Application webinar:

Forming & Shaping

Container Glass
Global Applications
 Glass bottles/containers manufacturing

1. The process & Industry overview (Alessandro & Vignesh)

2. Vacuum applicaiton & Plant overview (Alessandro)

3. Pitfalls (Daniel)

4. Roadmap to a succesfull installation (Wolfgang)

5. Atlas Copco Set-Up (Yuri)

6. Customer Stories and Sales experience (Vignesh)

2
Manufacturing process & Industry
Glass Industry overview
• Before COVID overview
– Glass Packaging Market Size was worth over USD 45 billion in 2016.
– The industry will grow by a CAGR of about 4.5% up to 2024.

• This Industry growth expectations are still looks promising, even after COVID

4
Glass containers manufacturing process

IS Machine (vacuum)

5
Glass forming methods
Forming & Shaping from IS machines
Individual section (IS) machine is separated into varying sections to
produce several containers of the same size simultaneously. The molten
glass is cut with a shearing blade into a specific gob size. The gob falls into
the machine by force of gravity down into the mold, where it starts to take
shape and become a parison. The parison is then flipped 180 in a second
mold to finish off the dimensions of the glass.

Blow and Blow

The Blow and Blow process is used to create narrow
Narrow Neck
containers.. The parison is created by using compressed
(Bottle)
air to form the neck finish and basic bottle shape

The Press and Blow process is the most commonly used

Push and Blow
method in wide mouth bottles and jars manufacturing. A
Wide Neck
metal plunger is used to push the gob down into the
(Jar)
mold, where it starts to take shape and become a parison.
The parison is then transferred into the blow mold to
finish off the dimensions of the glass.
6
Glass containers final shape
The aid of vacuum in process cycle

 Compressed air 3.5 - 7bar is used to force glass gobs into the shape of
moulds

 Vacuum is also applied through small holes in the walls of the mould
– Vacuum makes faster moulding, quicker cooling and sharper final dimensions,
better dimensional control allows thinner bottles = lighter product, less raw
material.
– Vacuum also lowers compressed air requirement by 80% reducing total energy
cost.

Increased productivity, Improved product quality, lower energy, lower material useage

7
Glass bottle making Process
A Short Video

8
Global OEM for IS machines
Glass forming machine manufactures

USA

Italy

Germany IS Machines:

“Individual Section”
Czech Or
“Independent Section”

Italy

9
END customers
Glass bottles manufacturers
 Vacuum application and plant overview

11
Glass containers manufacturing process
Vacuum requirement
• Moulds are divided in two half that are closed and rapidly evacuated by
equalization with a Vacuum network through very small holes in the
mould (0.4 mm) resulting in almost constant flow demand at vacuum
pump.
• Vacuum level between 150 and 300 mbar depending on manufacturer
and type of product.
• The vacuum requirement of each section of IS Machine varies from
type of machine and type of product between 100 and 250 m3/h flow.
• A standard IS machine may require from 600 to 1500 m3/h. But very
large ones can require up to 4000 m3/h.

Sizing requirement is given by OEM, but always check actual

vacuum level in existing installations.

12
Plant overview
Customer information
A production site capable of 1M bottles/day can
have up to 5 production lines lined up to give
continuous production 24/7.
A typical layout = IS machine connected through
DN100 lines to a vacuum network with following
characteristics:
- Main manifold can be DN200 or even bigger.
- Plants can have a buffer tank (1).
- A filtration system (2) required to protect the
pumps.
- Vacuum pumps system (3) is designed with
redundancy to grant 24/7 operation.

13
The vacuum system
How utility room will look like

14
Problematics and Pitfalls
Problematics for vacuum system and pitfalls
Best installation practices towards filtration

• Typical Contamination from process:

– Glass particles
– Kleenmold oil release agent used in mould (carbon/graphite based lubricant)

• Pitfalls
– Unexpected events as production machine breaks which lead to excessive vacuum pipe contamination
– Age of the machines or of built in filtration
– Type and quantity of the Kleenmold oil used => local process engineering projects
– Pipeline layout & sizing
– Filter sizing and draining practices
Pitfalls ?
What happens in case of an
Some of the problems encountered so far. excessive contamination of
the vacuum line because of a
machine break

