The plant's technical office conducted a study on energy consumption in the bottling lines as part of a series of investments aimed at reducing energy costs. This analysis was carried out in response to a need to replace the now obsolete pool of VLT® 3000/5000 series AC drives.
An accurate assessment of the various solutions available on the market based on Total Cost of Ownership (TCO) principles led to the designation of the Danfoss VLT® FlexConcept® solution as the best solution for the needs of the plant in Rome due to the many advantages it offers.
This is based not only on the increase in energy efficiency, but also on the reduction of maintenance costs related to the management of bottle transport along with the extreme ease of retrofitting.
Therefore, a decision was made to upgrade not only the drive that utilizes the VLT® AutomationDrive FC 302, but also the engines, with the VLT® OneGearDrive® permanent magnet gear motors replacing the traditional gear motors that had been installed.
In 2014, a total of 20 complete power drive systems (geared motors plus drives) were installed in Bottling Line No. 2 at the Rome plant, followed by another 36 in 2015.
When we evaluated the upgrading of our bottling lines equipped with Danfoss drives at the end of their service life, we also evaluated all other solutions on the market, and we decided to continue our relationship with Danfoss because we found what we were looking for in the VLT® FlexConcept™: a high degree of energy efficiency and great ease in replacing the existing concept. This simplicity is evidenced by the fact that we independently installed and tested the new drive system.Davide Scebba, Maintenance Manager, Peroni Brewery
The total electrical efficiency of the bottle transport belts increased by more than 30%, with an ROI of just over 23 months.
The space requirement for the VLT® AutomationDrive FC 302 is identical to or less than that of the previous VLT® 3000/5000 series. In addition, the numbering of the terminals and corresponding functions of the previous drives have been retained. The PROFIBUS emulation board of the previous series allows the drive to be replaced without reconfiguration of the PLC.
The permanent magnet motor which the VLT® OneGearDrive® gear motor is equipped with, has an efficiency of 96%, which is higher than the IE4 standard. This value, therefore, not only exceeds the current legislation, but will also be able to meet future legislative developments for at least the next decade, guaranteeing significant energy savings.
The only maintenance operation expected for the VLT® FlexConcept® solution is a change of the lubricating oil after 35,000 hours of operation; in other words, seven years with no need to work on the gear motor.
Due to the smooth surface and lack of cooling fins, the EHEDG-certified hygienic design decreases cleaning time by 40% compared to conventional systems, while the IP67 and IP69K protection grades guarantee the water-tightness of the system, making it fully washable.
The only maintenance required is a change of lubricating oil after35,000
hours of operation