Energy efficiency improvements on new tube packing machine

27 November, 2023

Working with long-term automation partners 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%, 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.

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.

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.