Energy Concept
Complete insulation of the high-temperature zones
An effective insulation can only be achieved by taking measures at the time of construction of the frame. The radiation loss of a machine fully insulated with 40mm Polyurethane hard foam is multiple times less than an uninsulated machine.
Heat Recuperation
The most efficient method for the internal energy recovery is the heat recuperation. The last pre-sprinkling is connected thermically with the first rinse after the main caustic soak (Caustic-II-spraying). Because of the low temperature differnce of only 5 - 10°C, plate heat exchangers are used. The heat transfer colls down the Caustic-II zone and therefore reduces the fresh water and energy consumption up to 25% or 30% respectively with no change in temperature of the cleaned bottles.
Pre-Sprinkling of the bottles for pre-heating with used process water on the feed board
The number of temperature steps in the heating zone has decisive influence on the energy consumption.
Pre-sprinkling with used process water on the feed board as a first heating step with very long action time allows to reduce the temperature of the discharged water considerably. Combined with the reduction of water consumption due to interval jetting and heat recuperation between caustic-II-jetting and pre-rinse, heat loss through discharged water can be minimized. A conventional machine has approximately double the losses compared to the low-energy machine.
Minimization of warm-up losses by means of small caustic and water volumes
The warm-up heat consumption (independent from output) of a bottle cleaning machine has to be differentiated from the operation heat consumption (dependent on output). In craftsbreweries often filling happens only one or two days a week. Warm-up heat consumption of a conventional machine in this scenario is more than three times the consumption of a PAC low-energy machine.
Controlled vapor exhaust
A infinitely variable vapor exhaust enables a reduction in heat loss through vapor up to two third.
Optimized liquid and chain routing reduces power consumption
The bottle cleaning machine is in electric consumption second to only the cooling equipment in the brewery. Electricity is needed for the pumps, the drive for the bottle transport system, the label discharger, the vapor exhaust fan, the internal fan (for label peel off from the sieve band, blowing off of the bottle bottoms, ventilation of the switch cabinet) and for control and regulation. The optimized fluid routing through short and wide pipes allows using pumps with low power ratings. The ideal chain routing and the use of roller chain sprockets reduce the electricity consumption of the main drive dramatically compared to conventional machines.