Aerzen USA insights and guidance for blower, compressor and vacuum pump applications

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Oil-free Air Conveying In Coffee Roasting Equipment

Aerzen Coffee Conveying resized 600Since its foundation in 1868 the Probat-Werke has concentrated with more than 600 employees worldwide on roasting machines and equipment for coffee and food industry. Until today, the world market leader has sold more than 110,000 roasting machines – from manual global roaster via fully automatic largescale roasters up to the new tangential roaster Jupiter Hybrid with which the most diverse roasting profiles can be prepared in one roasting machine.
For transport of the coffee, Probat prefers the pneumatic conveyance. As the
conveying air is in direct contact with the product, it has to be absolutely oilfree. For production of the conveying air as negative pressure, Probat has used Aerzen units since 1996.

In September 2012, Probat opened a new Research and Technology Centre. There, the conveying air required in the roasting machines is generated by two Delta Blowers Generation 5 and one Delta Hybrid. Upon storage of the green coffee into silos with overpressure between 1,000 and 2,000 mbar, the Delta Blower is used, also during transport to the roasting machine with positive pressure.
The Delta Hybrid is responsible for transport of the particularly sensitively
roasted beans to the roasted coffeesilos and to bagging station with negative pressure as well as for transport to grinding plant with overpressure. The Delta Hybrid unit generates a negative pressure of 300 mbar on suction side as well as an overpressure of 600 mbar on discharge side. Therefore, a conventional blower unit could be replaced acc. to the principle “Two become
Again, two Delta Blowers transport the ground coffee to the ground coffee silos and to the packaging machines with negative pressure. As an alternative, however, the Delta Hybrids can also be used. The required differential pressure is decisive for the selection dependent on the piping length and the specific energy advantages of the Hybrid.

All Aerzen units are fully automatically integrated in the process of the roasting equipment and are switched via a superordinated intelligent SPS control depending on the program. The respective blower units are driven with a constant volume flow whereby the pressure is built up depending on conveying capacity and pipe length. Thanks to a bypass solution, Aerzen
had developed together with Probat, a part of the volume flow can be led back from discharge to suction side for the positive pressure units.

Aerzen USA's Business Philosophy: People, Planet & Prosperity

BestPlacesToWork2013Logo resized 600

Aerzen USA is well known for blowers, compressors and vacuum pumps. However the key to success is in the company's business philosophy featuring collaboration with customers and following a "Triple Bottom Line" mindset that includes People, Planet & Prosperity.

Aeration Blower Saves $44K Annually For Wastewater Treatment Plant

The segment from WaterOnline Radio features interviews with John Franz, wastewater treatment plant manager for the City of Anacortes, WA, as well as Kevin Grant, a regional sales manager for Aerzen USA.
  • How Aerzen aeration blower efficiency is saving a Puget Sound utility an estimated $44,000 per year.
  • The energy and O&M gains offered by new blower technology.
  • The difference between positive displacement, turbo, and hybrid blowers.
  • How to manage air demand to find your efficiency "sweet spot."

 Listen To The Podcast:

A Turbo Blower for the Base Load, PD Blower for the Peak Load

Aerzen Turbo Blower and PD Blower WWTP

A biological municipal wastewater treatment plant with a considerably fluctuating discharge quantity can only perform its function with utmost energy efficiency and reliability if the process air consumption of the aeration basin can be adjusted continuously and is fully automated in order to deal with widely fluctuating load quantities. The example of the wastewater treatment plant shows how this is achieved with the use of a speed controlled Aerzen turbo blower.

More pressure for Aerzen Process Gas Compressors

Aerzen Process Gas Compressor Stage

Due to a new bearing and shaft design it is possible to increase the maximum admissible differential pressures to 25 bar in the process gas compressors VRa 236 H and VRa 336 H. Thus, with a multi-stage unit discharge pressures of up to 53 bar abs. can be reached.

How To Choose The Right Blower For Wastewater Treatment (Podcast)

Listen To The Blower Technology Selectio

Three main blower technologies are condsidered for waste water treatment applications:

An Engineer's Mini-Guide To Blower Technology Selection


Turbo Blowers. Positive Displacement Blowers. Hybrid Rotary Lobe Blowers. Which one should you choose for your wastewater treatement application? How much energy can you really save? Who can you trust to give you an objective answer? The best place to start is by downloading the Engineer's Mini-Guide To Blower Technology Selection.

Real-time Condition Monitoring For Blowers And Compressors

Aerzen iAir Remote Monitoring System

The Aerzen iAir Remote Monitoring System (RMS) is a comprehensive monitor that can be attached to any blower or compressor to capture real-time activities and conditions. Based on industrial cellular technology, the RMS can function in any location with cellphone coverage for both indoor and outdoor applications. The system is easily installed and linked directly to your cell phone for up-to-the-minute condition reports and notifications. This allows for peace of mind and troubleshooting when you are not accessible to the equipment.

Trucking – Pay now, or pay later

wrecked blower

Shipping damage is the top number one issue followed by scheduling and only then cost.  It is amazing how much freight gets damaged per year.  This is particularly true for new blower packages that are shipped via LTL (Less than truckload) and so called common carrier.  Although deemed the most cost effective – expediting and broker companies managed to push the cost down - it is the most difficult way to get machinery to a job site undamaged. Because freight must be consolidated in the carrier’s main hubs the equipment must be moved often.  The mostly heavy and odd shaped freight with uneven weight distribution is moved with fork trucks that are significantly undersized.  Making things worse is the fact that logistics is a business model where people make Cents on a Dollar and thus the time freight spends in non value adding moving around within terminals is kept to an absolute minimum causing fork lift drivers to drive fast and furious.  Freight gets shoved around, stacked (when it should not be) and dropped rapidly (giving drop-shipment a different meaning).  The result is that sound enclosures, castings, instrumentation etc gets damaged significantly before it even makes it to the final destination. 