• Piping from 2 plants and in

• Doulton filter in vacuum line after total 12 lines come together at
each glass forming machine vacuum room inlet pipe
• Only cleaned ones a year because • High gas velocity and no pre-
of high production load filtration
• Result = of no use • High load to Solberg filters

17
Pitfalls ?
What happens when I just
Some of the problems encountered so far. open the valve underneath
the LRS filter in order to drain

• No goose neck pipe connection

between filter outlet and pump • LRS draining was never done
inlet • Customer was not instructed
• Position of the filter on top of the how to drain
pump • Position and connection of
• Any residual oil will go straight in filter to pump is not OK
the pumps inlet.

18
 Expressway to the oil party
Hey you
are also
on the
party ?
Yeah, sure. It
was really
easy to get in
here

Who takes the detour when the direct route is so quick and easy ?

19
 Why oil contamination must be avoided
Process oil is entrained, saturates filters and contaminates the vacuum pumps

• The Kleenmold oil is not compatible with our pump Graphite 1.5 to 2.5 %
oil which will lead to excessive oil consumption and Sulfur 4.0 to 5.0 %
cooling and lubrication issues. Petroleum Oil 70 to 80 %
Additives 20 to 30%
• Vacuum pump oil filters clog and cause
temperature problems with downtime
• The graphite added for the lubrication of the glass
machines leads to higher wear in the vacuum
pumps
• Shorter service intervals = higher costs
• The saturation of the inlet filter causes high
pressure drops
• The pump will consume more power to achieve the
desired pressure = more costs

20
Party is over, the runway is closed
Hey, were
are the
other
guys?

I don’t know
…heard that
they stuck in
a detour

21
Roadmap to a successful installation
Pre-separation as part of the problem solution
Droplet separation by gravity
Droplet separation with demister or wire mesh
How can we eliminate oil mist from gas flow?
The use of a buffer tank as pre-separation by gravity

Separator type Limit drops (down to size of ) Pressure drop

Micron mbar
Gravity 300-400 <1
Wire mesh 5-10 1-2
Vertical lamella separators 30-40 1
Horizontal lamella separators 10-30 2-10
Ultrafine fiber 1-3 5-50
Swirl Separator 50-100 6-15
Cyclone 30-50 10-50

23
Besides effective filtration, pre-separation is essential !
The importance of the correct filtration system with demister

Separator type Limit drops (down to size of ) Pressure drop

Micron mbar
Gravity 300-400 <1
Wire mesh / demister 5-10 1-2
Vertical lamella separators 30-40 1
Horizontal lamella separators 10-30 2-10
Ultrafine fiber 1-3 5-50
Swirl Separator 50-100 6-15
Cyclone 30-50 10-50

24
Roadmap to a successful installation
Pre-separation as part of the problem solution
Droplet separation by gravity
Filtration with demister or wire mesh
 Gas velocity is an important factor
A mist is a group of droplets of different sizes travelling with the gas flow

The gas velocity “WG” [m/s] does not depend on vacuum

level and can be calculated from the volumetric gas flow
“VG” [Am³/s] and the section of the pipe/vessel

𝑉𝑉𝐺𝐺
𝑤𝑤𝐺𝐺 =

droplet
𝐹𝐹𝐺𝐺

26
 Gas velocity is an important factor
The role of gravity
Outlet

• The velocity of the gas determines residence time

of the gas in the buffer tank
• Gravity causes the drop to fall against the gas flow
L
forces and determines the time the droplet need to hgas
fall to the bottom of the buffer tank Inlet

• For oil-drop separation of drops larger than 400

microns in the buffer, the residence time of the gas
in the buffer must be longer than the required drop
fall time for the drop height.
L = the distance the gas has to pass from the inlet to the outlet

hgas = the distance the droplet has to fall to the liquid level
in a shorter time than the gas passes the separator

27
Sizing an buffer tank as gravity separator
The permissible flow velocity in mist eliminators (here buffer) are determined as follows

• wzul Permissible flow velocity (m/s)

• K (Cunningham Correction factor)
– Vertical gravity separators without internals 
K ≈ 0,033–0,05

• Density fluid kg/m³

The calculation determines how fast [m/s] a gas-load is allowed
• Density gas kg/m³
to pass a buffer, acting as gravity separator !
• The design velocity wAusl should be 75 % 
wAusl = 0.75 * wzul

