Vacuum technology for processing and packing
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Rotary Vane Vacuum Pump R 5 0100 F
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Vacuum technology is one of the key technologies for modern meat processing and has great influence on the quality and shelf life of the product. This is why the vacuum pumps used in these processes must meet a high quality standard.
Dr.-Ing. K. Busch GmbH has been manufacturing vacuum pumps for meat processing for over 40 years and has a great deal of knowledge and experience in this field. R 5 rotary vane vacuum pumps from Busch have proven their worth for decades. These are being continuously further developed and optimised in the company’s own research and trials departments. New experience gained in the field is always fed into this development work. Today Busch has 20 different model sizes of R 5 rotary vane vacuum pumps in its product range, which in turn are all available in various versions according to customer requirements. The installation sizes of the vacuum pumps, in terms of volume flow rate, range between 3 and 1600 cubic meters per hour. This means that all types of vacuum packaging machines and meat processing machines can be fitted with Busch vacuum pumps:
Packaging machines:
- Table top units
- Floor-mounted appliance
- Double chamber machines
- Tray sealer
- Belt machines
- Roller automats/deep drawing machines
- Rotary fillers
Meat and sausage processing machines:
- Tumbler/ mixer
- Sausage filler
- Cutter
The larger rotary vane vacuum pumps are also suitable for installation in central vacuum systems, such as those Busch offers for production facilities which operate with a number of packing lines. Centralisation of the vacuum supply offers an extremely economic alternative to individual vacuum pumps installed directly on or in the machine.
There is one thing which all R 5 vacuum pumps have in common: they are oil lubricated and operate according to the tried and tested rotary vane principle.
The seal fluid oil performs a number of important functions in this case. The first is that it seals the gap in the compression chamber which guarantees a high vacuum and secondly it lubricates the sliding surfaces and thus prevents wear. The oil also leads away heat produced in the compression chamber or ensures that there is an even operating temperature within the vacuum pump, which in turn ensures that much more water vapour can be transported through the pump. The seal fluid is a very important component of the vacuum pump, due to the multiple functions it fulfils, which guarantees reliability of operation and a long working life.
Busch vacuum pumps can tolerate the presence of water vapour extremely well which is a very important quality for fresh meat processing and packaging. For example, during vacuum packing, the vacuum pump sucks the air out of the packing chamber and thus drastically reduces the residual oxygen trapped in the packaging. Moisture in and on the meat evaporates under these conditions and is sucked out as water vapour. R 5 vacuum pumps are designed in such a way that they can convey large amounts of water vapour through the pump which is expelled together with the air.
Busch has a dense service network throughout the world. In Germany, Busch is represented by 14 branches, satellite stations and service centres to guarantee short and rapid access to customers. A broad range of services allow meat and sausage processing plants to decide on an individual service package tailored to their needs. Maintenance costs can be spared in this way, but the availability and reliability of operation of the vacuum pumps is also increased.
Busch Dienste GmbH
Marketing/Marketing Services
Uli Merkle • July 8, 2005
Handbook for the application of vacuum systems in plastics compounding Which vacuum systems are suitable for the compounding of plastics? What are the critical factors in deciding on a vacuum system for devolatilizing extrusion? The answers to these and many other questions are available in the new manual published by Dr.-Ing. K. Busch GmbH, manufacturer of vacuum systems for the plastics industry.
A new member has joined the ranks of handbooks and manuals that explain the use of vacuum technology for various industrial applications in practical terms: “Vacuum Systems for Plastics Compounding”. Fresh off the presses, this volume describes the various means of vacuum generation and weighs their advantages and disadvantages for different applications. A good amount of time is spent on the subject of filtration, as it is a critical factor to the success or failure of the vacuum system used. In closing, the book furnishes a comparison of the operating costs for the different vacuum systems. The Dr.-Ing. K. Busch GmbH group designs and builds vacuum solutions for the plastics compounding industry, having over a decade of experience in this area. With this newly published handbook, available in both German and English, Busch gives practitioners just what they need: clear, concise and applicable information. The handbook is free of charge and can be ordered at info@busch.de
Busch is displaying its vacuum systems for plastics compounding at the Fakuma trade fair in Friedrichshafen, Germany, Hall A6, Booth 6112.