Operating Time Versus Condition Based Oil Changes

Ralf Weiser

The majority of all operating manuals provide the equipment user with a time based plan when to change the machine’s oil.  This interval is typically designed to protect the oil and subsequently the machine from breaking down prematurely in most if not all operating conditions.  So far so good.  This comes with a price tag as the machine needs to be properly shut down and locked / tagged out.  Besides of the obvious cost for the lubricant you also incur labor and potential production down time cost.  For most of the smaller machines requiring less than a gallon of oil for each change it may not make sense to go with a condition based lubricant change.  Experts fix what needs fixing and this applies here also.  For larger quantities it may make much more sense to go with an oil condition based oil change schedule. 

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Experts fix what needs fixing

Aerzen USA - Technical Director - Ralf WeiserThis is directed to anyone who owns and operates any plant in any given industry.  I am in awe.  This is the year 2009 where saving money is more important than ever and yet unplanned emergency repairs costs due to run-to-failure as well as the dated run time based maintenance drain your manpower and cash reserves more than ever.  Do not get me wrong, there are pre-existing conditions that you sometimes cannot prevent, or your organization has done it for so long that the cultural change will take years for you to change. 

Ideally, anyone in charge of maintaining equipment - especially the ones of you who responsible for the budgeting - should sit on a rock and ponder how your organization can implement what I call Precision Maintenance philosophy.  No rocket science or big costs involved here.  It just describes the process of setting up trending your assets precisely.  The precise part is divided into three similarly important yet mind boggling simple steps:  Plan - Do - Review. 

Do you believe in everything you see and hear about Turbo Blowers?

Download The Engineer's Mini-Guide To Bl

Do you believe in everything you see and hear about Turbo Blowers?

What not to forget when you correct rotating equipment problems


What not to forget when you correct rotating equipment problems...

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Hello Mechanical World please meet Mrs. Electronics!


Hello Mechanical World please meet Mrs. Electronics! 

Positive displacement blowers and compressors have been around for well over 100 year.  Predominately process and maintenance folks have viewed them as mere mechanical devices that did not represent any worth in protecting and managing them electronically.  How dramatically different our world looks like today!  In a time where machinery is expected to fend for itself it makes great sense to monitor and manage your blowers and compressors and treat them as the assets they represent to your company.  The problem is how to best do it when you either buy new machines or systems.  Or how do you retrofit old blowers and compressors with systems that will later nicely integrate into your plant operating system? 

The system integration has always been one big obstacle in the integration process - next to cost of course.  Aerzen USA has generated a new approach to this challenge in form of our iAir Pneumatic Control Blower and Compressor control system that is offered as an augmentation to the already well known AS and ASG control platforms.  Here we have a controller

that is easy to use as it features a touch screen interface with all the pertinent information on a single screen shot.  If you want more information, simple touch the area of your interest and more details will show of on the display.  It can handle blower as well as single stage oil free compressor applications. In its basic version it can be connected to your plant system via Ethernet TCP, Modbus, Profibus or simply SCADA I/O's. 

Using instrumentation solves a whole variety of issues.  The most important one is that it protects against overloading or abuse of the blower or compressor.  Basic operating parameters are monitored and if necessary provide an alarm or shut down signal.  Another big ticket item especially in the construction phase of a new installation is that hard wiring cost can be greatly reduced by using a two-wire communication protocol that can connect at least up to 12 machines and still provide all the information as if you stood in front of the controller itself.  That is really powerful information for operators and plant managers alike.  Would you not want your machine telling you automatically that it needs attention?  How about uptime management that you would be able to do with it?  Please drop me an email if you are interested to learn more about how we can put money back onto your bottom line. 

Ralf Weiser -

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Right-sizing Aeration Blowers in Waste Water Treatment Plants


Right-sizing Aeration Blowers in Waste Water Treatment Plants

As the main consumer of electricity in a wastewater treatment plant, the aeration system greatly influences the overall cost of operation, that in the longterm by far exceed the initial investment cost. Several blower technologies can be chosen from and it therefore behooves the engineer to accurately evaluate the characteristics of the aeration blowers and carefully interpret some of the claims made by various manufacturers. The most energy efficient solution must be based on actual conditions that, in reality, will vary over an extended period of time.

The economical operation of a wastewater treatment plant depends largely on the design and the interplay of the aeration and process controls. Moreover, the human factor and the management objectives are at the heart of the plant's reality and should also be taken into consideration. Selection and thoughtful integration of all the subsystems is of paramount importance.

Taking a pragmatic approach, Aerzen USA developed a whitepaper on the subject. This paper presents ways to minimizing the energy usage: right-sizing, aeration control, defining the operating range and matching the blower technology to the application, and comparing operating data over time.

The paper presents four types of blowers: two dynamic and two positive displacement machines. Since each technology has its place, a comparison is made specifically based on the treatment of wastewater. Taken into account are the daily and seasonal swings in oxygen demand, fouling and aging of diffusers, air flow control and turndown capabilities, total blower efficiency and energy consumption over time, mode of operation, blower accessories, and plant set-up. The paper recommends engineers to exercise due professional diligence and to select the most suitable aeration blower technology based on a relevant comparison.

To learn more about selecting to correct aeration blower for your application download the new whitepaper "Aeration blowers in the wastewater industry in North America"

Video:Tom McCurdy explains Right-sizing Aeration Blowers in Waste Water Treatment Plants


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