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22 PRODUCTS & SERVICES


Variable drive saves costs on paper waste baler


A


UK cardboard packaging manufacturer is said to halved the


electricity costs of running a baler machine following the installation of an ABB variable- speed drive. Smurfit Kappa’s Northampton


plant produces fibre-based packaging such as trays for fruit and vegetables, fresh produce boxes and retail-ready packaging. The hydraulic baler is used to compact offcuts from the company’s cardboard processing lines into large bales ready for transport to a recycling plant. The company wanted to


improve the energy efficiency of the baler, which uses a motor- driven pump to compress the hydraulic fluid. When hydraulic pressure reached the set point, excess fluid was bled through a pressure relief valve, and with the motor running at a fixed speed this represented wasted energy. The motor’s constant use also


generated high temperatures so Smurfit Kappa had to install an additional motor-driven fan to keep it cool, also adding to the running costs. Smurfit Kappa’s energy and


environment chief Chris Sims asked ABB Drives Alliance member Inverter Drive Systems (IDS) to look at the energy saving potential of the application. Says Sims: “We originally selected IDS through a third party who had recommended the company for energy saving projects in different areas. IDS had already installed or modified some motors on other applications, so


July 2013


Pulp Paper & Logistics


I invited them to look for more energy saving opportunities.” Smurfit Kappa and IDS monitored the energy use of the baler. Investigations showed that the measured power consumption was 11.1 kW and the baler ran for 6,336 hours in a year. At an energy cost of 8p/ kWhr, this gave a total running cost of the baler of £5,626 ($8,586). IDS installed a 30 kW ABB


general purpose drive, ACS550, as well a pressure transducer. Said Andy Crocker of IDS: “The pressure transducer gives a 4-20 mA output that is proportional to the pressure. On the drive, we have the set point at just below


the valve opening pressure. When the hydraulic ram is moving and fluid is therefore flowing, pressure drops, so the drive speeds up the motor to maintain pressure. When the ram is not moving, pressure rises so the drive slows the motor.” This arrangement means the


drive can always give the pressure and flow needed without opening the relief valve and wasting the pressure in the fluid. Following installation of the


variable-speed drive, which took less than a day to complete, the power consumption was measured again and shown to be 5.6 kW. This gave a reduced energy cost of £2,838 ($4,330) a


year, a saving of £2,788 ($4,255), with a payback time of just over 17 months. Adds Sims: “As well as the


energy saving aspect, there has also been a reduction in noise from the application and the motor now also operates at a lower temperature. IDS were also very professional in their installation procedures and worked around our production times to minimise disruption.” More information from Neil


Ritchie, ABB Ltd, Discrete Automation & Motion. Tel: 44 1925 741 111. Fax: 44 1925 741 212. e-mail: energy@gb.abb. com. Web: www.abb.co.uk/ energy


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