Report Spring 2019 - Kaeser Compressors
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Contents Issue Spring 2019 Editorial 3 Editorial 4 KAESER KOMPRESSOREN Turns 100! From a machine workshop to a global leader 8 ‘Integrated Industry – Industrial Intelligence’ 100 Years Hanover Fair 2019 – Hall 26 Booth C51 4-7 KAESER KOMPRESSOREN 10 Flying High with Clean Air FACC – an Austrian global player 100 years ago, my grandfather, Carl Kaeser Sr. – together with eight employees and two apprentices – founded a machine 13 Variable Pressures and Heavy Duty Site Performance workshop that specialized in gear cutting and car engine over- Dipl.-Wirtsch.-Ing. Dipl.-Wirtsch.-Ing. New MOBILAIR M171 portable compressor Thomas Kaeser Tina-Maria Vlantoussi-Kaeser hauling. In 1947, my father, Carl Kaeser Jr., made the decision Chairman, Managing Board 14 Spice is the Variety of Life! to start manufacturing the first serial production reciprocating Managing Board The Fuchs Group – cultivating a world of good taste compressors. 8-9 17 In the Service of Research Today, KAESER KOMPRESSOREN SE remains a fully The solutions we seek will be found only through collaborati- Compressed air for the Institute of Thermal Turbomachinery at the KIT family-owned business that offers and markets its industrial on: with the development of the potential harbored in human compressed air technology products and services in over 100 communities that comes to fruition only through open and 20 The Beauty of Water SIGMA AIR UTILITY at Neoperl GmbH in Müllheim countries through its own subsidiaries and exclusive sales part- constructive co-operation between dedicated people who ners. KAESER KOMPRESSOREN has remained competitive are free to act on their own initiative. 23 The Sky’s the Limit for 100 years and has been able to grow successfully through Premium quality craftsmanship in series production: its combination of uncompromising customer orientation and Digitalization, the Internet of Things (IOT), Smart Factory, AutoGyro GmbH, Hildesheim constant innovation with highly motivated and expertly skilled networking and artificial intelligence are all helpful tools to 28-29 employees and sales partners. make companies more efficient, flexible and innovative, and, 26 Prestige Vehicle Repair and Customization Long-term customer satisfaction: Koudsy Body Works (KBW), Australia ultimately, more competitive. This gives rise to completely We are all very grateful and can look back on our 100-year new business models for products and services that bring 28 The World’s Largest Trade Fair history with a sense of great pride and accomplishment. significant measurable benefits to our customers. KAESER KOMPRESSOREN at bauma 2019 Moreover, our history is not only a basis for the present and a Booth FM.708/15 and FM.708/17 solid foundation to enable us to look firmly and clearly to the Every era has its own challenges, potential and oppor- future, but is also the basis for us to meet and overcome the tunities. The guiding principle that helped my parents and 30 ‘Innovating the World of Textiles’ 30-31 Compressed air for the textile industry at ITMA 2019 in Barcelona, ever-evolving challenges that the future has in store. Breath- grandparents in their decisions in the past can therefore Hall 6, Booth D101 taking possibilities stand before us, which, at first, may present also be an inspiration to us today: set clear and innovative themselves as unsolvable problems. However, we need to customer- and employee-oriented goals, and have a burning tackle and solve these problems, but this cannot be achieved desire to achieve them. by individual skilled people. Imprint: Published by: KAESER KOMPRESSOREN SE, 96450 Coburg, Germany, Carl-Kaeser-Str. 26 www.kaeser.com Editorial office: Petra Gaudiello (resp.), Email: report@kaeser.com Layout: Sabine Deinhart, Kristina Seeliger Photographs: Marcel Hunger Printed by: Schneider Printmedien GmbH, Weidhausen The editorial office cannot accept liability for any unsolicited manuscripts and photographs. Reproduction, including excerpts, only with written authorization. VAT identification no.: DE 132460321 Register of companies: Coburg HRB 5382 We use and store your personal data for marketing purposes. For detailed information, see www.kaeser.com/int-en/privacy-marketing.aspx. You can refuse the use and storage of your data for marketing purposes at any time by sending an email to: customer.data@kaeser.com. 2 | KAESER report KAESER report | 3
From a machine workshop to a global leader KAESER KOMPRESSOREN Turns 1919: the beginning KAESER rotary screw compressor lies based on Carl Kaeser Sr. establishes the compa- the proprietary rotary screw airend with industrial PC ny as a machine workshop on the 27th of a new energy-saving rotor profile – the technology, re- June, 1919 in Coburg. It was a difficult time, SIGMA profile. Manufacturing these duces life cycle fraught with instability, just a year after the new rotary screw compressors begins in costs and further end of the First World War. After starting out 1973. Over the coming years, KAESER improves equipment as a maker of spare parts for motor vehi- KOMPRESSOREN takes its place along- availability. It has since cles and engines, especially gears, he later side the world’s leading manufacturers of become an integral branches out to produce specialized equip- rotary screw compressors. part of KAESER rota- ment for the glass making industry. ry screw compressors. Following the acquisition of the French Building on the success- Through the division of Germany after the manufacturer Compresseurs Bernard in ful launch of the SIGMA Second World War, KAESER is cut off 1982, KAESER develops the KAESER CONTROL, KAESER from a large portion of its original market in MOBILAIR series of portable rotary screw “computerizes” the entire the states of Thuringia and Saxony and is compressors for the construction industry, compressed air station in forced to pursue business in new markets in initially manufactured in Lyon, France. 2001. With the innovative southern and western Germany. A decision In 1991, shortly after German reunification, SIGMA AIR MANAGER, the that was to shape the company’s future. KAESER acquires Geraer Kompressoren- combined benefits of a state- KAESER’s expertise in engine manufactur- werke, one of Germany’s oldest compres- of-the-art industrial computer ing, coupled with strong demand for com- sor makers, and develops the OMEGA and high-speed network tech- pression equipment in the post-war econ- rotary lobe blower. Manufacturing starts in nology are introduced into the omy, results in compressors being added Gera in 1993. world of compressed air tech- to the product range. The first reciprocat- nology for the first time. Carl Kaeser Sr. established his machine workshop in 1919. Today KAESER is a highly successful global ing compressor developed by KAESER With SECOTEC, KAESER develops a This paves the way for further is shipped in 1948. Within a few years the completely new line of energy-saving re- gains in dependability, efficien- supplier of compressors and compressed air systems that remains true to its roots. company’s reciprocating compressor pro- frigerated dryers in 1994. In the same year, cy and cost transparency in the gram covers the full range up to 80 hp. Germany’s most advanced manufacturing compressed air supply. facility for refrigerated dryers goes into op- Expanding the product range eration in Gera. The road to expansion Carl Kaeser Jr., the founder’s son, takes Various construction projects in the initiative for the company’s next stra- KAESER launches the revolutionary Germany and abroad create addi- tegic departure: the development of rotary SIGMA CONTROL compressor control- tional space over the years to meet screw compressors. At the heart of every ler in 1998. This proprietary development, the company’s increasing capacity 4 | KAESER report KAESER report | 5
needs. In the spring of 2002, the new man- growth in production, KAESER expects the the future begins to take shape at the Co- 340 energy saving dryer is selected as a fi- KAESER creates 20 additional training po- ufacturing center for portable compressors new facilities to improve on-time delivery burg site. nalist for the prestigious Hermes Innovation sitions for young people with refugee back- (the MOBILAIR plant) opens in Coburg. rates and boost customer satisfaction. Another construction project is launched Award, conferred by the Hanover Trade Fair grounds in 2016. In 2004, the year begins with the official In 2008, KAESER opens a new plant for in Coburg in September 2015. This time it to honor outstanding and trailblazing tech- The former youth hostel in the Ketschen- opening of the new product development cladding components in Sonnefeld. It be- is for the research and innovation center – nological developments. With its innova- dorf district of Coburg is converted into a eas of Europe, North America and Asia center in Coburg, providing an ideal work- gins manufacturing panel components, soon to be the incubator of new ideas and tive thermal storage system, the new dryer residence for KAESER apprentices from all Pacific. November 2013: With its re-incor- ing environment for development engi- doors and enclosures for rotary screw com- inventions. The facility is completed in late achieves energy savings of up to 70% com- over the world. poration as a “Societas Europaea” (SE) neers. At the opening ceremony, Thomas pressors. 2017 and the first employees start moving pared to conventional dryers. In 2014, it is – a European stock company – KAESER Kaeser, Chairman of the Managing Board, in. selected for Plant Engineering magazine’s In recognition of its endeavors as a provider KOMPRESSOREN takes a further step in says, “Our goal is to develop and deliv- In October 2013, the company starts con- Gold Award for best product in the USA. of in-house training opportunities, KAESER its international strategy. The family com- er innovative products that are tailored to struction of a new research and develop- Awards in Germany and is awarded first prize in the Industry, Trade pany is now at home all over the world, of- customer needs in greater numbers and ment center at the Gera manufacturing at the international level KAESER as an employer and Services category by the jury adju- fering uncompromising “Made in Germany” more quickly than ever before.” In the site. Excellence in innovation is a top pri- Thomas Kaeser is awarded the State Medal As one of the largest providers of ap- dicating the “Training Ace” competition in quality. same year, KAESER KOMPRESSOREN ority. A steady stream of innovations keeps for outstanding contributions to the Bavari- prenticeship opportunities in its region, December 2016. The competition is held The managing board is comprised of the completes construction of a state-of-the- KAESER KOMPRESSOREN at the fore- an economy in 2012. The ongoing devel- KAESER KOMPRESSOREN excels in under the auspices of the German Federal chairman, Thomas Kaeser Dipl. Wirtsch.- art distribution center. Key elements of front of compressed air drying technology opment of innovative products, a defining training skilled personnel. KAESER ap- Ministry of Economics. Ing. and Tina-Maria Vlantoussi-Kaeser this innovative facility, which revolutionizes – amongst others. feature of the company since its earliest prentices and trainees regularly score top Dipl.-Wirtsch.-Ing. logistic processes throughout the company, beginnings, earns recognition and respect results in the Chamber of Industry and Ready for the future include a new, fully automated high-rack In May 2014, KAESER initiates the transi- among the general public and industry ex- Trade examinations, both regionally and With over 100 subsidiaries and sales part- warehouse and a high-performance picking tion to a smart factory approach. With the perts alike. In 2013, the new SECOTEC TF nationwide. To promote real integration ners worldwide, the international KAESER system for small parts and spares. Apart ground breaking ceremony for two new pro- within the company while simultaneously group is present in all major industrialized from laying the groundwork for continued duction halls for rotary screw compressors, taking action to address the skills shortage, countries, especially in the economic ar- 6 | KAESER report KAESER report | 7
SIGMA AIR MANAGER 4.0 KAESER SIGMA NETWORK KAESER KOMPRESSOREN at the 2019 ‘Hanover Fair’ – the world’s preeminent trade fair for industrial technology: Hall 26 Booth C51 KEY TECHNOLOGY FOR INDUSTRIE 4.0 INTEGRATED INDUSTR KAESER SIGMA NETWORK SIGMA AIR MANAG Integrated Industry – IOT CLIENT BIG DATA CLOUD IOT CL 01.– 05.04.2019 We look forward to Hall 26 Stand C51 Industrial Intelligence PREDICTIVE MAINTENANCE SIGMA AIR MANAGER 4.0 seeing you! Hall 26, Stand C51 KOM PRE SSO REN “Integrated Industry – Industrial Intelligence”: that’s the theme of this year’s ‘Hanover Fair ’, taking place on the 1st to the 5th of April, 2019, in Hanover, Germany. The theme was chosen to embrace the far-reaching concept of digital networking people and machines in the age of artificial intelligence. Hall 26 01.– 05.04.2019 Booth C51 “The focus is squarely on people. They Under the motto, “Air is just the beginning,” KAESER products and ideas will be show- perfect combination of compressors. The from compressed air system maintenance will see the new FSG with i.HOC. The pat- make the decisions and set the tone,” ex- ComVac, the leading international trade cased in almost 14,000 sq. ft. of exhibition result: unprecedented energy efficiency. based on scheduled service intervals to ented KAESER i.HOC rotation dryer utilizes plained Jochen Köckler. With those words, show for compressed air and vacuum tech- space. For plenty of useful information and Thanks to easy and intuitive operation, a predictive maintenance concept – this 100% of the compression heat. With full- the CEO of ‘Deutsche Messe’, under- nology, will highlight hot topics in the world easy onsite navigation, access the ‘Han- clear visualization and analysis functional- greatly reduces the life cycle costs for the flow regeneration, it reliably delivers flow scored the role of ‘Hanover Fair’ as the of compressed air and vacuum technology, nover Messe’ app on your phone (available ity, users have a full overview at all times compressed air supply. rates of up to 1766 cfm and low pressure home of industrial technology trailblazers, including: energy and resource manage- on the ‘Hanover Fair’ website). – from any PC. Combined with SIGMA dew points at ambient temperatures of up synonymous with progress for over seven ment, the accelerating trend in contracting AIR MANAGER 4.0, the KAESER SIGMA Maximum energy efficiency to 113 °F – with no need for electric heating decades. More often than not, the ideas and operator models