The Tönnies Group has built its bovine animal competence middle in Badbergen, Lower Saxony. The cuts of beef are vacuum-packed in thermoforming and shrink-wrap machines, a course of that has turn into more efficient than ever following renovations at the site: Now, energy-saving Atlas Copco variable-speed vacuum pumps are used to create vacuum circumstances at two central stations.What was once a mixed slaughterhouse has become a “bovine animal competence center”: For a long time, cattle and pigs have been slaughtered and butchered on the same time in Badbergen on behalf of different firms. In 2017, the Tönnies Group took over the location and decided to base its complete slaughtering operation in Badbergen – up till that point, this had taken place at the company’s major web site in Rheda-Wiedenbrück. In 2020, Tönnies Beef reopened the site after in depth conversion and renovation. The Group invested round 85 million euro within the building and state-of-the-art expertise at this website in a small city in northern Lower Saxony, between Oldenburg and Osnabrück. The slaughtering, butchering and finishing processes are based on the newest cooling technology, machine-based butchering and extremely automated choosing and delivery traces.
Several hundred tons of meat leave the location daily and 95% of the animal – virtually every little thing – is utilized. This permits Tönnies to satisfy different eating habits around the globe: While German customers favor lean beef, meat with a thick layer of fats is in style in Scandinavia and different European countries, based on the manufacturer’s website.
Efficient screw vacuum pumps provide forming, low and fine vacuums
“The cuts weigh between 1.5 and 9 kilograms after butchering,” explains Waldemar Metzger, Technical Manager of Tönnies Beef GmbH & Co. KG in Badbergen. The cuts are vacuum-packed for varied main customers. For this purpose, Tönnies has installed several packaging traces in the halls: Seven thermoforming curler machines and two robot-operated shrink-wrap packaging machines. Efficient Atlas Copco vacuum pumps are used in the methods to vacuum pack the tubular/shrink baggage and thermoformed plastic trays, and to keep the meat really fresh. They work in two stations and supply forming, low and fine vacuums.
เกจวัดแรงดันถังออกซิเจน thermoforming machines equipped by vacuum station 1. There are four Atlas Copco GHS 585 VSD+ variable-speed, oil-injected screw vacuum pumps that evacuate the air up to forty mbar (absolute), in addition to four small boosters that lower the stress even further to three mbar. One of the screw pumps provides the forming vacuum for the thermoforming roller machines, which solely require around one hundred to 150 mbar for the forming course of. The other vacuum pumps in this station are linked to the boosters. One of the pumps is redundant at any given time: This can also be the case in the second vacuum station, which comprises five GHS 730 VSD+ pumps that remove the air from the shrink luggage at the Cryovac traces. “The measurement of the cuts of meat is mechanically detected by our techniques,” explains Waldemar Metzger. “The packaging machines then mechanically insert the cuts of meat into the tubular luggage, that are cut to the correct dimension underneath a vacuum bell.” Under the hood, all ambient air is then evacuated in two stages till the pressure is around three mbar (fine vacuum).
“With the forming vacuum – or thermoforming vacuum, as it’s additionally known as – the plastic tray is fashioned by cutting the foil roll,” says the Technical Manager. After filling the shell with smaller items of meat, the shell is “wed” to the cover movie: The device closes and seals the packaging hermetic at three to 5 mbar using the fine vacuum. Sorting machines assign the person trays and tubular bags to bigger packing containers, which are then used to select customized packing containers for buyer orders.
Efficient velocity regulation reduces energy requirements by a 3rd or more
Waldemar Metzger has been working in Badbergen for 20 years and has been a part of the planning and execution phases of converting the blended slaughterhouse to a purely beef operation from the very beginning. This included the decision to purchase Atlas Copco variable-speed vacuum pumps. “As far as technology is concerned, being ready to differ the speed of the GHS vacuum pumps is essential to us and saves vitality,” stresses the Tönnies employee. “Compared to fixed-speed machines, you can reliably minimize down vitality necessities by around a third – even perhaps by half, relying on the range issue.”
The controls on the vacuum pumps have a user-friendly plain text show, which additionally indicates the working hours and upkeep intervals. Since the Atlas Copco pumps may be linked on to an exhaust system, it was attainable to make use of air-cooled pumps. According to the manufacturer, this improves the climate of the room; it’s no longer necessary to have the extra room cooling typically required when utilizing central vacuum methods.
The project was carried out on site by and with Oliver Hornberg, Managing Director of Eugen Theis Vakuumtechnik in Werther. He delivered the pumps to Tönnies Beef, ready to use – together with a 400 m pipeline within the converted slaughterhouse, measuring in locations to a diameter of DN 300. His company, Eugen Theis GmbH, was founded in 1984 and focuses on vacuum expertise. In 1999, Hornberg took over the enterprise from its founder, Eugen Theis, and 20 years later, in late 2021, bought it to Atlas Copco after he couldn’t find a successor. “Our two kids are pursuing other career paths,” he says. Hornberg himself stays Managing Director even after the corporate was sold to Atlas Copco and is trying forward to important development underneath the umbrella of one of many world’s largest suppliers of vacuum pumps. The firm already operates throughout Germany: “From Flensburg within the north to Regensburg within the south and Halle (Saale) in the east,” he says, outlining the attain of his firm: This additionally consists of Badbergen in the (north)west, as he generally stops by at Tönnies Beef to maintain up the machines.