Valencia, 18th May 2020.- Cabycal has developed and installed a 5.5-stage double tunnel for the factory of a leading company in the manufacture of household appliances. The manufacturer has undertaken a series of improvements to one of its production plants. One of that improvements has been the replacement of an old metal parts spray pretreatment tunnel with a new one with nearly 2,000 nozzles.
In addition to the mechanical assembly of the new machine, the equipment has been completed with the digital integration of the tunnel with the existing installation and the updating of the electrical installation, the control panel and automation.
This new double tunnel is capable of enabling only one of its lines and of registering a large number of parameters (pressure in the water circuits, temperature of the motors, vibration in the hydraulic pumps), in order to optimize the consumption of water and light and generate the least possible environmental impact. According to estimates, with the new equipment this company will reduce its electricity consumption by around 80%, representing an economic saving of more than 130,000* euros per year.
This energy saving is due to the detailed study of different factors developed by the electrical and automation engineering department of Cabycal for the optimization of the production process of the multinational. Among the factors studied are the reduction in installed power, the use of frequency variators in all motors, the elimination of 90% of reactive power and the operation of new pumps on demand for working pressure with an integrated PID function.
The factor that has drastically reduced the electricity consumption of the new treatment tunnel has been the decrease in electrical power. The new treatment tunnel has an installed electrical power of 72.6 kW compared to 329.8 kW in the old tunnel.
Another factor taken into account has been the use of frequency variators in all the pumps and fans that are part of the new treatment tunnel. Although this energy saving is less significant than that provided by the reduction in installed power, it is also important. By using frequency inverters, energy savings are achieved thanks to the improvement in the efficiency of the pump or the fan it manages. Reactive energy is eliminated by 90% and optimization of consumption in the pumps increases, since only the power necessary to reach the levels of work demanded in each treatment process is used.
Furthermore, in addition to energy savings, it is necessary to take into account more factors that the frequency inverters contribute to the production process:
- They eliminate water hammer and vibrations in the pipeline, which have an impact on increasing the useful life of the installed mechanical elements and reduce maintenance work. Increases the useful life of the motors, since the starting peaks generated by the motors are eliminated.
- They maintain a constant pressure in the pipeline as the system incorporates pressure sensors and the frequency variators regulate their speed by means of a PID (proportional, integral and derivative function) taking as a reference the pressure demand required by the multinational.
* Estimated calculation based on 16-hour days, 5 days a week and taking the Iberdrola fixed rate as a reference.