as all-round solutions, To achieve truly seamless integration NETWORK offers a perfectly coordinat- To learn how to achieve maximum cost ef- or additional cooling of the regeneration air. and trends that revolutionize industry are and predictive maintenance in the context of the compressed air supply into inte- ed and secure infrastructure for intelligent fectiveness and see the modern, high-effi- We have further expanded our energy- first presented to the global public in Han- of Industrie 4.0. grated industry environments, KAESER Industrie 4.0 services. Based on Eth- ciency rotary screw compressors that can saving SECOTEC series, featuring the in- over. This is where visionaries from around KOMPRESSOREN links machines using ernet technology, the powerful SIGMA achieve this, visit the KAESER booth in novative latent heat storage system, with the world, representing diverse industrial Key technologies for Industrie 4.0 the SIGMA NETWORK and the SIGMA NETWORK is a closed and secure network Hanover. You’ll get a close look at the in- the addition of several new models, extend- sectors, get together to capture synergies When designing a compressed air sup- AIR MANAGER 4.0 master controller. This specifically developed to support optimal novative water-cooled ESD rotary screw ing the output range up to 3178 cfm for the and to discuss and develop the solutions of ply system as a seamlessly integrated el- advanced controller provides optimal man- monitoring and coordinated control of com- compressor (flow rates: 212-1600 cfm), first time. At the ‘Hannover Messe’ we will the future. ement in an integrated industry concept, agement of the entire compressed air sta- pressed air station components. the DSD/DSDX (141-1200 cfm) and the be presenting the SECOTEC TG, which a key factor for success or failure is the tion. It functions as the station’s brain and Rounding off the KAESER Industrie 4.0 FSD (353-2154 cfm). These systems of- will be available on the market as of July/ The place where the future selection of the appropriate compressors represents the key technology for using ser- package is SIGMA SMART AIR. This inno- fer the most cost-effective performance of August 2019. To learn more about our ser- of industry is born and air treatment components. Get an up- vices in the Industrie 4.0 world of tomorrow. vative KAESER KOMPRESSOREN service any fluid-injected rotary screw compressors vices and product portfolio, come and talk Six leading trade fairs and one platform: at close look at compressed air solutions that This compressed air management system delivers predictive maintenance combined on the market. Also on display: the CSDX to the KAESER KOMPRESSOREN com- the world’s biggest industrial fair, visitors are more than just reliable and energy-ef- uses adaptive 3-Dadvanced Control to make with maximum energy efficiency and com- SFC (flow rate: 39-618 cfm), featuring a pressed air experts! experience the full range of technical inno- ficient. Thanks to advanced IT integration, compressed air production and treatment pressed air availability, far exceeding the future-ready, energy-efficient synchronous vations, starting with A for automation, and they can also be integrated seamlessly into smarter, more efficient and more secure capabilities of previous systems. reluctance motor and speed control – in se- We look forward to your visit and to telling covering every key area across the entire Industrie 4.0 production environments. than ever before. 3-Dadvanced Control con- This ensures real-time availability of oper- ries production from the end of 2018. you all about the latest technologies and value chain. KAESER looks forward to seeing you tinually analyses all operating data, simu- ating, service and energy data – an essen- From the FSG series, our largest line of oil- coming trends. at Booth C51 in Hall 26, where the latest lates alternative actions and calculates the tial prerequisite for making the transition free rotary screw compressors, fair visitors
Images: FACC Author: Martin Gold FACC, Austria’s largest aviation company, has risen to become a global player with high-tech within a few decades. The high-strength lightweight components are in great demand – as a result, today hardly any aircraft is delivered worldwide that does not con- tain a component from the Upper Austrians. Only compressed air that is free of oil and moisture is suitable for the application of innovative technologies. Upper Austria, long famed as the industrial area of expertise is the “acoustic surface.” heartland of the Alpine region, is now home A robot drills hundreds of thousands of to a rising star in a high-growth, high-tech approx. 1 mm-diameter holes in the inner sector. FACC, located just outside the town carbon surface of an engine nacelle. The of Ried im Innkreis, has risen to prominence lower end of the hole opens into a honey- in the aviation industry. FACC began as a comb-like core of expanded aluminium. Flying High with Clean Air spin-off from the research department of These holes have no effect on stability. Fischer, a ski manufacturer. The aviation However, the aluminium core has outstand- industry discovered the expertise in mate- ing sound-absorbing qualities: meaning rial science and lightweight construction of that the sound is damped right where it is the Austrian winter sports specialists back created. A remarkable fact, instead of con- in the 1980s. The company’s near-meteoric ventional drilling methods, the holes are rise began with a development project for made by high-pressure sandblasting. a supporting rod on the Airbus A300 air- liner. The company’s list of customers now Assembling a winglet in FACC Plant 3 (Aerostructures Division). Environmental protection and reads like a who’s who of the global aero- energy efficiency space industry: aircraft manufacturers such main plant in the Alps. Today the company Key future technology: lightweight parts for aircraft in three main areas. Aero- by an engine nacelle, for example – to de- The sandblasting process is the largest con- as Airbus, Boeing, Bombardier, Embraer, employs 3,400 people worldwide, includ- construction structures is the division that handles wing termine the exact number of layers needed sumer of compressed air in FACC Plant 4 in COMAC and Sukhoi, engine makers and ing 3,200 in Austria, who generate annual The core competency of FACC is develop- components such as elevators, rudders and at every location. This results in compo- Reichersberg. The remainder is distributed their suppliers all rely on products from the sales of approximately €750 million. ing and manufacturing carbon composite winglets. The Interiors division supplies air- nents that combine the toughness needed across a large number of hand tools, ten- craft manufacturers with passenger cabins, for the heavy demands of aviation with the sioning devices on grinding machines and from ceiling panels and overhead luggage minimum achievable weight. Another ad- other small consumers. It is absolutely es- bins to side panels. The third area – the En- vantage of carbon: there is practically no sential to have a reliable and secure supply gines & Nacelles division – specializes in thermal expansion. “An aircraft taking off of compressed air. The KAESER experts engine components and enclosures. in a hot desert region will be exposed to have configured the compressed air station an ambient air temperature of -58 °F just accordingly, ensuring that fluctuating air For all developers at FACC, the top design 20 minutes later,” says Christopher Jell, flow does not impact the economic efficien- priority is to keep component weight to an the Senior Manager of IE & FM Engines & cy of plant operations. Six fixed-speed rota- absolute minimum. The materials of choice Nacelles. “Our carbon components handle ry screw compressors of type DSD 201, 240 Images: FACC for achieving that objective are carbon these rapid and extreme temperature fluc- and 241 handle the baseload requirements, composites. FACC produces tailor-made tuations without the slightest difficulty”. while peak demand is covered by a DSD lightweight components made up of hun- 281 SFC variable-speed unit. The com- dreds of layers, and in some cases more Drilling with sand pressors can be switched on and off flexibly The engine nacelles are hardened in Up to 1000 or more layers of carbon FACC manufactures engine components the autoclave to attain their final material composite material are combined to produce using lightweight construction techniques than a thousand. Experts precisely calcu- FACC has gained an excellent reputation in to match current demand. This task is per- characteristics. engine nacelles. here in Reichersberg. late the stresses in advance – experienced the market for its technical skills. A special formed by the SIGMA AIR MANAGER 4.0 10 | KAESER report KAESER report | 11
New MOBILAIR M171 portable compressor Variable Pressures and Heavy Duty Site Performance More choices in the over 400 cfm range The current climate in heavy-duty civil and KAESER also designed the M171 with a The high capacity, cold-start battery en- commercial construction requires productiv- new axial condensate separator installed sure reliable operation even under extreme ity and flexibility in all aspects of equipment downstream from the compressed air af- weather conditions. Plus, the excellent Top: FACC selection. Power breakers, cable-blowing tercooler to ensure even better condensate cooling features allow the M171 to operate and other air powered tools operate on var- separation performance and reduced pres- in temperatures up to 122 °F. ious air pressures. To meet the needs of sure losses in the system. As before, the Maximum flexibility: the lightweight construction of the engine nacelles permits ideal streamlining of the engine in line with aerodynamic this market, KAESER introduced the new separated condensate is evaporated via the The M171 also features an advanced en- conditions. MOBILAIR M171 portable compressors in hot exhaust gases. Further, if the reheating ergy-saving fan that is controlled according the fall of 2018. Delivering 405 to 600 cfm option is chosen, compressed air discharge to operating temperature, and results in fuel master controller with adaptive 3D pressure 8573-1 and oil purity Class 1. The result is a in variable pressures, it is a great option be- temperature can be adjusted. All of the savings of up to 6 percent. Users looking control. Among other functions, it ensures residual oil content of less than 0.01 mg/m3. tween KAESER’s award-winning M125 and compressed air treatment methods men- for efficiency, flexible pressure options and that the pressure never drops below the the much larger capacities of the impres- tioned above can be used with a microfilter user-friendliness will find that the M171 hits lowest permitted operating pressure sive M250. combination to produce technically oil-free the mark. as detected at the pressure sensor air. measurement location. The decisive factor for FACC was KAESER’s The M171 comes standard with the SIGMA CONTROL MOBIL controller which pro- Many other features add to the user-friendli- Because the compressed air must ability to meet a mandatory specification, vides variable pressure ranges between ness of the M171 including an easy-to-read be free of oil and water, four re- frigerated dryers with energy namely the ability to deliver compressed air 85 and 205 psig. Simple to operate, it auto- matically adjusts the maximum air delivery but well-protected control panel, and large- neck fuel tank with overflow protection. The saving control (TI 521 FE and TE 141 models), two compressed free of oil and water. in each case allowing the compressor to be precisely configured to actual demand. heavy-duty steel chassis, galvanized steel canopy and solid steel flooring protect the air treatment lines with activated car- Additionally, SIGMA CONTROL MOBIL Deutz diesel engine and SIGMA PROFILE bon adsorber (ACT 601) and two air-main also ensures machine-friendly start/stop airend. In addition to the chassis-mount- charging systems are integrated into the operation, provides valuable operational ed models with height-adjustable tow bar, system to ensure delivery of water and oil- data, and alerts users when maintenance skid-mounted versions are also available. free compressed air in accordance with DIN is needed. The compressed air treatment also The SIGMA AIR MANAGER 4.0 master controller with adaptive 3D pressure control allows the applies the latest technical advances. individual compressors to be switched on and off as conditions require. Designed to be user friendly on-site and during transport. 12 | KAESER report KAESER report | 13
Images, above: Fuchs Group The Fuchs Group – cultivating a world of good taste Spice is the Variety of Life! It is certainly not a new realization that food is about much more than nourishment. The experience of flavors can represent pure enjoyment while enhancing our sense of culture and lifestyle. To attain the con- summate taste experience, we need the right ingredients. The goal of Fuchs Group in Lower Saxony, with its precious spices and spice mixtures, is to help turn a meal into a genuine culinary event. Image: Fotolia Fuchs Group is Germany’s largest spice tions in Abtswind and Hamlar (Bavaria), From the life of a peppercorn ness when harvested, among other factors. A special aromatic experience thorough quality check prior to the further manufacturer and the world’s largest pri- Melle (Lower Saxony) and Schönbrunn The Fuchs Group’s most important pepper Quality assurance accompanies the entire Upon arrival in Dissen, the sacks of Bra- processing steps. In the eight-story grind- vately owned company in its industry. (Schleusegrund, Thuringia). growing regions are in Brazil, specifically process, starting in the field with the grow- zilian peppercorns, along with other sacks ing mill tower, the various herbs and spices Established by Dieter Fuchs in 1952, it is in the northern half of this gigantic South ing plant. After the harvest, the raw product and transport packages containing a wealth are cleaned, dried, ground, sieved, mixed one of the biggest employers in its home A tradition of partnership American country. Because the north of is dried using the almost unlimited resource of different herbs and spice plants from all and placed in the final packaging in which region. It has its headquarters in Dissen, So, what is the company’s secret recipe for Brazil is hot, like the south, but much wet- of Brazilian sunshine, available 300 days over the world, are placed in temporary the finished product is sold. in the state of Lower Saxony, at the edge achieving maximum quality from the very ter, it is ideal for growing pepper. The pep- a year. This is followed by the next metic- storage in the 108,000 sq. ft. warehouse. of the Teutoburger Wald forest region. start of the value chain? Careful selection per plant is a perennial woody climbing vine ulous quality inspection. Afterwards every Catching the powerful fragrances pervad- Compressed air in the service of The product portfolio covers an unparal- of the ideal growing regions for its products that grows on trees, reaching heights of sack of raw product is assigned a QR code ing this space, visitors inevitably feel as if gourmets leled selection of spices, spice mixtures, and close partnerships between Fuchs up to 33 feet. When cultivated, the plant is that permits tracking of “our” peppercorn they have been transported to some far-off Throughout the entire production process herbs, spreads, pastes, sauces, dips and Group employees and the farmers and generally limited to a height of 10-12 feet. every step of the way, from the field to the bazaar. Amid this somewhat overwhelming of the Fuchs Group, there is a unifying many other ingredients for a healthy, cre- contracting partners on the ground. The ex- The small, unremarkable flowers grow on in-store packaging. Now the peppercorn – but highly aromatic sensory experience, theme: compressed air. For every step in its ative and varied cuisine with more than change of ideas and experiences and the spikes around 4 inches long, with 50 to 150 still whole at this point – can embark on its one occasionally detects a familiar scent operations, from the transport of the spices 8,000 products sold in over 60 countries. transfer of knowledge benefits the suppli- flowers per spike. After pollination, the fruits journey to Germany. amongst the stored sacks and containers: and herbs through to the cleaning, drying Fuchs Group employs approximately 3,000 ers in the growing regions – and ultimately (drupes) typically ripen within 8–9 months. oregano, cinnamon, paprika, nutmeg and – and grinding processes, and to control the people in 10 countries on four continents. it enables the Fuchs Group itself to ensure The various types of pepper (black, green, of course – pepper. From the warehouse, machines and systems, the Fuchs Group In Germany, the group has other loca- consistent quality. white and red) differ by the degree of ripe- the raw materials are transported to another needs compressed air. The company 14 | KAESER report KAESER report | 15
cannot afford any bottlenecks or disruptions in the compressed air supply. The reliabili- ty and availability of this universal energy Compressed air for the Institute of Thermal Turbomachinery source is of paramount importance. When at the Karlsruhe Institute of Technology it was time to replace the obsolete com- pressors from another manufacturer due to increasingly frequent breakdowns and problems, the obvious choice was the Co- burg-based system provider KAESER. For food processing operations, compressed air must meet the highest quality standards of Class 1.4.1 under DIN ISO 8573-1. The Fuchs Group compressor room now houses all of the equipment needed for energy-effi- cient compressed air production in accord- ance with those stringent requirements: Two new-generation ASD 40 rotary screw compressors with an integrated PTG 40-25 heat recovery system and two TE 102 ener- gy-saving refrigerated dryers. The de- The compressed air supply meets the stringent requirements of Quality Class 1.4.1 cisive factor ensuring full in accordance with DIN ISO 8573-1. compliance with Quality Class mention the many friends of good cuisine, 1.4.1: the who can now rest assured that the flavor high-perfor- specialists in Lower Saxony will continue Because the new compressed air system is highly efficient in terms of energy consumption, it is a perfect fit for the Fuchs Group’s sustainability strategy. Image: Fotolia mance KAESER filters connected down- to supply them with high-quality herbs and The Institute of Thermal Turbomachinery at the Karlsruhe Institute of stream from the compressors. In the con- spices long into the future. Technology (KIT) recently purchased an HSD 662 SFC rotary screw text of the company’s sustainability efforts, the new system also has a significant eco- compressor system. It will help to deliver compressed air to the exten- logical impact. This makes the employees sive experiment equipment and facilities in the research laboratories. of the Fuchs Group very happy – not to For the experts from KAESER, the task of installing the new system posed substantial – but not insurmountable – challenges. In the Service of Research The Institute of Thermal Turbomachinery oratory, was planned and designed in the al Church in Berlin, the German Embassy is part of the mechanical engineering de- 1950s by the architect, furniture design- in Washington and the office building for partment at the KIT. The institute, including er and former professor at the KIT, Egon the members of the German parliament Compressed air is needed in every step of The air in the 108,000 sq. ft. warehouse is The air-main charging system prevents over- its research facilities, is housed in a former Eiermann. Among the designs that earned in Bonn. Defining features of the building, product processing. Shown here: material heavy with the scents of the many herbs and loading the system and contamination of the conveying. spices stored there. compressed air network when the system is experimental power station. The building, Eiermann fame both in Germany and with its east-west orientation, are the clear restarted. which today is used exclusively as a lab- abroad were the Kaiser Wilhelm Memori- structure, expansive glass surfaces and the Images left and centre: Fuchs Group 16 | KAESER report KAESER report | 17
The rotary screw compressor system made a long and arduous journey: first, it was dismantled and lowered through the light shaft into the lower level of the building. of a ship in a bottle. For shipping and in- stallation, the selected system was initially dismantled into its individual components. They were then loaded onto a truck and, in a two-day process, lowered by crane The body of the compressor unit had to be guided carefully through the light shaft. into the base- The HSD 662 SFC from KAESER KOMPRESSOREN ment through the light shafts. This was selected as the center-piece of the high-pressure, exposed steel skeleton – an unequivocally modernist design. The building in which the significantly reducing pollutant concentra- tions in the exhaust gases they produce. without adequate access routes. It was im- mediately obvious that a standard product was followed by assembling high-temperature system. laboratories are currently accommodated is Numerous complex experimental setups was out of the question. The institute was the components now a listed architectural heritage site. are used to develop and evaluate new com- searching for a reliable partner not only to onsite in the compressor room on the lower bustion concepts and cooling methods. The provide a modern system meeting the de- level of the institute. The compressor sys- Research projects at the KIT advanced methods used include state-of- sired specifications, but also with the ability tem was commissioned just a week later, The Institute of Thermal Turbomachinery the-art laser technology to characterize the to design and install a system around the and has been performing its duties since carries out many research projects in close flow patterns typical of turbomachinery