( PR4US.com | Press Release | 2018-07-02 15:36:25 )
LIP Bygningsartikler A/S produces various building materials in its main plant in Denmark using highly automated processes. Each hour, a total of 80 tonnes of cement-based products are manufactured and packaged for shipping. There is an ongoing effort to further optimise the production process. That's why a Mink MV claw vacuum pump with a frequency-controlled motor was installed for the first time as part of a bagging system for handling paper bags –replacing two ejectors. The result was astonishing: the bagging process now runs completely fault-free. Compressed air is no longer needed, and this results in massive energy cost savings.
LIP Bygningsartikler A/S is a Danish family business founded in 1967. Tile cement and tile grout have been LIP’s main products since the beginning. Over the years, further products entered the range. Today, LIP also supplies cement-based joint filler and filler with an epoxy resin or silicone base. In Europe, LIP sells its building materials using its own dealer network. Since the company’s founding, its headquarters and production company have been located in Aaby on the island of Funen. Two other plants are located in Egypt, where only construction materials for the Middle East are manufactured.
Work at the Danish production company is performed in two shifts. The whole process, from assembling the individual materials to mixing and packaging, through to pick-and-place warehousing, is done almost completely automatically. This is how a total of 80 tonnes of various building materials can be manufactured per hour. This is equivalent to 75 pallets, which are prepared for shipping each hour.
The packaging for the tile cement and grout is done at five bagging machines in differently sized paper bags. In the past, only ejectors were used at these bagging machines. They used suction units to feed in and position the paper bags and open them for filling. This process was not always performed correctly. Leakage, for example, due to improperly fitted vacuum pads or the permeability of the paper bags, forced the ejectors to work at the limits of their output. At one bagging unit, the process for feeding in and opening the paper bags was so unreliable that, on average, every two to three minutes, a paper bag was not properly fed in. As a result, an employee had to be assigned to constantly monitor the conveyance process and manually intervene if needed. This situation was no longer acceptable for Operations Manager Rune Friis Vittrup, especially because the machine is used daily in constant two-shift operation.
So he looked around for another solution. The vacuum experts from Busch Vakuumteknik A/S recommended that he use a Mink MV claw vacuum pump – a new technology for generating a vacuum – and they provided a test pump. After a few days, Rune Friis Vittrup was already convinced that he had found the right solution for generating the vacuum. He tested the new vacuum pump on the bagging machine that had previously been the least reliable at conveying the paper bags.
Two ejectors were replaced by the new Mink MV claw vacuum pump. This vacuum pump is standard-equipped with frequency control and demand-oriented control. That means that the vacuum pump detects the pumping speed needed to securely hold a paper bag. Since its installation, the paper bags have been conveyed and opened without any disruptions; it is no longer necessary to constantly monitor the process with a staff member.
In addition to a process that functions reliably, Rune Friis Vittrup sees further benefits: the new vacuum pump no longer requires compressed air to operate. That means it is independent of a compressed air supply and the costs for generating compressed air are now saved. In addition, the vacuum pump runs so quietly that it can’t be heard next to the bagging machine. Mink MV claw vacuum pumps use dry compression to compress the air that is drawn in, meaning they do not require operating fluids like oil or water. This makes the vacuum pump virtually maintenance-free.
They work with a high level of energy efficiency, as the frequency-controlled motor runs with 1.3 kW nominal current at 100 percent output. This power consumption is lower than what a compressor needs to operate two ejectors. Thanks to demand-based control, the full output is not always needed, so the vacuum pump often works at a lower speed and thus with lower current consumption. In addition, it automatically turns off as soon as packaging is finished, whereby the compressors had constantly operated for the ejectors in two-shift operation.
Because of this positive experience, Operations Manager Rune Friis Vittrup now wants to replace further ejectors with Mink MV claw vacuum pumps to ensure absolutely reliable and stable vacuum supply at his bagging machines.