Sustainable innovation: advanced air solutions for 2-piece can manufacturing

Showing how to achieve low product life-cycle cost and minimal environmental impact by using resilient products.

High efficiency vacuum pumps and compressors

According to statements made by engineer Daniel Hilfiker, who is president of Pneumofore.

In a can factory, more than half of the electrical energy is used in the operation of air compressors and vacuum pumps. Continuity in the supply of pneumatic energy is essential to maintain constant production 24 hours a day, 7 days a week. The experts in this industry carefully select the equipment to be used, taking into account not only the initial cost but also the total cost over its useful life. Special attention is paid to electricity consumption and long-term maintenance costs. All this with the main objective of maintaining a smooth production process.

Given the complicated circumstances, at this point we will present some fundamental recommendations to avoid inconveniences in the operations.

Compressed air and vacuum dynamics

The can making process requires both vacuum and compressed air to function properly. A pressure of 3.5 bar(g) is required, sometimes reaching 7 bar(g) in certain operations. On the other hand, a vacuum level of 300 mbar(a) is used. Although the air found in factories is usually clean, in processes such as decoration it is advisable to use effective filters for pneumatic machinery. In addition, it is suggested to invest in durable equipment considering that the installation of a factory is a long-term investment.

Hierarchy of power

In a can factory, compressors and vacuum pumps are the main energy consumers. Given the increase in environmental awareness and the relationship between energy use and CO2 emissions, it is necessary to choose highly efficient equipment. In addition, it is important to have a clear schedule for regular and exceptional maintenance over time to maintain its like-new efficiency.

Technology and reliability comparison

In the market there are several options of air compressors and vacuum pumps with high power, but in many occasions their technical specifications can be exaggerated for advertising purposes. Most reliable are the actual results: references from installations that have been running smoothly for decades, which is important when looking for durability. The comments and experiences of customers who have used these machines for a long time can provide valuable information on maintenance costs, overhauls and spare parts availability. It is recommended to choose efficient and durable equipment to reduce the need for costly overhauls in the future.

Moreover, this result is the most beneficial and enduring in the long term.

Cost estimates during the entire useful life process.

The best option would be to choose a rugged equipment that will maintain its efficiency over the years. It is important to avoid, if possible, having to make revisions as these can be very costly. The purchase of new machinery requires a lengthy approval process and is strictly controlled by the purchasing and accounting departments. On the other hand, the cost of maintenance can be included in an annual budget and electricity consumption should also be taken into account, which is the highest expense over a 15-year period and is not an item to be purchased but an operating cost to be considered.

It is essential that a more comprehensive approach be taken when making decisions, considering Total Life Cycle Cost. This cost includes not only the purchase of the product, but also maintenance costs and electricity consumption over time.

Focus on efficient vacuum solutions

The Pneumofore UV50 rotary vane vacuum pump has a great advantage in can production by offering 75 kW for a flow rate of 2,700 m3 /h in its standard version with fixed speed. Although it may seem like a lot of power, this is due to its oversized electric motor that provides longer bearing life and better ventilation. In addition, it does not use the safety factor of the engine, but operates within the optimum range for which it was designed. On the other hand, in equipment that does use the safety factor, this can affect its performance and efficiency.

There is a trend in the industry to manufacture electric motors with limited durability, which only lasts until the end of the warranty. This means that they will soon become an obsolete component that needs to be replaced or overhauled. However, the philosophy behind Pneumofore is different and opposes this practice of “planned obsolescence” which is prohibited by law in Europe. The company is committed to creating durable components such as the Air-End motor, cooling system and electrical panel, ensuring efficient and sustainable operation for decades.

The UV Series vacuum pumps offer a 10-year extended warranty on efficiency through an easy maintenance contract. Pneumofore compressors and vacuum pumps can operate trouble-free for more than 100,000 hours and with a simple overhaul after 20 to 30 years, they can continue to operate for several more decades.

Operational independence and reliability

It is also important to highlight companies that help OEM independence, allowing in-plant service teams to operate autonomously and maintain equipment efficiently. In a factory, where downtime can be costly, having reliable equipment is critical, especially when it comes to five key energy resources: electricity, water, gas, compressed air and vacuum.

About the Author

Pneumofore, located in Italy, is headed by Daniel Hilfiker, who represents the third generation of Swiss engineers in charge of the company since 1923. Since its inception, Pneumofore has been dedicated to designing and manufacturing vacuum and compressed air systems for industrial companies worldwide. Its focus on sustainability, efficiency and excellence has been key to its success in the ever-evolving aluminum can manufacturing market.

Sustainable innovation: advanced air solutions for 2-piece can manufacturing

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