and unique structural constraints of the building. August 2018 – to the complete satisfaction collaboration with partners from around quantitative infrared thermography to detect The resulting choice: a HSD 662 SFC rota- of the institute’s management. the world, including universities, research surface temperatures. ry screw compressor system from KAESER institutes and companies in the turboma- These facilities require a reliable com- KOMPRESSOREN. It now makes up the Images: KIT chinery and automotive industries. The pressed air supply. For some applications, core of the high-pressure, high-temperature research work conducted at the institute the compressed air must be pre-heated to system that supplies compressed air to the under Professor Hans-Jörg Bauer centers temperatures of up to 1562 °F. many research and experiment facilities of around turbomachinery, and predominant- the Institute of Thermal Turbomachinery. ly aircraft engines, gas and steam turbines The main requirement: constant for energy production, and turbocharg- pressure and air flow So, how do you put the ship into ers used in combustion engines. The re- The previous compressor system had the bottle? searchers conduct experiments for which reached the end of its service life and The main hurdle to overcome before com- they develop and implement advanced needed to be replaced. The requirements missioning of the system was the physical measurement techniques and also apply for the new system were as follows: it would installation space. The compressor room is the latest numerical methods to simulate need to provide highly consistent pressure not much bigger than the rotary screw com- flow and heat transfer processes. and air flow at varying pressure levels and pressor system itself and the only access for fluctuating air delivery requirements. So route open to the KAESER experts was Key objectives of the institute’s research far, so good. But there was a special chal- through the hollow spaces below the light activities are to improve the efficiency of fu- lenge. The equipment had to be installed in shafts on the outer facade. The undertak- After being placed in the compressor room, the components were reassembled. Since then, the compressor has been doing its valuable work ture aircraft engines and gas turbines while the lower level of a listed historical building ing was not unlike the proverbial placement to the complete satisfaction of the institute’s management. 18 | KAESER report KAESER report | 19
SIGMA AIR UTILITY at Neoperl GmbH in Müllheim The joint Swiss/German family company Practical and beautiful pany knows the plumbing conditions on Neoperl was founded in Reinach-Basel in Millions of people use Neoperl products the ground like the back of its hand: water The Beauty of Water 1959. In 1961, the Group’s German head- every single day. For example, the jet regu- hardness, water pressure, lime content, im- quarters, Neoperl GmbH, was established lators can be found today on virtually every purities, construction methods and national in Müllheim. The owner-managed, medi- outlet fitting on washbasins and bathtubs. standards. The products are adapted to the um-sized business is the world’s leading They shape the water into a splash-free local conditions in the on-site production supplier for the plumbing industry with sales stream and make it pleasantly soft by draw- plants. subsidiaries in every corner of the globe, ing air into the flow. Moreover, they reduce wherever its customers are based. the fitting’s noise, help conserve water and To ensure proximity to its customers save on energy costs. throughout the world, the international com- Can water be aesthetic? Absolutely! At any rate, the German-Swiss family business Neoperl ensures that The success story began over half a cen- pany employs approximately 1800 staff in it flows in a highly aesthetic way. Neoperl products shape the water stream, regulate the flow rate and tury ago. Over the years, the company has Aesthetics also take center stage. In 2016, 17 countries. The extensive logistics infra- developed a wide range of sanitary prod- the product design of the Mikado aerator structure consists of 12 production plants in protect water from contamination. And although they can be found in use with just about every washba- ucts, which currently sin, bath or kitchen fitting, they spend their useful lives languishing in near-obscurity as they are virtually includes aerators, flow regulators, invisible. check valves, di- verters, connecting The advantages of a SIGMA AIR UTILITY hoses and shower hoses, together with are clear: there is no investment outlay, various accessories. and operating costs can be precisely calculated. One of the mile- stones in the com- pany’s history was the first noise-reducing aerator, which was won the Red Dot Award for its extraordi- Europe, Asia and the United States, as well developed in the 1970s. During the 1980s, nary, grid-like spray pattern, formed by the as sales subsidiaries in all key markets. the Neoperl Group introduced its long-life geometric arrangement of individual water technology and, in the 1990s, launched the jets. Success needs space world’s first aerator without a wire mesh. The world market leader in the sanitary fit- Today, Neoperl supplies products and Different regions, tings sector has had an outstanding track spare parts to the world’s leading fittings different conditions record for over 50 years. This means that manufacturers, technical OEMs and the Drinking water networks have unique fea- space is sometimes tight in the buildings wholesale and retail trade. tures in every country. With subsidiaries in on the company’s 15 acre site. Therefore, the customer’s country of origin, the com- the production area has been extended to Image: Fotolia KAESER report | 21
Compressed air at a fixed price Ideally customized to meet all of these criteria, the modern compressor system includes several different rotary screw compressors: one CSD 105, three CSDX 165 and one CSDX 165 SFC. Three down- stream TF 340 refrigerated dryers dry the compressed air to a Class 4 pressure dew point in accordance with ISO 8573-1. The SIGMA AIR MANAGER 4.0 master control- ler calculates the perfect compressor com- bination to meet current requirements. The entire unit is housed in a container located outside the production halls. As a result, the ventilation ducts are also outside, meaning fewer pipelines were needed to set it up, while outdoor installation is better from a fire safety perspective. Image: Neoperl GmbH Commissioned just a few months ago, the operator is already highly impressed with the new station. After just four weeks of The Müllheim production site uses compressed air as an energy source for every aspect of operation, the first before-after calculation its manufacturing operations. produced impressively gratifying results! Energy consumption is down by approxi- include a new manufacturing hall. Since the pressed air requirements. Following nu- mately 15% compared to the previous com- Müllheim production site uses compressed merous discussions, site inspections and pressor system. air as an energy source for every aspect of telephone conferences, it soon became its manufacturing operations, a dependa- clear that the solution that best met Neop- Image: AutoGyro GmbH ble supply of quality compressed air with erl’s needs and requirements was a SIGMA precisely defined parameters is essential. AIR UTILITY model. The advantages of this In addition, some of the compressors in station are crystal clear: the customer has the existing compressed air stations were no capital outlay, the running costs can be obsolete. These also needed replacing calculated in the form of a fixed basic price as part of the modernization program. As and maintenance is covered by KAESER’s a first step, an air demand analysis (ADA) service package – at zero additional cost. was carried out to calculate the exact com- Premium quality craftsmanship in series production: AutoGyro GmbH, Hildesheim The Sky’s the Limit The KAESER SIGMA AIR UTILITY station: Left: Interior view – configuration of the compressors and dryers. The inventor of the gyroplane, Juan de la Cierva, came very close to realizing this dream when he took Right: Exterior view of the station. to the skies with his ‘autogyro’ for the first time almost one hundred years ago. Powering the rotor by means of autorotation, rather than the helicopter’s use of active rotation, his invention revolutionized the world of aviation. From a garage workshop to the loped himself. He turned his hobby into a AutoGyro GmbH. He teamed up with two world market leader career by establishing his own business in friends to develop his first fully functional Even as a child, Otmar Birkner, the foun- Gehrden in 1995, High Tech Composites aircraft, which received a type certificate der of AutoGyro GmbH in Hildesheim, was (HTC), which specialized in manufacturing in 2004. Three years later, the first “Auto- passionate about developing and building composite (plastic) parts, such as pro- Gyro” went into series production. Since model aeroplanes. In his parent’s gara- peller blades. However, that was just the then, other models gradually followed eve- ge, he laminated his own first propeller beginning. In 2000, the company moved to ry few years: the “Calidus” in 2009 and the blades, made in moulds that he had deve- Hildesheim, where Otmar Birkner founded “Cavalon” in 2011, subsequently garnering 22 | KAESER report KAESER report | 23
the Red Dot Design Award in 2012. Last year, the exceptional design of the sleek planes received yet another accolade. The “MTOsport” won the coveted “Best of the Best” 2018 Red Dot Design Award, which officially attested to the ultra-light aircraft’s “innovative symbiosis of aesthetics and function”. On course for success Since its foundation, the gyroplane special- Compressed air is used to power almost every production stage. The gyroplane before the rotor is fitted. ist has reported steady growth and today employs a 100-strong workforce. From the first brushstroke of the draft through to the test flight, the majority of the components ristics, making it one of the safest aircraft “We use compressed air in all areas for the ultra-light AutoGyro (aside from the of all. Unlike fixed-wing aircraft, there is no of production” engine and a few instruments) are manu- danger of stalling or tailspin. Even in the Ninety percent of the components are ma- factured completely in the production facili- event of engine failure, the Autogyro re- nufactured and assembled with pinpoint ties at Hildesheim Airfield by the highly qua- tains full control capability and merely loses precision in the on-site production facilities lified team of technicians and engineers. altitude slowly as it is still able to perform a both by hand and with state-of-the-art CNC With sales partners in over 42 countries controlled landing. Almost like no other ro- machines. Most of the production stages around the world, numerous flight schools torcraft, the Autogyro can even be flown in require compressed air, from spray painting and service locations, and the gyro factory strong winds and can be used practically all to grinding or pressing processes. The orig- at its Hildesheim headquarters, AutoGyro year round. As extreme low speed is pos- inal compressor station includes an serves a worldwide network with the aim of sible, the gyroplane is ideal for excursions SK 24 and a compressor from another ma- combining safety and the gyro’s unlimited and day trips. Moreover, the sky’s the limit nufacturer, “which ultimately kept causing versatility for the pure joy of flying. Global- when it comes to the design. It can be cu- problems, unlike the KAESER compressor,” ly, some 3000 autogyros are deployed on a stomized in any way, from a company logo reports René Stecher, the factory foreman variety of missions, ranging from the Qatar to a family coat of arms or a distinctive color responsible for the compressed air system. Royal Guard to Australia’s “Shark Patrols” coating. A new unit was needed. Given the excellent and partners for adventure trips in Namibia. track record of the first KAESER compres- The company even received an un- sor, the obvious solution was to purchase Fly like Icarus, but safely usual commission to embellish an an additional SM 12. Attracting a good deal of attention, the AutoGyro with gold leaf and Swarovski secret of the rotorcraft’s growing popula- stones, recalls Judith Reichardt, who is re- Four years ago, the system needed to be rity lies in its innovative drive technology. sponsible for marketing and communicati- expanded once again since compressed air Although the gyro resembles a helicopter, on. Best of all, the innovative rotorcraft runs was also needed on-site for the assembly the rotor uses the air stream – rather than at one tenth of the cost of operating a heli- line in the plastics processing department an engine – to start the rotation process copter. Depending on the road traffic regu- located across the road. Two more SM 12 passively. Known as autorotation, this ge- lations, in some countries you can even roll AIRCENTERs were installed for this pur- nerates the buoyancy of the gyroplane. The up to a service station and fill up with Super pose. A wise decision as the system now aircraft is driven by a propeller engine. Plus fuel, Judith Reichardt adds. runs “smoothly and to our complete satis- Thanks to its design, the gyrocopter flies faction,” according to René Stecher. with very special and unique characte- Approximately 90% of the components are manufactured on-site. From spray painting to grinding, and from pressing processes to CNC machining, most production stages require compressed air. Emphasis is placed on maximum precision The tail units are also produced in the Final cockpit assembly: installation and The KAESER station provides the necessary in the individual production stages. factory at Hildesheim Airfield. connection of the aircraft’s avionics equip- supply of compressed air. ment. 24 | KAESER report KAESER report | 25
