SMC can help keep energy costs down
November 10th 2010

Pneumatics manufacturer SMC has warned that energy costs are accelerating rapidly. In response, SMC has unveiled energy saving components specifically developed for handling or transfer applications in automated manufacturing processes.

Series ZL112/212 multistage ejectors are designed with a triple stage diffuser which effectively increases the suction flow rate by 250%. Thanks to its innovative design, the amount of compressed air required to generate this increased vacuum pressure is reduced by 20%.

Series ZL 112, the smaller of the two models, is suitable for applications requiring a maximum suction flow rate of 100 l/minute (ANR) and requires an air supply of only 63 l/minute (ANR). With one-touch fittings easy piping is ensured and in addition to the standard options enjoyed by both the ZL models, the 112 multistage ejector can also be ordered with a supply/release valve.

Series ZL 212, uses the same 3 stage diffuser design but combines two stacked integrated diffusers in one single compact unit which effectively doubles the operational performance of the ZL112. Available with a range of vacuum sensor options including a digital vacuum pressure switch, both the ZL112 and 212 models can be specified with a port exhaust or with a built-in silencer.

"Any increase in energy costs has an immediate impact on a business's profitability, but any organisation that´s able to cut their demand for energy can put these savings straight on to their bottom line,” says Sebastian Fabio Agnello, development manager of SMC´s European Energy Saving Programme.

“Recently we installed a ZL112 ejector to a vacuum packaging application for a leading soft drinks manufacturer who were using a number of ejectors that were producing far more vacuum than was necessary to transport internal carton packaging.

“By replacing their existing ejectors with our multistage technology ZL112, we immediately saved our customer several thousand Euros a year in wasted energy costs and their investment on this energy saving initiative was recovered in just 12 weeks”, he continued.

According to Agnello, “by replacing a single stage ejector with one of our multistage technology ejectors, the air consumption required for vacuum generation is normally reduced by around 60%, which enables vacuum users to consider the benefits of even retro-fitting their machines as the savings are considerable as the payback on this  investment is relatively short”.

Joining the newly launched ZL products is a new range of vacuum saving valves - Series ZP2V. Developed initially for the semiconductor market these valves are designed to shut down the suction line when any leakage is detected from the vacuum pad not being fully aligned with the work piece, or even when the work piece is simply missing. The simple installation doesn’t affect the machine design and or machine’s functioning itself.

By effectively stopping the air suction when the system recognises any irregularities, the energy used in making this vacuum is kept to an absolute minimum. And, without the need for a work piece detection mechanism – which often use mechanical moving parts – unwanted surface scratches or marks on the work piece are now a thing of the past.  

Ideal for use as either a standalone single vacuum pad or for multiple vacuum pad applications where the vacuum pressure loss is reduced to a minimum and the work piece remains held by the rest of the operating pads, ZP2V users will also save money and time by eliminating the need for expensive sensors or a programmable logic controller (PLC).

Agnello concludes: “Some of the largest consumers of industrial energy in Europe are in engineering and manufacturing and recent research indicates that these sectors are currently spending around 20% of their total energy costs in the manufacture of compressed air. In today’s economic climate, the need to use this energy efficiently has never been more important and our energy saving products can literally mean the difference between making a profit or a loss.”

More articles from SMC Pneumatics (UK) Ltd: