Asia CanTech Bangkok, October

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Emory Parks
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1 Asia CanTech 2014 Bangkok, October

2 TCO of Air Compressors and Vacuum Pumps Daniel Hilfiker Pneumofore - Italy

3 Total Cost of Ownership TCO = Purchase Price + Operational Cost + Maintenance Cost + Repair Cost the approach of modern industry with future-oriented and green criteria

5 rotary vane technology for vacuum pumps and air compressors since

6 1975 Pneumofore for O-I Italy

7 Basics About 50% of the electrical power consumption in a Can Factory is for compressed air and vacuum. A proper setup of the pneumatic systems avoids countless problems in Production. Most important is the correct choice of the air compressors and vacuum pumps. Daniel Hilfiker

A proper setup of the pneumatic systems avoids countless problems in

8 Can Production Round-the-clock Production 24/7 Sequential Process Continious availabilty of Vacuum and Compressed Air One single Process down means all Production is down Daniel Hilfiker

9 Requirements for pumps and compressors durable and reliable design for continious operation easy and fast maintenance high efficiency - low power consumption Daniel Hilfiker

12 1 Coil Coil of aluminium or steel (raw material for cans) 2 Cupping press Stamp discs to be stretched 3 Wall ironers The ironing process reduces the thickness of cans 4 Trimmer The process removes the irregular edge of cans 5 Washing Washing by means of deionised water before coating 6 External coater Coating and base colouring of external cans wall 7 Oven External drying base colouring of cans wall 8 Decorator Decorating of external cans wall with brand design 9 Rim coater Vanishing of cans bottom 10 Internal coating Coating of internal parts of cans 11 Internal drying Drying of internal parts of cans 12 Necker/Flanger Reducing and flanging of can neck

13 Case Study with ROI calculation Return on Investment Analysis of the present system and comparison with rotary vane pumps and compressors Measure electrical consumption instead of Catalog data Consider all costs: manpower for service, consumable spare parts, cooling water cost, water integration. Daniel Hilfiker

electrical consumption instead of Catalog data Consider all costs: manpower

14 Case 1 with 3 x Liquid Ring Pumps Vacuum 150 mbar(a) - real capacity is 2601 m 3 /h Measured 3 x Pumps Power Consumption is 183 kw Cooling Water Temperature is 30 C Cooling Water Tower - Power Consumption is 12 kw 8000 hours/year 1 kwh costs 3,13 THB (0,078 Euro) 1 m 3 of water costs 13,6 THB (0,34 Euro) Manpower costs 200 THB/hour (5 Euro) Total cost / year is THB ( Euro)

Consumption is 12 kw 8000 hours/year 1 kwh costs 3,13 THB (0,078 Euro) 1 m 3 of water costs 13,6

15 Case 1 - ROI calculation Pneumofore UV30 + UV30 VS in HC version Vacuum 150 mbar(a) - real capacity is 2888 m 3 /h Measured 2 x Pumps total Power Consumption is 67 kw Air Cooling for Hot Climate up to 55 C 8000 hours/year - 1 kwh costs 3,13 THB (0,078 Euro) Manpower costs 200 THB/hour (5 Euro) Total Cost / year THB ( Euro) vs THB ( Euro) of Liquid ring! List price of 2 x UV30 rotary vane is THB ( Euro)

kwh costs 3,13 THB (0,078 Euro) Manpower costs 200 THB/hour (5 Euro) Total Cost / year 1.700.000 THB (42.

16 Case 1 with 3 x Liquid Ring Pumps Results Savings / year minus Euro = Euro With Pneumofore 2 x UV30 cost of Euro ROI is : = 1,57 years Short ROI + more capacity (2601 vs m 3 /h) + Variable Speed Drive for constant vacuum level If replacement with 1 x Pneumofore UV50 HC, the result of ROI is 1,06 years

663 = 1,57 years Short ROI + more capacity (2601 vs.

17 Case 2 with 2 x Screw Pumps details: Vacuum 150 mbar(a) - real capacity is 1960 m 3 /h Measured 2 x Pumps Power Consumption is 122 kw Cooling Water Tower, water pumps - Power is 40 kw 8000 hours/year 1 kwh costs 3,13 THB (0,078 Euro) 1 m 3 of water costs 13,6 THB (0,34 Euro) Manpower costs 200 THB/hour (5 Euro) Total cost / year is Euro

Power is 40 kw 8000 hours/year 1 kwh costs 3,13 THB (0,078 Euro) 1 m 3 of water costs

18 Case 2 - ROI calculation Pneumofore UV50 VS90 HC vs. 2 x screw pumps Vacuum 150 mbar(a) - real capacity is 2061 m 3 /h UV50 VS90 HC total Power Consumption is 48 kw 8000 hours/year - 1 kwh costs 3,13 THB (0,078 Euro) Manpower costs 200 THB/hour (5 Euro) Total Cost / year vs Euro of Screw! List price of 1 x UV50 VS90 rotary vane is Euro ROI is : ( ) = 1,23 years

Consumption is 48 kw 8000 hours/year - 1 kwh costs 3,13 THB (0,078 Euro) Manpower costs 200 THB/hour

20 'Cost Savings on Compressors and Pumps' overhauling of a 40 years old rotary vane compressor Daniel Hilfiker

21 1975 Pneumofore for O-I Italy

22 Options and features of our compressors and vacuum pumps. Machines ready to use. Electro - pneumatic control as standard. Electronic, digital, remote control as option. Simple ordinary maintenance. Highest efficiency. Easy repair / overhaul. Variable Speed for constant pressure / vacuum. Hot Climate version for air cooling up to 55 C. Heat Recovery systems. Lowest Total Cost of Ownership or Life Cycle Cost Daniel Hilfiker

23 'Cost Savings on Compressors and Pumps' Daniel Hilfiker

24 Summary Rotary vane technology for compressed air and vacuum based on 90 years of experience High capacity, high efficiency, air cooling up to 55 C. Important cost savings, replacement of screw and liquid ring machines with ROI of as low as 18 months Daniel Hilfiker

25 Thank you for your attention Daniel Hilfiker

REGULATORS 175/153 Series

REGULATORS 175/153 Series 175/153 Series 175 HEATING 153 COOLING Watson McDaniel reserves the right to change the designs and/or materials of its products without notice. 2002 Watson McDaniel Company Revised 7/2002 175 / 153 Screwed