Author: Beth Wood Long-term customer satisfaction: Koudsy Body Works (KBW), Australia Prestige Vehicle Repair and Customization For over 35 years, Koudsy Body Works In Australia’s New South Wales, (KBW) has been one of the leading special- ists for all kinds of vehicle repairs, includ- where Koudsy Body Works ing both cars and motorcycles. One glance (KBW) is based, the family- at the photo gallery on their homepage is enough to set the pulse racing of any cus- owned business has gained an tomer with a weakness for luxury models outstanding reputation, not just or vintage cars – the family business also for its vehicle repair and resto- specializes in the restoration of classic ve- hicles and car customisation. Extensive in- ration services, but also for its terior and exterior modifications are carried exclusive car styling packages. out with meticulous attention to detail. From black styling packs to spoiler/body kits, ex- haust systems or wheel and tyre packages, automotive fans of all vehicle makes and models have choices galore! Compressed air an integral part Koudsy Body Works provides the very highest level of service. It is important to management that their team is always up- to-date with constant training and that state- of-the-art machinery is made available. After all, the company’s philosophy is that Images: KBW “Every vehicle will leave looking better than before.” From powering air tools to the spray paint booth, compressed air is an integral part of the operation. Therefore, it is no surprise that air production is also work. Especially for the spray painting side the quality of the finish, but would also be some time now and it continues to operate expected to meet the very highest stand- of the business, without quality and reliable costly to re-do. We pride ourselves on the reliably and efficiently for us,” he explained. Without compressed air, ards. Just over a decade ago, an aging compressed air, we cannot function. The air quality of work we do and it is essential that compressed air system prompted Charles needs to always be clean with no moisture we use quality equipment. We have had the the repair shop grinds to a halt. Koudsy, the manager at KBW, to inspect in the line. This would not only jeopardize KAESER compressed air system for quite the entire air center and review the com- pressed air requirements. When it came to purchasing a new compressor that was both powerful and reliable, the obvious choice was an AIRTOWER 11 from KAESER KOMPRESSOREN. The compact com- pressor solution incorporates a rotary screw compressor and refrigerated dryer a single package, thus keeping space requirements to an absolute minimum – a key criteria in the vehicle repair industry. An oldie but a goodie Managing Director Charles Koudsy is de- lighted to report that the system has oper- ated reliably for over ten years. “If our com- Compressed air is indispensable in powering the tools used in the car repair Powering the air impact wrench... ...and the spray paint booth. pressor doesn’t work, our business doesn’t shop. 26 | KAESER report KAESER report | 27
KAESER KOMPRESSOREN at bauma 2019 The World’s Largest Trade Fair Booths FM.708/15 and FM.708/17. This year, the 32nd iteration of the world’s leading trade fair for construction machinery, building Industrie 4.0 also for portable even stricter statutory emission limits. For of the entire KAESER MOBILAIR product compressors the first time, a particle number limit is range: portable compressors with flow rates material machines, construction vehicles, equipment and mining machines will take place at Dubbed the ‘Fourth Industrial Revolution’, also being introduced for machinery with from 35 to 1624 cfm and power classes from the Neue Messe München exhibition grounds in Bavaria, Germany, from the 8th to the the phenomenon of human-machine in- a power range from 19 kW, necessitating 7.5 kW to almost 450 kW, from the small, teraction and the on-demand availability exhaust after-treatment systems in the compact M13 compressor right up to the 14th of April. Some 3,400 exhibitors from almost 60 countries will present the entire of all data will be more widely used in the portable compressor class. How KAESER oil-free compressed air giant M500-2. range of construction machinery, vehicles and hand tools available on the civil engineering and construction sectors closed the gap between the market de- When it comes to alternative drives to the in the future. It is reassuring to know that mand for light, compact, portable compres- diesel engine, the line-up will also include market. As the leading industry hub, bauma sets the trends for the future. KAESER’s MOBILAIR portable compres- sors and the additional weight of the larger electric drive and gas engine models, while However, the trade fair is not just geared towards technical specialists but is sors can be equipped with the necessary diesel particulate filters and radiators re- KAESER will unveil the large-scale M255 E also open to the public. technology. It comes as no surprise, then, quired by the exhaust after-treatment, will compressor designed especially for the that ‘The smart construction site’ is a major be revealed at bauma 2019. We will be pre- compressed air hire sector. Huge cranes, colossal excava- advantage of the platform at the last show focus at the KAESER exhibition stand. senting the next generation of lightweight tors and the latest technology in 2016 to do business and learn about MOBILAIR portable compressors, featuring Visit bauma in Munich and discover a host trends – anyone who is in specific key topics. The fair features live Visitors can take an up-close look under the an aluminium body, and brand new design of exciting innovations and technology any way active in the con- demonstrations of the machinery and its enclosure of the exhibits, or keep a watchful features. trends. The compressed air experts from struction industry will gath- different applications. Experts advise the eye on remote machines in real-time using Coburg look forward to welcoming you at er at bauma 2019, where visitors on the latest developments, while the MOBILAIR Fleet Management online The new models in the proven MOBILAIR Booths FM.708/15 and FM.708/17. The the leading trade fair for the panel discussions and conferences tool to access current operating data, eval- portable compressor series – M55, M59 and tower of MOBILAIR MODELS with colored construction and build- keep the trade audience up to date on a uate machine performance, find out when M65 – will also premiere at bauma 2019; PE enclosures will guide your way straight ing materials machinery wide range of subjects. the next service is due or pinpoint their lo- highly environment-friendly, their to KAESER. will showcase the new- cation. Moreover, the platform helps users innovative motors comply est trends and devel- A trade fair of superlatives plan operations, manage the accounts and with the new EU Stage V opments in the sector. It is the record exhibition space that makes document the work performed. Plus, re- and the US final Tier 4 Since its inception more bauma in Munich the world’s largest fair. mote diagnostics capability saves valuable standards. Visitors will than 50 years ago, bau- It occupies every hall at Neue Messe time when servicing is required. find a broad overview ma has garnered a rep- München, as well as the outdoor area, utation as the driver of which was extended especially for the Innovations in the innovation and success show. This equates to a huge 6,500,000 portable compressor programme in the global construc- sq. ft., divided into 1,900,000 sq. ft. hall According to the new tion machinery industry. space and 4,500,000 sq. ft. outdoor space. EU Stage V European Networking This view was shared The target markets are industry, trade, ser- emission standards, as by the over 600,000 vice providers in the construction and con- of 2019, construction visitors from more than struction materials industry, plus machinery will be re- @ MOBILAIR 200 countries who took key procurement players. quired to comply with KAESER report | 29
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