Danfoss VLT FlexConcept is being utilised at Austrian brewery, Wieselburger, to secure flexibility, fewer motor variants and energy efficient operation
The brewery in Wieselburg, Austria, dates back to 1650 and is now the cornerstone of today’s Austrian beer metropolis, Brau Union Österreich Group, which is owned by Heineken. The brewery constantly employs the newest technology to ensure sustainable and environmentally friendly production.
In 2010 the brewery embarked on a retro-fit project, choosing the VLT OneGearDrive from Danfoss’ VLT FlexConcept to replace the aging drives on one of the brewery’s filling lines. The old motors, which used chains as reduction gears, started showing their age and finding spare parts was becoming increasingly difficult. The brewery therefore decided to replace the motors in steps. This enabled them to introduce more energy efficient technology while using the old motors for spare parts for repairs at short notice.
One of the main benefits of installing OneGearDrives is that the factory no longer needs chains to connect the gearbox to the conveyor shaft, as the drive is mounted directly on the conveyor shaft.
Danfoss sales engineer Michael Hitter commented, “Chains alone introduce system efficiency losses of up to ten percent. Also, they are cumbersome to fit and add additional maintenance costs for spare parts and lubrication.
“The OneGearDrive solves this elegantly and efficiently by simplifying the installation. The hygienic design of the drives also makes it easier to clean, as there are no cooling fins, sharp edges and other areas where dust can accumulate.”
By sharing the same design and operation principles as the brewery’s many other VLT drives, the new drive solution was relatively easy to integrate into the existing set-up. The brewery already had positive experiences with the Danfoss frequency converters that were already installed in a central control concept, where the frequency converters are grouped in switch rooms or panels.
Wieselburg already had several VLT 5000 and VLT 2800 drives running in the plant. The new OneGearDrives are controlled by VLT AutomationDrive FC 302 units.
In October 2012 Wieselburger installed new equipment, after specifying to their supplier that OneGearDrives were to be used as part of the solution, bringing the total count of OneGearDrives in the Wieselburg plant past 30.
VLT FlexConcept comprises a VLT OneGearDrive controlled by either a VLT AutomationDrive or a VLT Decentral Drive FCD 302 frequency converter. FlexConcept provides users with flexibility in the choice of components during plant design, retro-fit and upgrade. The solution is well suited for decentral production facilities, in dry, wet or aseptic areas.
VLT OneGearDrive is a highly efficient permanent magnet 3-phase synchronous motor coupled to an optimised bevel gear box. The drive can achieve up to 89% efficiency and high torque, already exceeding the IE4 Super Premium Efficiency class, in a compact motor frame.
The uniform operating concept, identical functional principle and the easy connection of the OneGearDrive, which features axels of stainless steel, reduce installation time, service and maintenance.
At the same time the plant owners still have free choice of motors or frequency converter technology. With the VLT FlexConcept owners can reduce the number of model variants by up to 70%, which is especially advantageous in large plants, as stocking costs can be reduced considerably.
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