Busch Dienste GmbH
Marketing/Marketing Services
Uli Merkle • July 8, 2005
Handbook for pneumatic conveying in hazardous zonesDr.-Ing. K. Busch GmbH has published a compendium about pneumatic conveying in areas susceptible to dust explosion. The manufacturer of vacuum pumps for pneumatic conveying discusses potential sources of danger clearly explaining the responsibilities of the component manufacturers and system operators with respect to practical application and the ATEX 94/9 EG and 99/92/EG directives.
The work extensively deals with the subject of "Explosion", discussing which conditions are conducive to explosion and how they can be avoided. In addition, the book explains the meaning and benefits of the zones and their divisions. Finally, the author speaks about the preventative features of the Mink dry rotary-type vacuum pumps, which are certified for use in areas susceptible to dust explosion and, depending on the model, can be used in various zones.
This handbook is available free of charge in both the English and German languages at info@busch.de.
The ATEX-compliant vacuum pumps can be seen at:
Powtech, Nuremberg, Hall 10, Booth 210
Fakuma, Friedrichshafen Germany, Hall A6, Booth 6112
Busch Dienste GmbH
Marketing/Marketing Services
Uli Merkle • July 8, 2005
New screw vacuum pumps for zones 1 and 0A new generation of screw vacuum pumps has been introduced to the market by the Dr.- Ing. K. Busch GmbH company – the COBRA NC is designed as a process pump for the chemical and pharmaceutical industries. As well as the version for areas not potentially explosive, it is also available as the standard machine for zone 1 and zone 0.
With this new series of vacuum pumps, Busch have succeeded in implementing and standardising health and safety requirements in a simple and consistent way.
The result is dry running screw vacuum pumps in sizes of 100, 200 and 300 m3/h for zone 1 (Ex II 2G IIB T3 and T4 (i/o)) and zone 0 (Ex IIG1(i)/2(o) IIB3(i)/IIB(o) T3 and T4). With the existing ATEX certification, 98 percent of all substances can be pumped with this vacuum pump.
The simple modular construction of the COBRA NC and the carefully thought out safety package makes it possible to use the vacuum pump with a minimum of monitoring devices. In the zone 1 model, flame barriers are not needed. COBRA NC vacuum pumps are fitted with vibration detection as standard. This provides continuous monitoring of the state of the vacuum pump, thus guaranteeing high safety and availability of the vacuum pump.
The modular and simple construction also makes possible simple maintenance which can be carried out by the user. Modifying a model from zone 1 to zone 0 can also be done easily.
COBRA NC vacuum pumps achieve a final pressure of 0.05 mbar. This has the advantage that maximum suction capacity is achieved at an actual working pressure in the range of 1 to 100 mbar. From a technical point of view, the COBRA NC has decisive advantages compared to other screw vacuum pumps. The screw rotors, made of a single piece, have variable pitch. This allows optimal compression with homogenous temperature progression, thus avoiding condensation in the compression chamber. Interior cooling of the screws is not needed. Compression is not done against an end plate, thus allowing continuous outflow of fluids and an easy discharge of solid matter.
The screw rotors are sealed with floating ring seals lubricated with oil. These are easy to maintain or exchange, guaranteeing a long service life. Floating ring seals are extremely robust and resistant to chemicals.
COBRA NC vacuum pumps are fitted as standard with a water closed-circuit cooling system. This means that the pump operator is not dependent on water or waste water connections, or water quality. A circulating pump with a magnetic clutch provides optimal distribution of cooling water, resulting in steady temperature performance and low susceptibility to corrosion.
The drive for the vacuum pump is a flange-mounted standard electric motor, with the result that the drive and the process medium are kept apart, and fluids cannot get into the motor. Synchronisation of the screw rotors is achieved by spur gears in a separate gear housing.
Busch has been manufacturing screw vacuum pumps in its own production plant in Switzerland since 1993.
The skills developed there in manufacturing technology, and the experience gained in many applications of screw technology, even outside the chemical and pharmaceutical industries, have made Busch into one of the largest manufacturers of screw vacuum pumps in the world.
In addition to the COBRA NC screw vacuum pumps described here, Busch also offers a large range of ATEX-conformant vacuum pumps for just about any application.
