Reference

Wecker

Compact and powerful

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Industry:

Food & Beverage

Location:

Münster, Germany

Application:

Process technology

Installed products:

EVERDRY

Welcome to Wecker

Individual compressed air preparation, adapted to difficult local conditions. Effective engineering and good cooperation between all parties involved make it possible.

Compact and powerful

The operator is active in the food & beverage sector and specialises in coffee refinement, among other things. The compressed air is often used in production and comes into direct contact with the product (including coffee granulate) at several points. In this project, the important certifications in the food industry and the specifications resulting from an audit required the operator to maintain a stable pressure dew point of below -40°C in order to maintain the desired compressed air class with a DTP of class 2 according to ISO 8573-1. In addition, 100% availability of the compressed air in 24/7 operation was required.

The compressed air station consisted of several decentralised, oil-lubricated screw compressors that are fed to a manifold. Up to now, the compressed air has been treated dry and oil-free, at a degree of dryness of <3°C pressure dew point (DTP) and by means of activated carbon adsorbers.
The operator took an upcoming refrigeration dryer repair as an opportunity to talk to his specialised trade partner Wecker Druckluft GmbH from Münster about a replacement and to work out a concept. Due to the requirements of the audit, the latest guidelines in the food industry, as well as the desire for a trouble-free DTP, the preparation was rethought. There was one particular challenge: the preferred location for the compressed air preparation was a basement with a low ceiling. Standard dryers were too high for the required performance class for the installation site. However, the operator wanted to stick to the position of the existing compressed air preparation.

Two partners, one customised solution

In order to convince the operator of an individual solution, a meeting was arranged. Here, BEKO TECHNOLOGIES, a long-standing partner of the specialist retailer, presented current references in the food & beverage sector, results of customer audits and detailed information on optimisation and target achievement. As a suitable optimisation compared to a new refrigeration dryer, the design for a custom-built EVERDRY FRA 6000 Eco adsorption dryer was proposed to the operator, which specifically took into account the given ceiling height due to lower adsorbent tanks. There were two crucial success factors for the performance of a smaller built adsorption dryer compared to a standard size.

The first success factor was the Sorbead Air adsorbent from BASF selected for this case. The high-performance adsorbent is about 20% more efficient than conventional activated alumina. This efficiency allowed the overall height of the EVERDRY FRA6000 Eco to be shortened by about 30 cm while maintaining the dryer's performance.

Innovative technology reduces energy consumption and enhances performance of compressed air systems

The low desorption temperature of the Sorbead Air reduces the amount of energy required for regeneration and offers a long service life due to its abrasion resistance and mechanical and thermal stability - important for the requirement of problem-free, 100% availability of the compressed air.
The second success factor was energy-related and a real added value of the EVERDRY FRA6000 Eco dryer. It comes from the use of steam, which is abundantly available at the operator's site. Heated ambient air is used to desorb the adsorbent, which in standard dryers is normally achieved using centrifugal fans and electric heaters. In the present case, steam was used: it heats the fan air via a steam heat exchanger. In this way, an already existing energy is used instead of generating thermal energy via expensive electric current for desorption. A positive energy balance, just eco.

The joint concept convinces

The operator was impressed by the joint consulting services, the implementation of a special construction height and the high energy savings compared to the offers of other suppliers and awarded the contract.
order. The oil-lubricated screw compressors now go to a manifold and from there through an EVERDRY FRA6000C Eco adsorption dryer and the activated carbon adsorber, including appropriate filtration. Instead of the compressed air class 1-4-1 of the old system, the compressed air is now provided with class 1-2-1 and is thus 50 times drier. This not only improves the degree of dryness, but also the absorption capacity of the oil vapour in the activated carbon adsorber. The quality is significantly more stable and thus the production reliability.

Advanced compressed air system exceeds expectations

The joint concept of Wecker Druckluft GmbH and BEKO TECHNOLOGIES exceeded the requirements of the operator through special construction size, adapted to the local conditions, BASF Sorbead Air adsorbents as well as the efficient use of existing steam for regeneration. Throughout the entire project phase, Wecker Druckluft and BEKO TECHNOLOGIES maintained permanent personal contact with the operator. The operator accepted the dryer during a preliminary acceptance test at the BEKO TECHNOLOGIES plant in Netphen. At the same time, Wecker Druckluft GmbH trained its service technicians on the device. The new dryer was delivered disassembled because the operator's entrance gate was smaller than the installation site. Subsequently, the subcomponents were assembled on site. Commissioning took place in the presence of Wecker Druckluft, BEKO TECHNOLOGIES and the operator. Since June 2019, the dryer has been running efficiently and reliably, the operator is satisfied with the technical performance, and the pressure dew point is far better than required. The compressed air requirements are thus up to date and perfectly positioned for years to come. Further projects will follow.