Applications of Pneumofore Technology

Compressors can often be used for a broad range of applications with minimal study of the entire system. Vacuum pumps, however, with its growing significance in creating vacuum for specific applications, is more complex and frequently requires specially designed solutions. Pneumofore specializes in vacuum engineering and develops vacuum pump solutions for numerous industries, including:

 

pipeline   Pipelines
Drying by vacuum is faster and cheaper, provided the pumps evacuate water vapor. Ready-to-use systems for mobile operation on trucks or containers. [Gazprom, BJ Services, Trans-Asia Pipeline]
    Drying / Degassing
Simple energy calculations motivate the use of vacuum to dry wet components, rather than heat. Valid for wood, metal, pulp and paper, polymers and more.
  Food Processing   Food Processing
Vacuum cooling of fresh food and selected cooked solid food semiproducts. Cleaning of animal interiors in slaughterhouses. Higher bread quality and bakeries economy with vacuum chamber.
                     
airbus   Aerospace
To simulate the environment of airplanes at different altitudes, with considerable variations of pressure, achieved by variable speed drives. [Honeywell, Airbus, Fraunhofer Institute] 
    Ceramics, Bricks and Tiles
To eliminate water traces in the dough before entering the oven, for a homogeneous consistency and a fine surface. Also for ultra hard, top quality Italian ceramics.
  Bacon_150pix   Food Packaging
Less humidity often means a longer shelf-life. Vacuum packed meat with dual pressure systems. Moving of packaging material or food in serial, industrial scale.
                     
  Aluminium Cans
Vacuum is found in several manufacturing steps: a clean and continuous use of large, centralized systems with air cooled UV pumps. [Rexam, Crown Cork, Can Pack, Mivisa Envases, United Can]
  Hollow Glass   Hollow Glass
Vacuum systems for glassworks to improve the moulding at the IS machines in terms of speed and precision. Air cooled solutions, expertise and references worldwide.
  Pasta_150pix   Pasta
Vacuum for degassing, short before shaping, in the majority of Italian pasta factories. Good mood with tasty pastasciutta. Also for maccaroni in Iran using air cooled UV pumps.
                     
Water importance   Environment
Low Life Cycle Cost and Short Return of Investment also mean Less Environmental Pollution. Our Mission is to avoid Waste of Energy, Material and Water. Our Key since 1923.
  electronics   Electronics
Hightech IT production facilities install UV pumps for almost secret processes in Europe and Asia [Infinion, Chipbond, Opto-Tech, Formosa Information, Seagate]
  Bottling_150pix   Bottling
Dedicated, tailored vacuum systems for bottling processes of liquids with exclusive 100% air cooling. To eliminate viral contamination of water in cooling towers. [Tuborg]
                     
windings   Electrical Windings
Vacuum is used for the perfect and fast surface coating of the wiring. From serial, industrial scale motor production to single, large size transformers.
  Chocolate_150   Pick & Place
To move and pack without contamination in clean rooms with centralized vacuum systems to speed up crucial and precise production steps.
  Styropor_150   EPS
Many white balls grow with vapor in limited volumes using pentane and vacuum. EPS insulates temperature and absorbs mechanical pressure.
                     
pharma   Pharma / Medical
Various applications from medicine production, to pick & place and packaging processes. [Becton Dickinson, Lifescan, Borisovmed]
  sugar_150   Pneumatic Conveying
Size and weight of grains require sometimes more vacuum than Side Channel Blowers can perform. Exact vacuum for perfect dosing.
  surface coating   Surface Coating
The appearance of plastic, metal objects or textures changes by covering their surface with thin layers, using multi-stage vacuum systems. Usually tailored solutions for shorter deposition times.

