Asia CanTech 2014 Bangkok, 27-29 October
TCO of Air Compressors and Vacuum Pumps Daniel Hilfiker Pneumofore - Italy
Total Cost of Ownership TCO = Purchase Price + Operational Cost + Maintenance Cost + Repair Cost the approach of modern industry with future-oriented and green criteria
rotary vane technology for vacuum pumps and air compressors since 1923 www.pneumofore.com
1975 Pneumofore for O-I Italy
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
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
Requirements for pumps and compressors durable and reliable design for continious operation easy and fast maintenance high efficiency - low power consumption Daniel Hilfiker
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
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
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 4.885.920 THB (122.148 Euro)
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 1.700.000 THB (42.486 Euro) vs. 4.885.920 THB (122.148 Euro) of Liquid ring! List price of 2 x UV30 rotary vane is 5.000.000 THB (125.150 Euro)
Case 1 with 3 x Liquid Ring Pumps Results Savings / year 122.148 minus 42.486 Euro = 79.663 Euro With Pneumofore 2 x UV30 cost of 125.150 Euro ROI is 125.150 : 79.663 = 1,57 years Short ROI + more capacity (2601 vs. 2888 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
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 106.981 Euro
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 30.593 vs. 106.981 Euro of Screw! List price of 1 x UV50 VS90 rotary vane is 94.160 Euro ROI is 94.160 : (106.981-30.593) = 1,23 years
'Cost Savings on Compressors and Pumps' overhauling of a 40 years old rotary vane compressor Daniel Hilfiker
1975 Pneumofore for O-I Italy
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
'Cost Savings on Compressors and Pumps' Daniel Hilfiker
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
Thank you for your attention www.pneumofore.com Daniel Hilfiker