Sections

Higher Productivity for Swiss EPS Manufacturer

Home : Case Studies : Higher Productivity for Swiss EPS Manufacturer
Select an alternate language version:

New Vacuum System Improves the Styropor Production Process

Swisspor

In Switzerland, near Lucerne, the EPS manufacturer Baukork Swisspor produces both blocks and small moulds under severe environmental restrictions since decades. Switzerland's laws don't allow emissions of the gas pentane in the atmosphere, therefore it is collected and burned. This environmentally controlled approach with considerable impact on the cost of production equipment creates exceptional sensibility for any other environmental aspect.


The most popular technology for vacuum generation is the water ring vacuum pump system. This solution, although durable and reliable, unfortunately suffers from sizeable changes in the temperature of cooling water, which has a major impact on the maximum vacuum level. It also requires considerable power supply due to the constant friction of the water ring in the pumps body.

The installation of one UV vacuum pump in 2003 allowed higher vacuum levels with obvious improvements in the products' quality, such as a higher cohesion of single EPS balls (from welding level of 56,3 % to 71,2 %), and therefore stronger resistance to bending.  The cycle times for the moulding of shapes up to 0,5 m3 could be reduced by 6 %. The power consumption with liquid vacuum pumps was measured at 21,2 kW, while the UV system requires only 7 kW. The Pneumofore solution consists of the 1000 m3/h rotary vane vacuum pump UV16 with dedicated accessories to avoid the penetration of water or pentane into the UV pump.  The system was monitored over years, under various climate conditions and accordingly improved to the present technological level. The after-sale service is managed directly by Pneumofore and the preventive maintenance contract gives access to extended warranty on the entire system for 5 years. This important EPS reference has been an important lesson for Pneumofore engineers, who now dispose of exclusive know-how for improving most EPS production systems based on liquid ring technologies. The Pneumofore solution reduces power consumption, increases the vacuum level, provides constant capacity throughout the  year, operates silently, and, last but not least, improves EPS product quality.

Vacuum SystemFor additional information regarding the case study of Swisspor, Pneumofore can refer to detailed analysis executed by the Swiss company Enco Engineering in Chur. The report dated February 2003 describes the situation in regards to energy, performance and product quality by viewing the before UV and after UV picture. This report is available upon request and similar documentation is also provided for the prominent EPS machines OEM Heitz in Germany, which run a UV8 in the AERO production facility next door.

 

 

 

   

 

May 2006

SEE ALSO
MORE CASE STUDIES
COMPRESSED AIR VACUUM
PLANT AIR
Industrial Compressed Air at low or high pressure for Steel, Mining, Glass & Other Applications
BEVERAGE CANS
Steel, Mining, Glass & More
HOLLOW GLASS
Bottling, Forming, Central Systems, Water Savings
FOOD
Processing/packaging, Pasta, Beer, Meat & More
DRYING/DEGASSING
Pipelines, Tiles, EPS
OTHER
Semiconductors, Flight Simulation, Rentals, Thermoforming, Pharma/Medical & More
ROTARY VANE BY PNEUMOFORE

simple, reliable & durable

Direct coupling means few moving parts, low rotation speed, low temperature. This virtually eliminates repairs and ensure superior reliability and longevity.

high energy savings

Air cooling through vertical layout, direct coupling, and intensive oil injection can result in up to 70% less power usage than other systems.

designed for extremes

Tested and proven for high performance in desert and tropical climates and available for special requirements like explosive gas or food safety.

low cost of operation

Low maintenance, negligible repairs, high energy savings and high reliability (no production downtime) make this the least costly long-term option available today.

easy to install and run

Ready-to-use turnkey system with optional Variable Speed drive. No foundation or water needed. Compact footprint with heat recovery. ISO 9001 and ISO 14001 certified.

first class support

Each unit comes with integration engineering and a 5-years warranty. Extraordinary and regular service by Pneumofore certified professionals is available worldwide.
LEARN MORE ABOUT ROTARY VANE TECHNOLOGY
FIND A CASE STUDY FOR YOUR APPLICATION
CONTACT PNEUMOFORE FOR YOUR SPECIFIC NEEDS
SWISS ENGINEERING
ITALIAN DESIGN
GLOBAL PRESENCE