28
For separation of droplets larger than 400 microns The deeper
the vacuum
the higher
The gas velocity in the buffer should be less than 2m/s (red line) is the
allowed gas
Permisable gas velocity in a gravity seperator velocity
12,00 0,70

0,60
10,00

0,50
permissable gas velocity m/s

8,00

gas density kg/m³

0,40

6,00

0,30

4,00
0,20

2,00
0,10

0,00 0,00
10 50 250
Pressure mbar(a)

29
 Gas velocity is an important factor
Important parameters are flow cross section FG, the length L and gas height hgas FG = 𝐴𝐴 = 𝜋𝜋𝑟𝑟 2
𝜋𝜋
= D²
4
Using the formula we can check correct size of buffer tank

𝑉𝑉𝐺𝐺
𝑤𝑤𝐺𝐺 = L D

𝐹𝐹𝐺𝐺
hgas

• The diameter “D” of the buffer is important to calculate

the flow cross section “FG” [m²]
• The distance of the buffer tank inlet to outlet “L” is
important
• The gas high “hgas” is important to calculate the droplet
falling time

30
 The time needed for the droplet to fall < gas residence time
Time for the droplets to settle down on the liquid Reservoir
∏ Pi 3,142
D Separator diameter (m) 1,4
L Separator length (m) 1,9
h Gas height in the separator (m) 2,1
fG Cross section share for gas flow =FG/Fges 1
FG Flow cross section for the gas flow (m²) 1,539
Fges Total cross-sectional area of the separator (m²) 1,539
VG Gas load (m³/h) 6000
wG Gas flow velocity (m/s) 1,083
wzul Permissible flow velocity (m/s) 1,686 L hgas
wFall Droplet fall velocity (m/s) 1,8
tFall Droplet fall time (s) 1,167
tresi residence time (s) 1,755
tzul Permissible residence time 1,127
K Cunningham Correction factor 0,04
Density fluid kg/m³ 800
Density Gas kg/m³ 0,45
wausl Design velocity (75% of wzul ) 1,265

Droplets bigger than 400micron will fall faster than

31
the gas passes the vessel and thus separated !
Using our buffer tank as pre-seperator
How to estimate the right size from the AC portfolio or if needed external

All needed figures can

be found on the
drawings

32
Comparison of gas residence time with mist droplet fall time
t residence > t fall
Vessel Volume Seperator length L actual speed (flow in Am³/h)
500 1000 1500 2000 3000 4000 5000 6000
actual speed (flow in Am³/s)
0,139 0,278 0,417 0,556 0,833 1,111 1,389 1,667
t residence [s]
8092 3003 45 270 0,97 1,541 0,770 0,514 0,385 0,257 0,193 0,154 0,128
8092 3003 52 500 0,75 1,847 0,924 0,616 0,462 0,308 0,231 0,185 0,154
8092 3003 60 1000 1,16 6,560 3,280 2,187 1,640 1,093 0,820 0,656 0,547
8092 3003 78 2000 0,86 8,863 4,432 2,954 2,216 1,477 1,108 0,886 0,739
8092 3003 86 3000 1,8 18,551 9,275 6,184 4,638 3,092 2,319 1,855 1,546

Vessel Volume Gas high actual speed (flow in Am³/h)

500 1000 1500 2000 3000 4000 5000 6000
droplet fall velocity in m/s
1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800
tfall droplet [s]
8092 3003 45 270 1,166 0,648 0,648 0,648 0,648 0,648 0,648 0,648 0,648
8092 3003 52 500 1,01 0,561 0,561 0,561 0,561 0,561 0,561 0,561 0,561
8092 3003 60 1000 1,37 0,761 0,761 0,761 0,761 0,761 0,761 0,761 0,761
8092 3003 78 2000 1,14 0,633 0,633 0,633 0,633 0,633 0,633 0,633 0,633
8092 3003 86 3000 2,08 1,156 1,156 1,156 1,156 1,156 1,156 1,156 1,156

33
 Using our buffer tank as pre-seperator
How to estimate the right size ? Gas velocity wG should be less than 2m/s (better with safety fact. 75%)

