The Tönnies Group has constructed its bovine animal competence middle 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 extra efficient than ever following renovations at the site: Now, energy-saving Atlas Copco variable-speed vacuum pumps are used to create vacuum circumstances at two central stations.What was a combined slaughterhouse has turn into a “bovine animal competence center”: For decades, cattle and pigs have been slaughtered and butchered on the same time in Badbergen on behalf of different companies. In 2017, the Tönnies Group took over the site and determined to base its whole slaughtering operation in Badbergen – up till that time, this had taken place on the company’s primary web site in Rheda-Wiedenbrück. In 2020, Tönnies Beef reopened the positioning after in depth conversion and renovation. The Group invested round eighty five million euro within the constructing and state-of-the-art expertise at this web site in a small town in northern Lower Saxony, between Oldenburg and Osnabrück. The slaughtering, butchering and ending processes are based mostly on the latest cooling know-how, machine-based butchering and extremely automated picking and transport lines.
Several hundred tons of meat go away the location daily and 95% of the animal – practically everything – is utilized. This allows Tönnies to fulfill totally different consuming habits around the globe: While German consumers prefer lean beef, meat with a thick layer of fats is well-liked in Scandinavia and different European nations, in accordance with the manufacturer’s website.
Efficient screw vacuum pumps present forming, low and fine 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 objective, Tönnies has put in several packaging strains in the halls: Seven thermoforming curler machines and two robot-operated shrink-wrap packaging machines. Efficient Atlas Copco vacuum pumps are used in the systems to vacuum pack the tubular/shrink baggage and thermoformed plastic trays, and to keep the meat actually contemporary. They work in two stations and supply forming, low and fantastic vacuums.
The thermoforming machines provided by vacuum station 1. There are four Atlas Copco GHS 585 VSD+ variable-speed, oil-injected screw vacuum pumps that evacuate the air as a lot as 40 mbar (absolute), as nicely as four small boosters that lower the strain even additional to 3 mbar. One of the screw pumps provides the forming vacuum for the thermoforming curler machines, which only require around one hundred to a hundred and fifty 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 is also the case within the second vacuum station, which includes 5 GHS 730 VSD+ pumps that take away the air from the shrink luggage on the Cryovac lines. “The dimension of the cuts of meat is automatically detected by our methods,” explains Waldemar Metzger. “The packaging machines then mechanically insert the cuts of meat into the tubular bags, that are minimize to the correct size under a vacuum bell.” Under the hood, all ambient air is then evacuated in two stages till the pressure is around 3 mbar (fine vacuum).
“With the forming vacuum – or thermoforming vacuum, as it’s additionally called – 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 duvet movie: The tool closes and seals the packaging airtight at three to 5 mbar utilizing the fine vacuum. Sorting machines assign the individual trays and tubular baggage to bigger bins, which are then used to select customized boxes for customer orders.
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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 purchase Atlas Copco variable-speed vacuum pumps. “As far as know-how is concerned, with the ability to differ the speed of the GHS vacuum pumps is essential to us and saves energy,” stresses the Tönnies employee. “Compared to fixed-speed machines, you possibly can reliably cut down energy requirements by around a third – maybe even by half, relying on the diversity issue.”
The controls on the vacuum pumps have a user-friendly plain text display, which also signifies the operating hours and upkeep intervals. Since the Atlas Copco pumps may be linked on to an exhaust system, it was potential to make use of air-cooled pumps. According to the producer, this improves the local weather of the room; it is no longer essential to have the extra room cooling often required when utilizing central vacuum techniques.
The venture was implemented on web 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 four hundred m pipeline within the transformed slaughterhouse, measuring in places to a diameter of DN 300. His firm, Eugen Theis GmbH, was founded in 1984 and makes a speciality of vacuum know-how. In 1999, Hornberg took over the business from its founder, Eugen Theis, and 20 years later, in late 2021, bought it to Atlas Copco after he could not discover a successor. “Our two youngsters are pursuing other profession paths,” he says. Hornberg himself stays Managing Director even after the corporate was sold to Atlas Copco and is wanting forward to significant growth under the umbrella of one of the world’s largest suppliers of vacuum pumps. The company already operates throughout Germany: “From Flensburg in the north to Regensburg in the south and Halle (Saale) in the east,” he says, outlining the attain of his company: This also consists of Badbergen in the (north)west, as he generally stops by at Tönnies Beef to take care of the machines.