Atlas Copco central vacuum stations provide packaging lines at Tönnies BeefVacuum expertise helps beef stay recent for longer

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The Tönnies Group has constructed its bovine animal competence heart in Badbergen, Lower Saxony. The cuts of beef are vacuum-packed in thermoforming and shrink-wrap machines, a course of that has turn out to be more environment friendly than ever following renovations on the site: Now, energy-saving Atlas Copco variable-speed vacuum pumps are used to create vacuum situations at two central stations.What was once a blended slaughterhouse has turn into a “bovine animal competence center”: For many years, cattle and pigs have been slaughtered and butchered on the similar time in Badbergen on behalf of different companies. In Economical , the Tönnies Group took over the positioning and decided to base its whole 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 extensive conversion and renovation. The Group invested round 85 million euro in the constructing and state-of-the-art know-how at this website in a small town in northern Lower Saxony, between Oldenburg and Osnabrück. The slaughtering, butchering and finishing processes are primarily based on the latest cooling know-how, machine-based butchering and highly automated selecting and transport strains.
Several hundred tons of meat leave the site daily and 95% of the animal – practically every little thing – is utilized. This permits Tönnies to fulfill totally different consuming habits around the globe: While German shoppers prefer lean beef, meat with a thick layer of fat is well-liked in Scandinavia and other European nations, according to the manufacturer’s website.
Efficient screw vacuum pumps provide forming, low and fantastic 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 various major customers. For this function, Tönnies has installed a quantity of packaging traces within the halls: Seven thermoforming curler machines and two robot-operated shrink-wrap packaging machines. Efficient Atlas Copco vacuum pumps are used within the methods to hoover pack the tubular/shrink bags and thermoformed plastic trays, and to keep the meat really fresh. They work in two stations and supply forming, low and fantastic vacuums.
In less than thermoforming machines supplied 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 40 mbar (absolute), as well as four small boosters that decrease the strain even further to three mbar. One of the screw pumps provides the forming vacuum for the thermoforming curler machines, which solely require round a hundred to 150 mbar for the forming course of. The different vacuum pumps on this station are linked to the boosters. One of the pumps is redundant at any given time: This can be the case in the second vacuum station, which includes 5 GHS 730 VSD+ pumps that remove the air from the shrink bags at the Cryovac lines. “The dimension of the cuts of meat is mechanically detected by our systems,” explains Waldemar Metzger. “The packaging machines then routinely insert the cuts of meat into the tubular luggage, which are minimize to the correct measurement beneath a vacuum bell.” Under the hood, all ambient air is then evacuated in two phases until the stress is around three mbar (fine vacuum).
“With the forming vacuum – or thermoforming vacuum, as it’s also known as – the plastic tray is fashioned by cutting the foil roll,” says the Technical Manager. After filling the shell with smaller pieces of meat, the shell is “wed” to the quilt film: The device closes and seals the packaging hermetic at 3 to 5 mbar using the fine vacuum. Sorting machines assign the person trays and tubular bags to bigger boxes, that are then used to choose custom boxes for customer orders.
Efficient velocity regulation reduces power necessities by a third or more
Waldemar Metzger has been working in Badbergen for 20 years and has been a part of the planning and execution levels of changing the blended slaughterhouse to a purely beef operation from the very beginning. This included the decision to buy Atlas Copco variable-speed vacuum pumps. “As far as know-how is worried, having the ability to differ the pace of the GHS vacuum pumps is essential to us and saves energy,” stresses the Tönnies worker. “Compared to fixed-speed machines, you probably can reliably cut down vitality requirements 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 display, which also indicates the operating hours and maintenance intervals. Since the Atlas Copco pumps can be linked directly 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 is no longer essential to have the additional room cooling typically required when utilizing central vacuum systems.
The challenge was applied on site by and with Oliver Hornberg, Managing Director of Eugen Theis Vakuumtechnik in Werther. He delivered the pumps to Tönnies Beef, prepared to use – including a four hundred m pipeline in the converted slaughterhouse, measuring in locations to a diameter of DN 300. His company, Eugen Theis GmbH, was based in 1984 and makes a speciality of vacuum technology. In 1999, Hornberg took over the enterprise from its founder, Eugen Theis, and 20 years later, in late 2021, sold it to Atlas Copco after he couldn’t find a successor. “Our two children are pursuing other profession paths,” he says. Hornberg himself remains Managing Director even after the company was sold to Atlas Copco and is trying forward to important growth underneath the umbrella of one of the world’s largest suppliers of vacuum pumps. The company already operates throughout Germany: “From Flensburg within the north to Regensburg within the south and Halle (Saale) within the east,” he says, outlining the reach of his firm: This additionally consists of Badbergen in the (north)west, as he generally stops by at Tönnies Beef to keep up the machines.
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