 

 

 

pipeline  

Pipelines
In the 90's only liquid ring vacuum pumps were known to create vacuum for pipeline drying purpose. The liquid was usually water, as the evacuated air contained water vapor, compatible with the cooling water. The performance of liquid ring vacuum pumps strongly depends on the sealant's (water) temperature. With gas available in rather hot or below 0°C countries, water sealed pumps failed to fully satisfy Pipe Drying Companies. The complexity of Generator - Liquid Ring Vacuum Pump - Cooling Water Tower was further complicated by replacing them with Ultra Dry Compressed Air System with much higher power requirements due to compressor size and multi-stage drying systems with chillers. In energetic terms worse than the liquid ring vacuum pumps. Nevertheless, 20 years ago environmental awareness with energetic / environmental considerations were not the priority of companies active in the petrochemical industry worldwide. In 2006 Gazprom, the largest in this field, simply installed one generator and UV50 vacuum pumps on a truck trailer, a completely air cooled system, based on the exclusive performance of UV pumps to evacuate large water vapor quantities. This solution was further improved in terms of drying speed, by installing additional (roots) stages on the UV H backing pumps, as done by BJ Services and Trans-Asia Pipeline Services.

Casestudies: Narmada, BJ Services, Gazprom

   
 

Drying / Degassing
In nature, the drying processes find place in the sun. The largest source of heat has been used to dry all sorts of materials, later also fire was applied to reach higher temperatures in limited spaces, like ovens or kilns. Today, humans need to dry bricks and tiles to build their houses as done thousands of years ago. Basically it is about taking gas or vapor or simply air out of a liquid or nearly solid item. Degassing is done in Italian pasta factories as well as in brick factories. Extruders mix components for a homogeneous structure, which is later backed; the presence of water in the dough is to avoid because water turns into vapor with a much larger volume, creating cracks and even changing the taste perception of pasta. Thus vacuum is applied, with precise mbar(a) and m3/h dosing. Polyester Chips must be packed with low residual humidity, as done with up to 3 stage vacuum systems, in the shortest possible time. Still, vacuum is usually applied slowly, otherwise the product could break, as happens when wood is dried with excessive speed. Other materials like leather or all sorts of aggressive chemicals contain dangerous elements, which could contaminate our vacuum pump, thus needs to be protected accordingly. Simpler is the vacuum drying of metal components, right after the washing, as alternative to heat, which requires more power, more time and causes temperature dependent deformation. Also pipelines are dried prior to operation, this and other degassing applications have a dedicated section.

Casestudies: Brakes India, Polyester Chips

   
Food  

Food Processing
The industrialization of food processing considers more and more vacuum as energy form. Our pumps manage to evacuate water vapor in pasta factories, even in Iran, with air cooling only. Tumblers to soften meat at Kerry Food and Hilton Food in Ireland also use reliable and durable Pneumofore vacuum systems. In the last years we observed a growth of vacuum chambers for baking bread or simply storage of perishable food like vegetables or fish. After excessive repair expenses caused by competitive technologies or small, compact vane pumps, and with the rising importance of shelf-life, taste and environmental considerations, our customers finally satisfy their production needs with tailored, centralized vacuum system solutions with Pneumofore UV pumps. See dedicated section for pasta and food packaging.

Casestudies: Caillor in France

   
airbus  

Aerospace
The simulation of altitude for airplanes requires a vacuum system, capable to vary the absolute pressure, sometimes with steep gradients. This application differs herewith from most other processes, as vacuum is not required constant and continuous. The media to evacuate is pure air, no presence of contaminants. Considering the size of airplanes and their space requirements in testing facilities, vacuum systems are specified with considerable high capacities and challenging pressure-variation capability. A simple power consumption analysis results in the evidence of Pneumofore's advantages, with UV pumps showing double the efficiency of liquid ring vacuum pumps. The easy air cooling of UV pumps, the capacity of 3.200 m3/h for each UV50 and their variable speed option represent the state-of-art in rotary vane technology, as done by Pneumofore only. These test facilities run only few hours per month, the investment for the vacuum system shall result in a simple-to-manage installation with minimal power requirements. Based on these criteria, Pneumofore successfully collaborated with prestigious aviation companies like Honeywell, Airbus and the Fraunhofer Institute.

