new application, SEW-EURODRIVE received another contract for a second transport line for PET bottles with soft drinks. Nittel explains: “By now, SEW- EURODRIVE has plenty of experience retrofitting existing systems. Our customer, Coca-Cola Hellenic, recog- nised how important energy-efficient drives are for the company and is so confident about SEW drive technology that the Coca Cola Hellenic now specifies MOVIGEAR as the drive system of choice in its calls for bids to system designers.”
SEW-EURODRIVE
www.sew-eurodrive.co.uk MARCH 2011 Design Solutions Enter 206
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