Plastic manufacturer cuts vacuum pump energy use by 63%
In a typical plastic products manufacturing factory, vacuum is required in most of the production process. It is important for thermoforming forming machines, where a plastic sheet (PVC, PE or acrylic sheets) is heated and then formed to a specific shape in a mold, under vacuum. The plastic sheets are literally sucked into shape, perfection of the finished shape is also depending on vacuum.
An UAE based leading plastic manufacturer were using 6 units of liquid ring vacuum pumps. However, these machines were high energy consumed, since each unit fitted with a 15kW motor which dedicated to each production line shares a central chiller unit to supply the seal water. There is no control on pumps to operate at a pressure required by production, resulting in unnecessary loading and energy loss. After analyzing customer’s situation and requirement, Atlas Copco proposed a centralized vacuum system with a GHS 1900 VSD+ and an oil injected screw vacuum pump with a 37kW installed motor power, which can replace the liquid ring vacuum pumps with a dedicated configuration. The solution was offered with the aim to provide significant energy savings, limited maintenance costs and reduced down-time.
GHS 1900 VSD is fitted with a variable speed drive and MK5 Elektronikon controller. The pump varies its speed based on the demand coming from the process, resulting in significant energy savings. Also, the Set Point Control in controller maintains the exact pressure needed for the application for further energy savings. Hence, GHS 1900 VSD directly reduced 63% energy consumption for this user compared to the old installation. The screw design is based on the well-known plug and play principle of Atlas Copco compressors, which has been optimized by vacuum pump design engineers to deliver peak performance and maximum energy efficiency. The highly efficient oil sealed rotary screw has a very robust design. it has a significantly longer element life than traditional vacuum pumps. Furthermore, the GHS 1900 VSD will maintain a stable network pressure throughout the vacuum pipe line which will help the production to get vacuum quickly when the sheet is heated up and ready to apply vacuum to make the shape.
The GHS VSD+ is a revolutionary machine that sets a new standard in the vacuum industries and is a perfect example of the Atlas Copco reputation for energy savings, sustainability and respect for the environment. In addition to plastic industry, the type of vacuum pump is used widely in variety of industries like food, chemical, electronic etc, its benefit will be felt far and wide in the region.
For more information, please contact: Sarath Soman - Regional Business Development Manager Email: sarath.soman@atlascopco.com