Casestudies: Airbus

   
Tiles  

Ceramics, Bricks & Tiles
The presence of solid silicate and clay particles in the suction of the vacuum pumps is causing the slow erosion of all materials, unless a dedicated filtration system is installed. This application used to be served by liquid ring vacuum pumps. But the degassing process must be continuous at a specific vacuum level, the quality of tiles and bricks must be kept also when the press is hot: this is achieved with UV pumps in several bricks plants. We offer fully engineered vacuum solutions with air cooling, with less power need, less noise and without continuous repair of the pump's cylinder.

Casestudies: Lusoceram in Portugal, Marble Tiles Production

   
Bacon_150pix  

Food Packaging
In the field of food packaging different vacuum levels for higher packaging speed are needed and certain humidity and specific vacuum values have to be maintained constant with air as only cooling medium. Small on-board vacuum pumps are often used in the food packaging industry. However, as soon as the size of production is large enough to allow the centralization of vacuum, Pneumofore can offer the experience to increase the vacuum level using multiple stages, allowing longer shelf life of the products and sensibly improve the cold room operators' working ambient. Many on-board vacuum pumps mean running noise, oil mist and low performance that can be solved with the centralization of the vacuum pump system.  Also, reduced power consumption and increased packaging speed are important features of UV installations on this field. All these are requirements for operation, during four seasons 24 hours for 365 days a year.

Casestudies: Kreatina

   
Cans  

Aluminium Cans
A clean application with continuous operation, usually with several 1.000 m3/h capacity, cans and tins production represents a key market for Pneumofore UV pumps. After replacing liquid ring and screw pumps in existing plants for decades, today our units are considered already in the preliminary specification phase of "green field" projects. The success is based on the simple handling and trouble-free operation over several years. The air cooling of UV pumps avoids problematic cooling water circuits, the simplicity of the rotary vane air-end allows simple overhauling, the ease of maintenance and rare service requirements, these and more reasons result in the attractive "Return of Investment" and "Life Cycle Cost" Calculations.

Casestudies: United Can in Jakarta, Rexam Italy Service, Rexam Spain and UK, Mivisa Envases

   
Hollow Glass  

Hollow Glass
The industrialization of food distribution was based on glass, as hygienic reusable container material. Hollow glass is being replaced lately by new, mostly synthetic materials but keeps its key position in prestigious liquids packaging like wine, beer, juice, jam etc. The moulding process of glass containers is the core application of Pneumofore UV vacuum pumps. In this tough round-the-clock heavy-duty application, Pneumofore managed to collect experiences over more than 50 years. This positions our company on top as worldwide leader of vacuum pump systems for IS machines. The presence of lubricants at the IS machine requires dedicated filtration solutions. Our offer includes the system calculation and layout to guarantee a specific vacuum level. Variable speed options to minimize power consumption, from 35 to 60 Hz, also up to 32.400 m3/h capacity.

Casestudies: Wiegand - NampackSevam, Seves, Sis,ecam, Hindustan National GlassMISR Glass, Saint Gobain, Malaya Glass, Middle East Glass

   
Pasta_150pix  

Pasta
The challenge varies for each pasta factory and that is where Pneumofore as solution provider succeeds, due to the tailored design of the entire vacuum pump system instead of the simple supply of standard vacuum pumps. Pasta requires the perfect amount of vacuum to improve the quality of the final product. With a 100 mbar(a) vacuum level the humidity in the mixture is sucked out but this needs to be done with a perfect balance of mixture amount and vacuum amount. The vacuum pump system must operate 24 hours a day 365 days a year, which makes  durability and reliability of the vacuum pump system very critical due to the losses of an eventual stop of the machines. The filtration system, the constant vacuum requirements and the variable capacity requests as well as, above all, the perfect taste and perception of pasta make Pneumofore a very important player in the field of industrial vacuum pump systems for Italian pasta factories.