Vessel Volume Cross section [m²] actual speed (flow in Am³/h)

500 1000 1500 2000 3000 4000 5000 6000
actual speed (flow in Am³/s)
0,139 0,278 0,417 0,556 0,833 1,111 1,389 1,667
Part number Size gas velocity 𝑤𝑤𝑤𝑤 m/s
8092 3003 45 270 0,22 0,630 1,259 1,889 2,518 3,777 5,036 6,295 7,555
8092 3003 52 500 0,34 0,406 0,812 1,218 1,624 2,436 3,248 4,060 4,872
8092 3003 60 1000 0,79 0,177 0,354 0,531 0,707 1,061 1,415 1,768 2,122
8092 3003 78 2000 1,43 0,097 0,194 0,291 0,388 0,582 0,776 0,970 1,164
8092 3003 86 3000 1,43 0,097 0,194 0,291 0,388 0,582 0,776 0,970 1,164

Please also consider the dimensions of the inlet and outlet flange to avoid high pressure differences

34
Roadmap to a successful installation
Pre-separation as part of the problem solution
Droplet separation by gravity
Filtration with demister or wire mesh
Actions to improve the droplet separation
Introduce a wire mesh or demister pad

• For improved droplet separation at higher gas flow

velocities separation aids are used
• The most cost-effective and relatively efficient
measure is the use of an demister mesh
– The most common type of separator is a knitted wire
mesh package made of wires with 0.1-0.28 mm
diameter is inserted.
– The packages have a depth of 100-300 mm.
– The knitted wire mesh separator is particularly
suitable for separating small drops in the range 5-10
μm.
– Also demister is sized based on a max. permissible
flow velocity (around 6 m/s)

36
Actions to improve the droplet separation
Introduce a wire mesh or demister pad

Smaller droplets are caught

in the Demister Pad and
combined to larger droplets,
which are then separated by
gravity
37
BEST FIT FOR THE DEMISTER
Standard 3 stage filtration

• Step 1: Baffle plates

• 360 Deg C separation at inlet
• Gas loses kinetic energy and leaves solid items

• Step 2: SS 304 demister pad or SS Wire Mesh

• Droplets down to 3/5 micron are stopped

• Step 3: 1 micron Polyester filter

• Stops very small particles

38
Atlas Copco recommended set up

Installation is an important factor

Action plan
Step-by-step plan to optimize the current state

• Installation of a vacuum buffer

Reduce the flow velocity Significantly reduce the oil transfer into the pump

• The manifold should be as large as possible

(DN250 / DN300 recommended for large installations).

• All connections with goosenecks

In this type of installation, the manifold can still be used as a horizontal separator

• The SKP filter installed next to the pumps ( lower than the inlet of the pump)
Use the force of gravity for the oil separation and to guarantee regular controls of the separation
(Use 1 micron Element)

40
Layout considerations
Expansion tank to slow down the flow
• Check if main line already includes a “large” buffer tank.
• If not propose to install one in line to CVS pumps installation

41
Installation of a proper sized manifold with Gooseneck connections
The manifold should be leaked with a gradient to a drainage point
• Reduce risk of heavy oil load to filters and pumps

42
Proper installation of the filter
Filter installation
The filter purpose
Stop and collect all residual oil mist before the pump
Extend service intervals of the pumps.
The filter position
Below the pump*
With goose neck connection to the pump
Isolation valves and a bypass
Allow Service and cleaning of the filter
Keeping vacuum pump in operation **
*Oil will not evaporate
**Work without filtration for short period does not harm the pump

43
Filter Sizing
Based on environment considerations
Filter should be selected based on:
Velocity of the max flow through the pump @ 150/200 mbar
Inspecting real site conditions and installation
Contamination due to age of installation or type of oil used

Standard duty recommendation

• Install as a minimum the STD sized SKP with metal mesh or
demister in those installations with low oil contamination, a good
piping layout and separation tank.
Harsh duty recommendation
• We recommend to install a suitably sized SKP with Demister pad
and 1 µm polyester cartridge in those installations with high oil
contamination (old installation, poor pre filtration at machine).

44
 SKP When in doubt on an application?

Selection Do NOT contact Solberg DIRECT  Contact the Applications Team

Atlas Copco Part

Solberg Part Nr. Description Max Flow [m3/h] Harsh Applications (Glass,
Nr.

