Festo helps Cerulean achieve 90% energy efficiency improvements

Soaring energy prices and the need to continuously drive down costs are key considerations for manufacturers. So, when packaging machinery specialist Cerulean decided to redesign its highly successful FPS-1 tube packer, high energy efficiency and reduced total cost of ownership (TCO) became key design requirements. It turned to Festo.

Working with Festo, Cerulean identified where CAPEX and OPEX savings were achievable during the tube packing process. Together, they were able to optimise the design and performance of the new FPS120s to achieve energy efficiency improvements in excess of 90 percent, saving 4.5 million litres of compressed air per year.

The new Cerulean FPS120s tube packing machine is designed for hygienic packing at speeds of up to 120 tubes per minute and incorporates the latest control and display technology. A user-friendly colour touch screen enables the user to control set up, packing options and store all settings in a library for quick change over and later use. The touch screen supports multiple languages and can be configured for local operator preferences. Changing tube or carton size typically takes less than 15 minutes, allowing the FPS120s to meet the flexible requirements of a modern tube making facility.

Design optimisation

To deliver significant improvements in TCO, Festo and Cerulean conducted a comprehensive review, from component selection to running costs at designated outputs. Festo online tools were invaluable in this regard.

The Pneumatic Simulation Tool allows users to input the desired application parameters, such as number of cycles/minute requirement, tube diameter/length, positioning time, etc. The online tool then identifies the optimum pneumatic cylinders, flow controls, valves and settings based on energy consumption to deliver the most efficient options.

Festo’s Pneumatic Sizing Tool can then be applied to refine the system design. This online tool addresses aspects such as positioning time and CO2 emissions. It gave Cerulean confidence that all of the pneumatic cylinders and valves specified for the new FPS120s were correct for the application.

“Over-specification is a common mistake in pneumatic systems,” says Nathan Colbert, key account manager at Festo. “Festo’s online assessment tools make it quicker and easier for customers to identify the best components for their application and refine their design, delivering both CAPEX and OPEX savings.”

These initial design assessments showed that Cerulean could achieve immediate savings using standard products from Festo’s core range, including VUVG-LK valves, DSNU cylinders and the MS Air Prep. Further efficiency savings were achievable by reducing tube lengths and diameters, which decreases dead volumes and cycle times.

Improving energy efficiency

Cerulean also invited Festo to undertake an energy efficiency survey on an original FPS-1 tube packer and compare the results with an equivalent survey of the prototype FPS120s. Festo energy efficiency services are based on key lessons learned within its own production facilities and follow an ISO approved and proven approach.

The results proved that the FPS120s tube packer would offer significant TCO improvements over the old FPS-1 model: it delivers a 48% improvement on maximum air consumption, and an impressive 92% improvement on average air consumption. Cerulean have calculated a saving of 4.5 million litres of compressed air per year based on the machine running 24 hours a day, 7 days a week, 365 days a year (but not allowing for any downtime).

Says Shaun Toms, portfolio manager at Cerulean: “In today’s economic climate, manufacturers like us have a growing responsibility to become more efficient in order to compete in today’s highly competitive marketplace. This entails a programme of continuous improvement and innovation. We wanted our next generation tube packer to address our customers’ pain points around energy consumption and total cost of ownership. Festo’s automation expertise was invaluable in helping us attain this goal.”

Festo

282-294 Farnborough Rd
FARNBOROUGH
GU14 7NH
UNITED KINGDOM

+44 (0) 1252 775000

info_gb@festo.com

www.festo.co.uk

More news
1 day ago
steute Technologies restructures its business fields
steute Technologies, an international technology company offering switches, intelligent sensors and wireless systems, has announced a comprehensive restructuring of its business fields.
2 days ago
Showcasing design, production and process engineering in the food and drink sect
Taking place on 1 May 2024 at the National Motorcycle Museum, Food Manufacturing Live serves the design, production, process and maintenance engineering teams across the UK food and drink manufacturing sector.
2 days ago
Understanding safety and security for the protection of human and machine
How do you master employee protection, liability protection, productivity and data protection? How do you increase your quality and simultaneously prevent manipulation on your machines? How do you protect your data and employees in equal measure? Pilz is hosting a free webinar on 15 December, 9:30-10:30 am, to address just these questions.
2 days ago
Schaffner opens new regional channels for its range of EMC solutions
EMC solutions provider, Schaffner, announces new partnerships with three distributors to further broaden the reach and scope of its product range and support services across Europe. The new agreements with Telerex, CATS and DSL Components will open new supplier corridors and enable customers to have local and faster access to products.
3 days ago
New SCARA robot transforms pick-and-place and assembly operations
ABB Robotics is expanding its industrial SCARA robot portfolio with the addition of the IRB 930. The new robot, compromising three variants capable of handling 12 kg and 22 kg payloads, has been designed to meet the demands of new growth opportunities in traditional and new markets.
3 days ago
Pilz CMSE training in high demand, as 10,000th graduate qualifies
With the CMSE qualification (Certified Machinery Safety Expert), Pilz created a completely new training programme for machinery safety in 2013. After a decade Pilz is now proud to congratulate the 10,000th graduate to successfully complete the CMSE examination.
3 days ago
New eBook offers expert insights on embedded security
Mouser Electronics announces a new eBook produced in collaboration with global semiconductor leader Analog Devices (ADI). In Embedded Security: Keeping Edge Data Safe, experts from ADI and other companies take a deep look at embedded security concepts and their importance.
4 days ago
New era beckons at UK’s largest online valve supplier
Gary Hopkinson, founder of Valves Online, a sales partner for Bürkert, has announced his retirement, planned for the end of this year. In March, the UK’s largest online valves supplier underwent a business acquisition by R&G Fluid Power Group. Gary has been assisting the transition while Valves Online is set to retain its successful business model.
4 days ago
Lowering production costs in the beverage industry
BrauBeviale, one of the leading capital goods fairs for the beverage industry worldwide, is due to take place in Nuremberg from November 28 to 30, 2023. Schaeffler will be on site with a presentation that focuses on solutions for economical and efficient beverage production.
4 days ago
NSK Europe makes significant environmental progress in FY2022-23
NSK Europe continues to make improvements to its environmental credentials, with the past 12 months seeing significant progress in a number of key metrics as the company works towards its ultimate carbon-neutral goal.

Login / Sign up