Casestudies: Zar Macaron, Pezzullo, Chirico

   
Water importance  

Environment
Pneumofore does not clean up the dirt, it works right at the source, where pollution is born. With 35% of the energy used by the world's industry spent for Air Compressors and Vacuum Pumps, we contribute heavily by producing such machines with higher performance, less kW / HP but also exemplary durability and reliability. We hold a bright light in a foggy market and declare true technical data, invest in R&D to improve efficiency, succeed with the lowest specific power consumption of Air Compressors and Vacuum Pumps, we offer air cooling where competitors use water. These and more features of our machines, which are designed to create the minimal impact on our planet, stay in clear contradiction with today's standard business philosophy of fast money. During our 87 and more years of experience, it has not been rare to loose customers due to our high selling price, but switching to screw or liquid ring technology caused them considerably higher Operating Costs by consuming more power, which corresponds also to the heavier environmental pollution. And they returned to us, since the Pneumofore machine was still running after decades, while other technologies or copies of our's, simply failed in terms of Life Cycle Cost and Peace of Mind. Being the production process of our machines also an energy-intensive activity, we qualified for the environmental ISO14000 certification in 2002 and we overhaul our machines again and again, up to 50 years old machines continue to return to our factory for simple check or repair. Like this we work against the consume-oriented, fast growing industrial evolution, frequently motivated by shareholders full of profit expectations. As a multi-generational family owned company, our satisfaction surely depends on the success in financial terms, but is strongly influenced by sane engineering ethnics. Pneumofore sales are frequently driven by Return of Investment Calculation when replacing other, obsolete technologies. The rising costs of electrical power and water works to our advantage, customers easily get the green light to invest in Pneumofore machines with ROI values of 18 months or less. "Prima di essere ingegneri voi siete uomini" by De Sactis in 1858 on the famous white marble sculpture at the Polytechnikum of Zurich, Switzerland, where the 3 generations of Swiss engineers, owners of Pneumofore, have been educated in the last 100 years.

Articles: Kyoto Protocol, Water Importance, Renting Industrial Equipment, Modernization of Eastern Europe Glassworks

   
electronics  

Electronics
A domain of high vacuum engineering, with turbomolecular and diffusion dry-pumps. However, these steps in production are executed in batches, on the spot, in limited areas. Also because vacuum levels of 10E-10 mbar(a) are difficult to contain and maintain in large volumes. Pneumofore takes care for the rough vacuum, we pump from ambient pressure of 1013 mbar(a) down to 0,5 mbar(a) [29,9 inHg V], other Companies do the pumps to go lower in Residual Pressure. With ultra-high-tech know how for the latest generation of IT processors, sometimes basic notions of simple rough-vacuum engineering are considered less or almost neglected. The success in Asia and Europe is mainly due to the trouble free operation, simple maintenance and total reliability, supported by extended total warranties of 5 years of UV pumps. With our aluminium vanes being an integral, non-consumable part of the Rotary Vane Air End and with Pneumofore guaranties, which cover also the efficiency, besides the functionality, our positing in this constantly evolving market is growing and secured.

Casestudies: Infineon

   
Bottling_150pix  

Bottling
In the industry of food processing, strict food production regulations can potentially halt the entire production or, in the very least, cause enormous fines and possibly high costs for treating cooling liquid waste. New laws requiring lower tolerance for bacteriological contamination can easily create problems for beer bottling plants using liquid ring pumps, often seen in this sector. This means that environmental and bacteriological problems have to be taken under control. Pneumofore tackles such problems with a special design based on the advantages of its existing vacuum pump technology. With vacuum, the bottling of beer allows increased productivity but exposes the vacuum pumps to suction of bioactive liquids, such as beer. In the beer bottling process UV pumps are operating to avoid the contamination of the cooling water used for liquid ring vacuum pumps. Pneumofore was a hot candidate for the 'Danish engineers Products Price 2005' because of the results of halving the installed power and elimination of troubles with cooling water at a Danish brewery.

Casestudies: Tuborg

   
windings  

Electrical Windings
Pneumofore is strongly committed to develop new processes used in insulating electrical windings and capacitors for medium and high-voltage devices (motors, transformers, generators etc.). Vacuum Pressure Impregnation (VPI) is the only process that can guarantee the perfect electrical insulation for high-voltage applications and besides several benefits coming from dielectric materials and special resins or oils, constant vacuum level is important to keep good surface treatment all year long.
Depending on reactor size it is important to achieve high pumping speed and low pressure levels in order to optimize the productivity. Pneumofore has already successful references in this field and is involved in projects for vacuum centralization of several autoclaves.

Casestudies: Sicme Motori

   
Chocolate_150  

Pick & Place
Ferrero, an italian chocolate producer with plants in Italy, Belgium and Argentina, chose Pneumofore to provide vacuum solutions for multiple applications, from drying to transportation or pick and place during the box packaging phase. With a centralized vacuum solution, a higher production speed can be achieved. Several UV vacuum pumps provide 24/7 vacuum supply. However, Pick & Place is found in a huge number of industries, especially where a serial production requires an automated and fast moving of product or packaging, as found also in food, medical, containers and electronics production sites. Finally, our machines installed at Becton Dickinson in UK, run to satisfy a Pick & Place process within a medical factory, and the UV pumps at Seagate in Asia move little screws for Hard Disk assembly.

   
Styropor_150  

EPS
Besides tubs of fine thickness, commonly named thermoforming, another synthetic material application is the moulding of EPS or polystyrene. These materials also allow thermal insulation, e.g. for fresh fish boxes: another use of vacuum for industrial big series production of food containers, which have to respect all civil food regulations and perform as environmental friendly as possible. The relevant presence of vapour during the EPS moulding process represents a difficult task for every vacuum pump manufacturer. In this production vacuum is needed in order to mould the EPS into the desired shape. The vacuum pump system has to be designed to satisfy all manufacturing needs like high material density, low relative humidity and fast moulding speed.

Casestudies: Baukork Swisspor
Special report in German "Vakumm - Anlage zur Produktion von Stiropor (EPS) Formteilen": Text, Bilder, Zeichnung

   
pharma  

Pharma / Medical
The Pharmaceutical Industry uses vacuum for specific processes in the Medicine Production and in the final Stage of Packaging. Vacuum, the absence of air, supports 'clean' requirements, where contamination by volatile impurities is avoided. Access to the production area in Pharmaceutical Industries is limited, we rarely know about improvements regarding constant Vacuum Level or lower absolute residual pressure, which might speed up or simplify specific steps. When we replace liquid ring or screw pumps with our Rotary Vane Technology, our installations base on Return of Investment calculations and we are perfectly aligned to the strict standards of precision and reliability requirements of the Vacuum System. UV pumps are also appreciated in such continuous applications for their clean exhaust, as happened at Becton Dickinson in Ireland, substituting rotary screw pumps. In Belarus, the air-cooling and strongly reduced power consumption of UV pumps, combined with our vacuum system engineering competence, allowed considerable savings compared to the previous liquid ring system. Lifescan, in Scotland, moved away from costly repair and spares of 'compact vane pumps' by installing a Pneumofore system, which offers industrial values of durability with easier Maintenance.

Casestudies: Borisovmed in Belarus

   
sugar_150  

Pneumatic Conveying
A wide range of materials can be moved with pneumatic conveying. But cement differs from polymer granulate or cereals, in specific weight, fragility, hardness, etc. thus pipe sizes and materials are calculated in accordance. When moving products with vacuum, rather than pressure, a risk is always present by the potential contamination of the pumps, which pretends tailored filtration systems.

   
surface coating  

Surface Coating
Surface coating applications are mostly related to different pumping stages required to reach very high vacuum levels. The vacuum chain does not admit weak rings and the trouble-free primary evacuation step is crucial to guarantee constant and high ultimate pressures. Pneumofore Rotary Vane technology avoids efficiency loss and minimizes maintenance operation for stable performances also after years of operation. Vacuum coating processes ranging from paper, polymeric and glass substrate metallization to surface and heat treatment of metal tools require very reliable vacuum pumps. Our aim is to combine current features of UV series vacuum pumps with on-going product developments in order to meet all customer needs. Glass coating systems count many vacuum chambers that can be connected to the same rough vacuum system by reducing operational costs and time of evacuation. Additional vacuum pumps of smaller size for higher vacuum levels are near the single chambers.

 

 

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