The Tönnies Group has built its bovine animal competence center in Badbergen, Lower Saxony. The cuts of beef are vacuum-packed in thermoforming and shrink-wrap machines, a process that has become extra efficient than ever following renovations at the website: Now, energy-saving Atlas Copco variable-speed vacuum pumps are used to create vacuum circumstances at two central stations.What was once a blended slaughterhouse has become a “bovine animal competence center”: For decades, cattle and pigs had been slaughtered and butchered on the similar time in Badbergen on behalf of different corporations. In 2017, the Tönnies Group took over the site and decided to base its complete slaughtering operation in Badbergen – up until that time, this had taken place on the company’s main website in Rheda-Wiedenbrück. In 2020, Tönnies Beef reopened the location after in depth conversion and renovation. The Group invested round 85 million euro in the building and state-of-the-art technology at this site in a small city in northern Lower Saxony, between Oldenburg and Osnabrück. The slaughtering, butchering and finishing processes are based mostly on the latest cooling expertise, machine-based butchering and extremely automated selecting and delivery traces.
Several hundred tons of meat depart the positioning every single day and 95% of the animal – practically every thing – is utilized. This allows Tönnies to fulfill different consuming habits around the globe: While German customers choose lean beef, meat with a thick layer of fats is popular in Scandinavia and other European nations, based on the manufacturer’s website.
Efficient screw vacuum pumps provide forming, low and nice 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 numerous major prospects. For this function, Tönnies has installed several packaging lines within the halls: Seven thermoforming roller machines and two robot-operated shrink-wrap packaging machines. Efficient Atlas Copco vacuum pumps are used within the methods to vacuum pack the tubular/shrink baggage and thermoformed plastic trays, and to maintain the meat really recent. They work in two stations and supply forming, low and fine vacuums.
The thermoforming machines equipped by vacuum station 1. There are 4 Atlas Copco GHS 585 VSD+ variable-speed, oil-injected screw vacuum pumps that evacuate the air as much as forty mbar (absolute), in addition to four small boosters that decrease the pressure even additional to three mbar. One of the screw pumps supplies the forming vacuum for the thermoforming curler machines, which only require around a hundred to one hundred fifty mbar for the forming process. The different vacuum pumps on this station are connected 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 contains 5 GHS 730 VSD+ pumps that take away the air from the shrink luggage at the Cryovac traces. “The size of the cuts of meat is automatically detected by our methods,” explains Waldemar Metzger. “The packaging machines then routinely insert the cuts of meat into the tubular baggage, which are cut to the right dimension under a vacuum bell.” Under the hood, all ambient air is then evacuated in two phases till the pressure is around 3 mbar (fine vacuum).
“With the forming vacuum – or thermoforming vacuum, as it’s additionally referred to as – the plastic tray is shaped by slicing the foil roll,” says the Technical Manager. After filling the shell with smaller pieces of meat, the shell is “wed” to the cover film: The device closes and seals the packaging airtight at three to five mbar using the fine vacuum. Sorting machines assign the individual trays and tubular luggage to larger boxes, that are then used to choose customized packing containers for customer orders.
Efficient pace regulation reduces power requirements by a third or more
Waldemar Metzger has been working in Badbergen for 20 years and has been part of the planning and execution phases of changing the combined slaughterhouse to a purely beef operation from the very starting. This included the decision to buy Atlas Copco variable-speed vacuum pumps. “As far as know-how is anxious, with the flexibility to vary the pace of the GHS vacuum pumps is crucial to us and saves energy,” stresses the Tönnies employee. “Compared to fixed-speed machines, you’ll find a way to reliably minimize down energy requirements by around a third – even perhaps by half, depending on the diversity issue.”
The controls on the vacuum pumps have a user-friendly plain textual content show, which additionally indicates the operating hours and maintenance intervals. Since the Atlas Copco pumps may be related directly to an exhaust system, it was possible to use air-cooled pumps. According to the manufacturer, this improves the climate of the room; it’s now not essential to have the additional room cooling usually required when using central vacuum systems.
The project was implemented on site by and with Oliver Hornberg, Managing Director of Eugen Theis Vakuumtechnik in Werther. He delivered the pumps to Tönnies Beef, ready to make use of – including a 400 m pipeline in the transformed slaughterhouse, measuring in places to a diameter of DN 300. His firm, Eugen Theis GmbH, was based in 1984 and makes a speciality of vacuum know-how. In 1999, Hornberg took over the enterprise from its founder, Eugen Theis, and 20 years later, in late 2021, offered it to Atlas Copco after he couldn’t find a successor. “Our two youngsters are pursuing other profession paths,” he says. pressure gauge 2.5 นิ้ว remains Managing Director even after the corporate was sold to Atlas Copco and is looking forward to important progress under the umbrella of one of many world’s largest suppliers of vacuum pumps. The company already operates all through Germany: “From Flensburg in the north to Regensburg in the south and Halle (Saale) in the east,” he says, outlining the reach of his firm: This additionally includes Badbergen in the (north)west, as he typically stops by at Tönnies Beef to take care of the machines.