Keeping cool in the face of sweet temptation
For many people, chocolate is more than just one of life’s sweetest temptations. The complex machinery required for the industrial production of this luxury food item also presents engineers with major challenges. In an ever-tightening market, traditional companies in particular, such as the Ludwig Weinrich chocolate factory, need to rise to current economic and ecological challenges. To do this, they need reliable partners.
The project: New pumps for cooling water system
In the complex chocolate manufacturing process, the transport of cooling water to production systems may seem at first glance to be of secondary importance. In fact, it is a crucial aspect of the process. During the different stages of processing, the chocolate mass and other ingredients must be heated and then cooled immediately under controlled conditions. Unless this can be performed reliably, large quantities of chocolate may become unusable and the entire production cycle can come to a standstill.
The customer: Ludwig Weinrich chocolate factory
The Ludwig Weinrich chocolate factory in the town of Herford in East Westphalia, Germany, has been producing chocolate for more than 120 years. A fourth-generation family-run enterprise dedicated to sustainability, it has around 400 employees who work with sophisticated chocolate recipes every day to create perfect moments of indulgence.
Cooling water system with Movitec VF pumps
The challenge: Redundancy and reduced energy costs at one stroke
The Ludwig Weinrich chocolate factory decided to replace its existing error-prone cooling water system, to ensure system availability and smooth manufacturing operations. Since, as in many other branches of industry, the old system was associated with rapidly escalating energy costs, the company also hoped that the new cooling water system would slash energy consumption to a level more appropriate for a modern manufacturing facility.
The solution: Selection of demand-driven pumps
As in many other projects, KSB collaborated with the Wendik Pumpen-Service company based in Herford, Germany. The two companies have a long history of collaboration in installing and maintaining KSB pumps spanning more than 50 years.
After extensive consultation with KSB, the data required for the system was collected internally and evaluated. Wendik Pumpen-Service then used this data for planning the new cooling water system and selecting the pumps. The company opted for the Movitec VF high-pressure centrifugal pump, which, in conjunction with PumpDrive 2, achieves the desired energy savings by delivering performance that constantly adapts to demand. The Bowe & Vaal company installed the piping for the system. Wendik Pumpen-Service installed and successfully commissioned the pumps and is also responsible for servicing
The installed redundancy means that the Ludwig Weinrich chocolate factory now has process reliability it can depend on. The selection of demand-driven pumps has also delivered incredible energy savings of 75% – a highly effective combination that works.
Two Movitec VF pumps equipped with PumpDrive 2
Figures I Data I Facts
Plant: Cooling water system for chocolate production
End user: Ludwig Weinrich chocolate factory
Pumps, frequency inverters, sensors, valves:
- 2 x Movitec VF 060-01-1 high-pressure centrifugal pumps with PumpDrive 2 (motor-mounted)
- 2 x SERIE 2000 DN100-PN10/16 swing check valves
- 8 x BOAX-SF DN100-PN16-EPDM-XU centred-disc butterfly valves
- 7 x BOAX-SF DN065-PN16-EPDM-XU centred-disc butterfly valves
Products used
Movitec
立式多级高压离心泵，节段式设计，相对布置的吸入和排出管口具有相同的公称直径（管道式设计），直联式。带能效等级为 IE4/IE5（依据 IEC TS 60034-30-2:2016 标准）的无磁体同步磁阻电机 KSB SuPremE（例外：尺寸为 0.55 kW/0.75 kW、转速为 1500 rpm 的泵带有永磁体），配合无转子位置编码器的 KSB PumpDrive 2 或 KSB PumpDrive 2 Eco 转速调节系统运行。固定点符合 EN 50347 标准，外壳尺寸符合 DIN V 42673 (07-2011) 标准。可选购 ATEX 型式。
BOAX-S/SF
中央截止阀，带用于 DN 350 起的截止阀的符合 ISO 5211 标准的方形轴端，带热屏障，弹性衬垫（EPDM XU 或丁腈 K），带手柄、手动减速变速箱或电动执行器（BOAXMAT-S 和 BOAXMAT-SF），带定心凹槽的壳体 (T2)，带螺纹法兰凹槽的壳体 (T4)，用于单侧拆卸法兰和作为尾阀安装，不锈钢 1.4308 阀瓣，接口符合 EN 标准。
PumpDrive 2/PumpDrive 2 Eco
自冷式变频器，模块化构造，可通过模拟标准信号、现场总线或者操作单元无级改变异步和同步磁阻电机的转速。由于配有 PumpDrive 自冷装置，因此可安装在电机上、墙壁上以及开关柜中。无需辅助控制器即可控制最多 6 个泵。