SKP-ACM510W5-DN80 8092302482 1 and 5 micron + mesh element max flow 510 NA

SKP-ACM670D5-DN100 8092302484 5 micron + 12" Demister Pad max flow 670

For GHS350 , GHS585 and GHS730
SKP-ACM670D1-DN100 8092302485 1 micron + 12" Demister Pad max flow 670

SKP-ACM1175D5-DN150 8092302488 5 micron + 16" Demister Pad max flow 1175

For GHS 900
SKP-ACM1175D1-DN150 8092302489 1 micron + 16" Demister Pad max flow 1175

SKP-ACM1835D5-DN150* change 5 micron + 20" Demister Pad max flow 1835

For GHS1300, GHS1600, GHS1900 (Existing SKP200 with flanges DN150)
SKP-ACM1835D1-DN150* change 1 micron + 20" Demister Pad max flow 1835

SKP-DM30 485Z DN200* change 1 micron 30" demister 30" element 4000 for GHS3800 ( SKP30" demister with DN200 flange)

SKP-DM36 489Z DN200* change 36" vessel 36" demister max flow >5000 For GHS4600 and GHS5400 (SKP300 w DN200 flanges)

* = New

45
Proper Usage of the filter
Filter Service
• The Polyester filter
– Change-Out Differential: 10” to 15” / 250-380mm H2O Over Initial dP
– The polyester element may be washed in warm soapy water,
vacuumed, gently blown out or replaced. The element should be dry
before reinstallation.
– To be replaced after a maximum of three cleanings.

• Epoxy Coated Wire Mesh and Stainless Steel Wire Mesh Elements:
– Cleaning similar to polyester, except mild solvents may be used.

• Demister Pad:
– SS 304 or Polypropylene
– The demister pad may be washed in warm soapy water or replaced.

46
Proper Usage of the filter
Filter drain
• Manual Drain
– Set-up
• Do not reduce the size of the connection/valve
• Valve before, after drain container and Air inlet
– How?
• Drain SKP to container during operation
• Isolate drain container from SKP
Vent the container
Drain the container

• Auto vacuum drain?

– Beko is not advised  Cannot handle the oil
– Solberg  Good but expensive (overengineered for this
rugged application)
– Simple assembly can be built locally with plumbing
components and controlled by GHS
48
Few Success Stories
Success story
Canpack glass India

• Existing user of 4 units of UV 50 for 6 years

• Canpack was adding a new IS machine
– needed another 3000 m3/hr
– It could have been a repeat order for UV50!

Description P4 Atlas Copco

Rated ( Nameplate) Flow m3/hr 3300 3800
Motor Rating in kW 90 55
Max Flow @ 200 mbar.a 3116 3466
Total power kW @ 200 mbar.a @
72.7 59.7
3110 m3/hr
1800 975
Operating Bandwidth m3/hr to to
3116 3466

50
Success story
O-I Manufacturing Italy S.p.A. (Aprilia)

 Previous installation: 2 × Pneumofore UV 30

 Final vacuum degree: 280 mbar(a)

 1 × GHS 1900 VSD+ installed and Average energy saving of 41%!

Success story
Sisecam, Turkey

• 2 x GHS 3800 VSD+ replacing the P4

• Pls look at the VSD load pattern!

52
Success Story
Drujba Glassworks, Bulgaria

• Production of jars and bottles

• Existing pumps:
– LRVP 2 x 55 kW & Pneumofore
– Operating Vacuum : 200 mbar.a

• Our Solution:
– GHS 1900 VSD+ x 3

• Key reasons for winning

– Energy savings
– No water!
– Less Noise level
– LRVP went down frequently

53
Success Story
Phoenicia Glass works, ISRAEL

• Producing 200 BPM & Nearly 1 million bottles every day

• Existing Installation: • Our Solution:
– Make GD Wittig – 6 x GHS1900 VSD+
– 3 x WPSO204 ( 1160 m3/hr, 30 kW) – Savings achieved upto 47%
– 2 x WPSO404 ( 2320 m3/hr, 55 kW) – Screw tech with VSD
– About 10000 m3/hr – Vacuum Set Point
– 200 mbar.a – Water Savings
– Water-cooled – No Oil Spillage!

