VLT FlexConcept helps Molson Coors’ Borsodi
Brewery to save a lot of energy
consume a lot of energy in running their processes. At Molson Coors’ Borsodi
Brewery in northeastern Hungary, an upgrade of the gear motors on a glass
bottle filling line has resulted in energy savings of 33-42%.
Improved reliability and productivity as well as
reduced water consumption and emissions bring extra cost savings. The payback
time of the retrofitting project will be less than three years.
The glass bottle filling line with a capacity of
35.000 bottles (0.33 liters and 0.5 liters) per hour had served the Borsodi
Brewery for 24 years. Only a few motors were speed controlled by an AC drive,
so the performance of the complete system was far less than optimal. As Molson
Coors Group has set ambitious targets regarding energy and water efficiency and
carbon intensity, a total of 36 old gear motors needed to be replaced with more
efficient, speed-controlled motors.
“When planning the upgrade, our main attention was
focused on energy savings to be achieved,” says Gábor Széman, Technical Service
Manager, Borsodi Brewery. “We were introduced to the Danfoss VLT® FlexConcept®
− which is a flexible, highly efficient conveyor drive system. Initial
calculations showed an energy savings potential of approximately 40%, based on
a comparison of the most inefficient, old gear motor of the filling line, and
the high efficiency of 89.4% achieved by the VLT® FlexConcept®,” he continues.
The first step was to measure the energy
consumption of an old bevel gear motor equipped with an AC drive. Then, the
same measurement was repeated in the same location and under the same
conditions with a VLT® OneGearDrive®, a highly efficient permanent magnet (PM)
3-phase synchronous motor controlled by a VLT® AutomationDrive FC 302.
“In different operating situations, the result was
energy savings of 33-42%. This result fully supported the first theoretical
calculation, as predicted. Based on this result we decided to go ahead with the
upgrade, replacing all the old gear motors and AC drives with 36 new units of
VLT® OneGearDrive and VLT® Automation-Drive FC 302,” says Mr. Széman.
Installation of the VLT® OneGearDrive® is easy and
fast as it is mounted directly on the conveyor shaft, so chains are not
required. “With the Danfoss VLT® FlexConcept® we control each motor and
therefore, we have the possibility to optimize the production and also reduce
losses. We are very satisfied with the performance of the new VLT® FlexConcept®
drive system, and we are already planning a new retrofitting project,” Mr.
When calculating energy savings and all other
savings achievable in spare parts, cleaning time and operation costs, the
payback time of the upgrade will be less than three years.
savings and reduced emissions
In addition to the energy saving benefits, the Danfoss VLT® FlexConcept®
provides the Borsodi Brewery with other useful advantages, such as:
in costs for spare parts and stock
Before the upgrade, a spare parts stock of more than ten different types of
gear motors was required for maintenance purposes. Thanks to the Danfoss VLT®
FlexConcept® enabling a reduced number of variants, the stock could be
reduced to five units only (comprising VLT® OneGearDrive® and VLT®
AutomationDrive FC 302).
in operation costs
The old gear motors caused system faults, which resulted in production loss and
increased operation costs. Thanks to VLT® OneGearDrive®, the risk of system
faults is considerably lower, which improves productivity.
in cleaning time and water consumption
Thanks to the special design of the VLT® OneGearDrive®, which has no fan, no
cooling fins, and has a special surface, the unit is very easy and fast to
clean, so the brewery saves time, water, and detergents.
of CO2 emissions
The energy-efficient Danfoss VLT® FlexConcept® enables the brewery to reduce
CO2 emissions by approximately 130 tons annually.
The old filling line was served by a total of 36
gear motors, bevel gear motors with induction motors with efficiency rating
IE1, and a few mechanical adjustable gear motors.
Borsodi Brewery is located in the village of Bőcs, near Miskolc, the capital of
Borsod-Abaúj-Zemplén county in northeastern Hungary.
The brewery started beer brewing in 1973 with an
initial production capacity of 875.000 hector liters. In 2012, the Borsodi
Brewery was taken over by Molson Coors Brewing Company, an American Canadian
brewery company which is one of the biggest brewers in the world.
The Hungarian beer market is around 5.7 million
hector liters in total (2013).
is one of the biggest beer producers in Hungary. Borsodi was the first producer
of canned beer and non-alcoholic beer in Hungary.