Efficient Airflow

Stephan Gürlich: Airflow determines how evenly a product is treated. If hot or cold spots occur, processes are prolonged or over-drying occurs – resulting in direct yield losses. As heating and cooling processes account for up to 60 per cent of energy consumption, any optimisation has an immediate effect on operating costs. Precise air distribution ensures reproducible conditions across all levels, even with dense loading. This shortens drying times, reduces weight loss and stabilises quality. In view of rising production and energy costs, this issue is becoming increasingly important.

Stephan Gürlich: The choice of airflow principle always depends on the product. For lying goods, Vetec Anlagenbau relies on horizontal airflow with patented nozzle geometry, as implemented in the CROSS-POWER system. The air velocity is many times higher than in conventional systems, so that the process runs faster and more evenly. For sausages or other hanging products, however, the AEROMAT with its alternating flap system, which generates dynamic circulation, has proven itself. The decisive aspect is how the surface, structure and moisture content react. The more precisely the air movement is adapted to these requirements, the more efficient the overall result.

Stephan Gürlich: The effect is particularly noticeable with meat and sausage products – although this depends on the product position and type of system. For flat products such as bacon or beef jerky, which are processed in the CROSS POWER, the high, uniform air velocity ensures that drying is faster and more uniform – with positive effects on yield and product quality. On the other hand, for hanging products such as hot dogs or sausages, the AEROMAT system ensures particularly uniform air distribution. In both cases, the precise air flow prevents overdrying and consequently significant weight loss. Otherwise, this would have to be compensated for with additional meat quantities. At the same time, energy requirements are reduced thanks to shorter process times and stable process conditions. Practical examples show that: Flow quality not only means better results, but also lower ongoing costs.

Stephan Gürlich: Existing plants often feature outdated flow components, high pressure resistance or inefficient drive technology. Even individual technical adjustments can bring about significant progress here: Efficient IE4 motors increase the efficiency of the air drive, flow-optimised heat exchangers cut pressure loss in half, and heat recovery systems reduce energy consumption by up to 30 per cent. Precise control of fresh air and exhaust air is equally important in order to tailor the process exactly to the target humidity and product protection. This allows existing lines to be further developed according to modern efficiency standards.

Stephan Gürlich: These components work together in the overall system. The use of IE4 motors with frequency converters ensures particularly efficient air propulsion. Heat recovery utilises existing waste heat and reduces energy consumption by preheating fresh air – in practice by up to 30 per cent. The precise control of the fresh air flaps is equally important: It prevents unnecessary exhaust air loss and keeps the target humidity stable. During cooling, the system automatically utilises cold outside air, provided it is available. All these factors not only improve energy efficiency, they also protect the product by preventing thermal overloading.

Stephan Gürlich: The principles of precise airflow are universal, as long as they are tailored to the respective product. This is demonstrated by applications in a wide variety of segments ranging from meat products and snacks to dried pet food snacks. The decisive factor is always how the air movement can be adapted to the structure, humidity and load density. Modern systems allow for a high degree of fine adjustment. This enables companies to efficiently handle both smaller batches and larger production volumes without having to change the fundamental process logic.

Stephan Gürlich: First: Efficiency is achieved through the interaction of many details – from flow geometry and drive technology to heat recovery. Second: Uniformity is a crucial quality factor, as it prevents weight loss and creates reproducible processes. Third: Economy and ecology are not mutually exclusive; precise airflow control makes it possible to achieve both at the same time.

One important trend is AI-supported flow simulations, which are already being used today to tailor plants even more precisely to products and to identify potential efficiency gains at an early stage.

VETEC Anlagenbau GmbH, based in Verden, Germany, is one of the world's leading companies for smoking, cooking, cooling, drying, baking, pasteurising, fermenting and defrosting meat, sausage, fish and cheese products, as well as snacks.

For additional information, go to:

Stephan Gürlich
Senior Projektmanager
Vetec Anlagenbau GmbH
Karoline-Herschel-Str. 2
27283 Verden
info@vetec-anlagenbau.com
https://www.vetec.com