54
Growing GHS VSD+ references globally!
Company Country Model qty
Ardagh Glass UK GHS 1900VSD+ 8
Verallia Chili GHS 900VSD+ 1
Verallia Chili GHS 1600VSD+ 1
• Over 80 units in operation
Orora glass Australia GHS 1300VSD+ 6
BA Glass Portugal Portugal GHS 1900VSD+ 1 • Over 40 Glass Factories world wide
BA Glass Spain Spain GHS 1900VSD+ 1
Allied Glass Contain UK GHS 1900VSD+ 2 • Sizes from GHS730 to GHS5400
STEKLARNA Slovenia GHS 1900VSD+ 1
• Our improved experience with the
Alver Oram Algeria GHS 1600VSD+ 1
filtration system
OI Argentina GHS 1900VSD+ 1
OI UK GHS 1900VSD+ 2
OI UK GHS 4600VSD+ 2
OI Italy GHS 900VSD+ 1
Noelle Von Campe Germany GHS 5400VSD+ 1
Sisecam (Yenisehir) Turkey GHS 3800VSD+ 1
Sisecam (Mersin) Turkey GHS 3800VSD+ 2
CAN Glass India GHS 3800VSD+ 1
AGI Glaspac India GHS5400VSD+ 1
AGI Glaspac India GHS1600VSD+ 2

55
Growing GHS VSD+ references globally!
Company Country Model qty
OWENS-ILLINOIS DO BR Brazil GHS 900VSD+ 1
AGC Flat Glass Czech Czech Republic GHS 350VSD+ 1
Ardagh Glass GmbH Germany GHS 3800VSD+ 3
OI Brazil GHS 900VSD+ 1
OI Brazil GHS 3800VSD+ 2
OI Brazil GHS 1900VSD+ 8 Growing
Yinan Sanhui Glass China GHS 730 VSD+ 1 references Due
Fuyao Group(Shenyang) Automobile Glass China GHS 900 VSD+ 1 to the Positive
Fuyao Group(Shenyang) Automobile Glass China GHS 900 VSD+ 1 word of Mouth
Druzba glass Plovdiv (BA Glass) Bulgaria GHS 1900VSD+ 3 feedback from
BA Romania GHS 1900VSD+ 1 the users!
Bormioli Rocco Spain GHS 1600VSD+ 1
Embalvidro Portugal --> Angola GHS 1300VSD+ 3
Steklarna Slovenia GHS 1900VSD+ 2
Hebei Yanjin Glass China GHS 730 VSD+ 1
Jiangxi Shengli Glass China GHS 730 VSD+ 2
OI France GHS 3800VSD+ 2
Ardagh Glass UK GHS 4600VSD+ 3

56
Competition
overview
 58

Main COMPETITORS
Competitors
Pneumofore, Italy
• Main focus product: Rotary Vane vacuum pump and compressor
• Known player in Glass bottle and can manufacturing application

UV 100 is 2 numbers of UV 50 in one box

Pneumofore : things to know
• All pumps available in Fixed Speed & VFD version
– The VFD Inverter is typically hanging outside the pump

• So far they had performance figures data upto 60 HZ

– As per their new datasheet, they declare higher flow and show data upto 65 Hz

• Pneumofore was almost like a monopoly in the global glass market so far
– They keep very high pricing level & not much negotiation
– UV 16 : Above 35000 EUR / UV 24 : Above 40000 EUR / UV 30 : Above 50000 EUR / UV 50 : Above 85000 EUR
– These are approx. minimum price levels and inclusive of filters.

• In the exhibition, they showcase 5 years warranty for the vane element
– For UV 50, the approx. Vane replacement cost quoted in India was : 25000 Euros approx

• Trying to offer free spares along with the new pump or for the existing pumps
– Instead of dropping prices
– They also extend the buy back of old pumps

• What they talk about us?

