The European Union intends to achieve climate neutrality by 2050 – an ambitious target indeed. And all around the globe climate protection and sustainability have also been put on the agenda. In order to achieve these goals, it is first and foremost CO2 emissions that must be reduced. That is relatively easy for private persons and smaller companies. Large commercial enterprises, however, are faced with some special challenges here. In the beverage industry, in particular, one possibility for cutting energy consumption, enhancing sustainability and tapping savings potential may be optimising beverage filling temperatures. This is where Krones comes in, supporting commercial enterprises with its new LCS Warmfill retrofit package.
In order to mitigate climate change and enhance sustainability, commercial enterprises must substantially reduce the amount of energy they consume. One major lever here, especially for beverage makers, lies in higher filling temperatures. Retrofit packages like the new LCS Warmfill from Krones, which includes comprehensive analyses, technical upgrades and optimisation software, help companies save energy, cut costs and equip their lines for any future assignments.
“Sustainability was the driving force behind developing Warmfill as a retrofit solution,” confirms Shannon Kerscher, Lifecycle Services (LCS) Product Owner at Krones. “We’ve seen a growing number of customers reach out to us wishing to increase resource-economy in their existing production lines. At the same time, the market has also given higher priority to this, and so it only made sense for us to develop products that meet that need – especially in the field of LCS since our new machines and lines are already in very good shape in this respect.”
Warm filling cuts energy consumption
The filling temperature in existing lines has so far frequently been lower than necessary. Often the product water fed into the mixer is relatively warm and then cooled down for filling, only to have a heater bring the sealed bottles back up to a temperature above dew point, so as to prevent condensation due to humidity. And that heater is one of the most energy-hungry machines in a line.
Although a lower filling temperature makes for lower energy-efficiency, it was in the past accepted as a necessary trade-off for enhanced process stability. However, the reduction in mechanical stress on the filler’s components achieved by a lower liquid pressure no longer constitutes a convincing argument for cooler filling temperatures. That is because regular overhaul and maintenance routines for the filling valves extend the line’s useful lifetime, making it possible to substantially raise filling temperatures and thus yielding significant energy savings.
And this is precisely where Krones’ new LCS Warmfill retrofit solution comes into play with its holistically conceived approach that will enable a large number of customers to take the vital step towards a more sustainable filling operation. Thanks to its effective combination of technical analyses, line optimisation software and a new high-speed carbonation nozzle, it is possible to substantially raise filling temperatures. “In warmer regions, in particular, like South America or parts of Asia, that may prove to be a real game-changer,” says Shannon Kerscher. What’s more, she continues, a Warmfill retrofit package will often have paid for itself within one year in regions with high energy costs.
Case study: retrofit in South-East Asia
The potential savings are demonstrated by a line we retrofitted at a company in South-East Asia that fills 590-millilitre bottles at a speed of 60,000 bottles per hour. Before the conversion, the liquid had to be cooled for filling from 32 degrees Celsius down to 15 degrees Celsius and after filling heated up again to 28 degrees (dew point + 2 degrees Celsius). Thanks to the retrofit package, the filling temperature could be raised to 25 degrees, which made for a substantial reduction in the energy needed both for cooling and heating – with consistently stable production processes. Just a few months after the retrofit kit had been successfully installed, it became clear that the investment would pay for itself within one year.
The LCS Warmfill retrofit package is available in a two-stage and in a three-stage version
“At present, the Warmfill retrofit works for PET lines filling carbonated soft drinks (CSDs) and bottles holding 0.3 to 0.6 litres,” says Shannon Kerscher. An extended version for larger bottles and glass containers is planned for this year.
Specifically, customers can choose between two line optimisation solutions, depending on whether their line must be overhauled or not:
The two-stage LCS Warmfill Basic retrofit package is suitable for well maintained lines. The first stage here focuses on technical analyses: Based on data provided by the customer, Krones’ specialists calculate the maximum possible filling pressure, from which they then derive the maximum filling temperature. At the same time, the specialists analyse the filling velocity: They check to what extent the target temperature can be reached without reducing the rated speed. They also analyse the treatment time per stock keeping unit (SKU), including the requisite time reserves for pressure compensation and settling phase. The result is a soundly researched, hypothetical appraisal of the inherent potential, which serves as the basis for drawing up the technology upgrades needed across the line. What measures will make sense will in each case depend on the individual line configuration.
The second stage is all about translating theory into shopfloor reality – implementing the technical optimisation measures. The service technicians from Krones install the EvoCO₂ high-speed carbonation nozzle developed specifically for this purpose in the mixer and, if necessary, make targeted adjustments at the stretch blow-moulder, labeller or filler. To complement this, further machine settings and processes can be optimised, thus ensuring that the improvements identified are smoothly integrated into a stable, efficient filling process.
The three-stage LCS Warmfill Premium retrofit package, by contrast, is suitable for customers with lines in need of an overhaul. Stages One and Three of the premium solution are identical to those in the two-stage version. It is the second step that makes the difference. Here, too, the first step is to carry out a comprehensive technical analysis of the filler in order to prepare it for the Warmfill retrofit to optimum effect. That is because the better the condition of this essential machine, the greater the potential for raising the filling temperature. However, before practical implementation is tackled, the line is given an overhaul in order to restore it to the best possible technical condition. Only after this has been done will it be technically optimised: The high-speed carbonation nozzle will be installed in the mixer, as will any other upgrades necessary elsewhere, and all settings and process parameters will be fine-tuned.
EvoCO₂ makes all the difference
The new adjustable high-speed carbonation nozzle EvoCO₂ is the heart in both versions of the LCS Warmfill retrofit kit. This nozzle, a design enhancement of the field-proven Krones high-pressure carbonation system, features simpler technology than other comparable solutions and is a real game-changer: Instead of several nozzles like in cavitation carbonation systems, just one nozzle, the EvoCO₂, is sufficient here, which needs less energy and still ensures maximum process stability – even with production outputs varying between 100 and 33 per cent. Yet another advantage is this: The nozzle can be completely integrated into the Contiflow mixer’s control system and HMI and into the CIP cleaning system as well.
The winning formula: technology plus service
In contrast to the solutions on offer so far that usually comprise just the installation of a carbonation nozzle, Krones is now going for all-round support – from the first inquiry right through to the time when the kit is up and running. And the main focus here is on people: Permanent contact persons are specified who can be reached round the clock. That means any queries, malfunctions or adjustments can be seen to without delay. To complement this, fast and reliable spare parts deliveries ensure high line availability and minimised downtimes.
Yet another difference is that the technology concerned has been fully integrated into the Krones system. All relevant information is displayed on the line’s user-friendly human-machine interface (HMI), including status messages and function overviews. Functions can be selectively controlled directly via the HMI. The pictorial representation enables the operator to view the line’s behaviour at any time during production. There is no change in routines for the operators: processes, display logic and operating philosophy correspond to the Krones environment they are familiar with.
“With our LCS Warmfill retrofit packages, we offer our customers a solution that not only enhances their operations’ sustainability, it is also sustainable in itself. What’s more, the energy savings it yields directly translate into substantially lower operating costs,” emphasises Shannon Kerscher. “We supply a complete package ensuring stable, reliable, cost-efficient production.”
