KHS converted the heater boxes by adding ceramic reflectors.
German mineral water bottler Teinach has undertaken a modernisation of its PET bottle filling line with help from filling and packaging specialist KHS, improving the level of energy efficiency in the process.
The improvement to Teinach’s energy efficiency was achieved, in particular, by optimising the heater boxes on the PET stretch blow molder.
At its plant west of Stuttgart, the mineral water bottler achieves an output of about 150 million bottles of water and soda per year, a third of which are made of PET. Preform heating consumes a lot of energy and is thus a relevant factor when it comes to the operating costs incurred during the manufacture of PET bottles, KHS said. But Teinach were “immediately enthusiastic: about the savings potential offered by KHS’ InnoPET Blomax Series III machines, the Dortmund-based company added.
It would replace a stretch blow milder at Teinach’s plant in operation since 2007.
“Over the last nine years the machine has given us wonderful service,” explained Teinach head of engineering Michael Schanz. “KHS then showed us that with little effort we could improve further on our levels of energy efficiency.
“After we’d discussed the details, it only took a few weeks before conversion started.”
The upgrade primarily consisted of converting the heater box on the Blomax Series III Compact, where the PET preforms are heated for the downstream stretch blow molding process. It has meant saving over 40% in energy and “practically half” in energy-related costs by converting the heater box, which KHS achieved by adding new reflectors made of modern ceramics to the heater boxes and precisely adjusting the geometry. Thanks to their special design, the physical properties of the ceramic elements have a very positive impact on the energy distribution, resulting in less energy being needed to heat the preforms. The reflectors and infrared emitter are also built so that the sensitive bottle thread area is not unnecessarily heated. The amount of cooling in this area can then be reduced, thus saving Teinach even more energy. This higher efficiency often also makes it possible to shorten the heating segment, explains Goebel. If fewer heating elements are required in the heater, the infrared emitter consumption also drops as a result.
“We have almost 600 Series II Blomaxes in operation worldwide,” explained KHS head of service engineering Frank Goebel. “We aim to continue to support the operators of these durable machines even after many years of service.
“For many companies, energy-optimized PET stretch blow molders are an excellent way of reducing production costs.”
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