– Our motor rating is with SF and no savings ( Atlas Copco AML data seems available to them!)
– Trying to project our spares cost is high
60
– Pushing customers to ask “Atlas Copco to demonstrate the flow and power test at their factory or at site”
Data Sheet 2016

61
Data Sheet 2019

62
Technology difference
How reliable is the GHS VSD+ screw technology?
• Pneumofore
• Atlas Copco
– Conventional Vane technology
– 4:6 Profile patented Oil-Sealed screw element - Industry
– Reliable but Inefficient compared to the latest screw pumps
leading efficiency.
– Vane technology:
– Pulsation free – Capable of More flow for less power
– More wearing than on screw technology
– Limitation of max speed

– We are pioneers in Oil-injected Screw technology

compressors, blowers & vacuum pumps design globally.
Huge reference for all tropical conditions. – Not an integrated design like GHS VSD+, just an added
– The design concepts, reliability, proven track record is inverter with limited speed range
our strength

63
Variable Speed Drive ( VSD)
Does it have EMC (Electro Magnetic Compliance) certification??

• Integrated VSD with additional RFI filters and Line • Seems to operate at specific frequency points
reactors to control to harmonics. EMC certification Retrofitted VSD and need to educate the
is available customer about EMC certification.
• Special VSD Duty motor to give wide turn down & • Standard Duty motor can not give wider
Runs at all the rpm seamlessly operating flow range
64
Know bit about the service factor
You may face this argument
• “Atlas Copco motor is with service factor. Will it can consume more than nominal power ”
– The motors are invertor duty specially designed for VSD applications. And is designed with Service Factor.
– The motor has additional power capabilities to handle the continuous peak loads.

– What matters is the SER (kW/m3) ; real power consumption divided by real flow.
– The savings are really coming from the “Wide operating flow range” & How efficient are we at the part load savings
Highlight the user friendly “Elektronikon”
Microprocessor based controller

• Pneumofore : Very basic control:

– Accuracy of the pressure control?
– No smart control or algorithm:

• Atlas Copco Elektronikon Mk5:

– Constant Vacuum Set point feature
– All operating parameters…
– Smartbox ( Monitor your pump performance
from your mobile or PC)
Competition
Wittig Elmo-Rietschle

• Oil lubricated rotary vane vacuum pumps with water cooling

• The cooling and lubrication takes place by oil injection into the vacuum pump.
– The re-cooling of the lubrication oil takes place in the water-cooled oil cooler.

• Direct Drive with flexible coupling interconnected

– Gear is interconnected in the models from X-WPSO 504 to 764.

• Models: X-WPSO 204 | X-WPSO 264 | X-WPSO 324 | X-WPSO 404 X-WPSO 504 | X-WPSO 644 | X-WPSO 764

• X-WPSO Wittig: Suction capacities from 1200 up to 4500 m³/hr,

– vacuum range 1 to 200 mbar (abs.)

• X-WKP-WPSO WITTIG Rotary Vanes with rotary lobe: 2000 to 18000 m3/hr
– Vacuum range 10 to 100 mbar (abs.)
Wittig Elmo-Rietschle
Points to remember

• Flow is lesser than GHS VSD+

• Bigger motor rating

– One size higher than us

• Just look at the oil consumption

• Only Water-cooled variants are

available
– Additional water consumption

68
Wittig Elmo-Rietschle
Points to remember

• Catalog says
– Operating Vacuum level is 1 to 200 mbar.a

• Price Positioning
– For 4500 m3/hr : Approx 125,000 USD

69
Competition
Sullair

• Screw technology
• Not optimized for Vacuum Application
– Bigger Motor rating & oversized bearings

• Higher power consumption

– Example
– VS16-50 : Flow 20.5 m3/min (1230 m3/hr) & 37 kW Motor rating
– GHS1900 VSD+ with 37 kW motor rating
 71

OTHER COMPETITORS

• Nash is the most diffused supplier of LRP in existing installation…. Target for replacement
• KAESER can be found in companies with same brand compressor
• Aerzen is looking at this market but limited by their ultimate vacuum capability
 72

CONCLUSION
Key take aways

• The machine for producing containers is called Individual Section machine (IS)
– Number of sections 6 to 20
– Vacuum level 150-300 mbar
– Average flow for new machine 1000/1300 m3/h (medium), 3000 m3/h (large)
• A good layout of vacuum line is key
– Buffer tank to reduce velocity and have pre separation
– Avoid draining straight into the pump
– Size correctly the filter
• We are an important player with global references
• Our key competitor is Pneumofore
Thank you