Dr.-Ing. K. Busch GmbH
Marketing/Marketing Services
Uli Merkle • March 11, 2005
Savings on energy and maintenance | |
Mink system (Fig. 1)
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Comparison - vacuum (Fig. 2)
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LMC (Fig. 3)
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A testimony: LMC Caravan GmbH
Manufacturing ten motorhomes and thirty to thirty-five caravans a day, LMC Caravan GmbH of Sassenberg, Germany is one of the largest recreational and mobile vehicle manufacturers. The strict quality standards imposed by LMC on its products are reflected in its modern production plant, where CNC routing cutters work high quality materials. The highest priority for Bernhard Knollmeier, technical director, is the dependable operation of the machinery and equipment. In addition, the cutting of costs for energy wherever possible is of great importance, which led him to closely examine his present vacuum system and alternative vacuum technologies that are available.
LMC operates six CNC routing cutters for the processing of parts for its motorhomes and touring caravans. The routing cutters perform work on all of the assembly parts, from the outer walls to the smallest drawer front and furnishings of the caravan. One or two rotary vane vacuum pumps are installed on each of the routing cutting stations to generate the vacuum required to hold the plastic material while it is being worked on.
To guarantee the dependable performance of these vacuum pumps, the pumps were serviced and the vanes replaced once a year. Because LMC operates two or three shifts, maintenance could only be performed during the company holidays when production was at a standstill. Besides the labour costs for the maintenance, the costs for the replacement of the vanes were quite sizeable, so much so, that Bernhard Knollmeier looked around for less expensive alternatives. He found the solution at the Dr.-Ing. K. Busch GmbH company, namely a rotary claw-type vacuum pump that produces compression without contact (Fig.1). Where there is no contact, there is no wear, and where there is no wear, there is no need of maintenance. Convinced by this technology, Bernhard Knollmeier replaced the rotary pump he had been operating on a routing cutter with a Mink claw-type vacuum pump from Busch.
Astonished, he discovered that a smaller sized vacuum pump produced greater clamping strength, and did so significantly quicker. This is attributable to the fact that the Mink vacuum pumps’ non-contact design prevents them from wearing. Thus, the duration of operation does not affect the vacuum capacity and end pressure of Mink vacuum pumps.
Dry rotary vane vacuum pumps are subject to extreme vane wear. The chart (Fig. 2) compares the vacuum performance of a Mink vacuum pump and a dry rotary vane vacuum pump after 2000 hours of operation. When they are new, both pumps have a nominal suction capacity of 250 cubic metres per hour.
The vanes in a rotary vane vacuum pump are manufactured from a carbon material and turn in a grey cast iron cylinder. The faces of the carbon vanes rub against the inner cylinder walls at a constant rate of 3000 revolutions per minute or they are constantly pressed in and out of the vane slots. Friction results in the wear of the vane material, which drastically reduces the performance of the vacuum and suction capacity.
Another positive development was the reduction of noise experienced with the Mink vacuum pump, the noise level being significantly lower than a comparatively sized rotary vane vacuum pump.
All these are arguments that Bernhard Knollmeier considered when deciding to use Busch rotary claw-type pumps for the future in his manufacturing department. In fact, he is even thinking further ahead, considering centralising the vacuum system. That would mean removing each of the pumps connected to the CNC routing cutters and installing the central unit in a separate room from where each of the routing cutters would receive ample vacuum to perform their clamping functions (Fig. 3). The advantage of such a system would be savings of at least 30 percent. How is this possible? Because such a system would only produce vacuum when it is required. Individual pumps would automatically shut down when they are not needed and automatically start up when needed to accommodate peak demand, etc.
Fundamentally, it is possible to regulate the speed of the Mink rotary claw-type vacuum pumps. That means the motor only turns as fast as is necessary to generate the suction required at the specific time. In the practice, vacuum pumps require the highest level of suction at the beginning of a clamping task, because the air in the lines between the clamping table and the vacuum pump must be evacuated as quickly as possible. After this is accomplished, the vacuum pump only has to be ready to remove air that has reached the lines due to leaks in the lines, suckers, clamping table or the work piece, a task that requires significantly less suction. The frequency converter detects the change and reduces the speed so that the vacuum pump only delivers the suction volume that is specifically required. As a result, additional energy savings are possible, because the vacuum pump only uses as much electricity as is necessary to satisfy the demand at the specific time.
Another advantage of central vacuum systems is the reduction of noise, which is made possible by the pumps’ placement away from the workplace. In addition, the heat generated by the vacuum system can be used for heating or warm water heating purposes, translating into further savings. LMC has found a skilled and reliable partner in the Busch company, one who not only manufactures standard vacuum pumps with different working principles, but one who has a host of experience in the design of central vacuum systems.
Busch Dienste GmbH
Marketing/Marketing Services
Uli Merkle • March 2, 2005
