Drive solution reduces energy consumption of plants

22nd May 2015

By: Mia Breytenbach

Creamer Media Deputy Editor: Features

  

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Energy can constitute up to 90% of the life-cycle costs of drive systems that have not been enhanced, notes specialist drive engineering company SEW-Eurodrive.

The company addresses this issue using its effiDRIVE energy-saving solutions, which are based on SEW-Eurodrive’s proven modular concept.

“Even a single efficiency-optimised drive component can positively impact on a system’s overall energy balance, combining these components in a modular energy- saving system can result in savings of up to 70%,” says SEW-Eurodrive mechatronics engineering manager Norman Maleka.

He indicates that the focus of engineering drive efficiency is the complete operating system. “With existing process sequences in mind, the goal is to reduce power loss, enhance power requirements and recycle the released energy.”

In South Africa, there is a strong drive among SEW-Eurodrive clients to increase their energy efficiency, Maleka states, noting that this trend is expected to become stronger.

“The need for local manufacturers and clients to move to energy efficient solutions is twofold: to reduce operating costs while maintaining existing infrastructure and capacity, and to lower plant power requirements and improve stability.”

The effiDRIVE solution is suitable for several industries, including food and beverage, airport logistics and building ventilation systems, as well as intralogistics, such as storage and retrieval systems. The solution can also be retrofitted onto existing machines and systems, Maleka points out.

The solution presents an integral approach that takes into account plant or application energy use by identifying and evaluating all possible energy-saving potential.

Drive technology – ranging in use from material delivery, the entire production cycle and further processing to storage and shipping – usually accounts for a considerable proportion of a plant’s total energy consumption, which effiDRIVE and other energy efficient components aim to reduce, Maleka explains.

“Customer-specific consulting further enables us to identify the optimal solution for individual systems, regardless of whether they already exist or are being developed,” he continues.

SEW-Eurodrive further develops an optimisation report that documents the consultation results. By verifying the energy-saving solution in conjunction with the technical implementation of the measures, the company can propose a solution that comprises energy efficient drive technology such as Movigear – a mechatronic drive, which forms part of the effiDRIVE solution portfolio.

“Our energy-consulting offering serves as a demonstration that enables clients to witness the real savings, rather than only the theoretical savings, in the actual plant environment,” he says, adding that the most energy efficient solution depends not only on the components used but also on the supporting analysis and consulting services.

As a result, SEW-Eurodrive energy efficiency specialists perform regular and thorough tests on the application of its technology.

Maleka points out that all energy-saving factors are identified and implemented consistently. “During the current highly volatile power supply periods . . . in South Africa, the benefit to the end-user is measurable success through reduced energy consumption and costs, in addition to lower carbon dioxide emissions.

SEW-Eurodrive started raising awareness of the effiDRIVE solution at the Electra Mining Africa expo in August last year, with Maleka noting that several customers have expressed interest in this service since then.

The food and beverage industry has expressed the greatest demand for this service to date, owing to the production volumes and pace at which the industry is developing. “This particular industry requires more plant availability, while the shifts are operating 24/7 at some of these plants,” he says.

Meanwhile, drive technology, such as the Movigear, enables the application to achieve the highest energy efficient IE4, as well as special product features for the food and beverage industry.

“As the drive is mechatronic, it includes the gearbox, servomotor and inverter in one compact unit. It has the highest motor efficiency, owing to a permanent field synchronous motor, and meets premium efficiency IE4 according to the International Electrotechnical Commission 60034-30,” Maleka explains.
End-users could save as much as 50% in energy costs when using this unit, he says, pointing out that overall system efficiency is between 10% and 25% higher than that of conventional solutions.

The drive is also a good alternative to a conveyor drive, Maleka believes.

SEW-Eurodrive in 2013 installed the Movigear at glass manufacturer Consol’s factory in Nigel, in Gauteng, with the drive also being used as a standard product at many of Consol’s facilities.

“The product is enjoying significant success in the market, as it is locally assembled, and SEW-Eurodrive has a large local stockholding, ensuring faster turnaround times and service,” he adds.

SEW-Eurodrive has noted a significant sales increase for the Movigear in the past year, not only in the food and beverage industry but also in the automotive, warehousing and logistics industries, Maleka says.

He concludes that minimal effort is required to install or exchange the unit. The reduced number of variants of the drive also makes spare parts stockholding significantly cost effective.

Edited by Leandi Kolver
Creamer Media Deputy Editor

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