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

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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 turn out to be more environment friendly than ever following renovations at the website: Now, energy-saving Atlas Copco variable-speed vacuum pumps are used to create vacuum situations at two central stations.What used to be a blended slaughterhouse has become a “bovine animal competence center”: For a long time, cattle and pigs had been slaughtered and butchered on the identical time in Badbergen on behalf of different companies. In 2017, the Tönnies Group took over the location and decided to base its entire slaughtering operation in Badbergen – up till that point, this had taken place on the company’s main web site in Rheda-Wiedenbrück. In 2020, Tönnies Beef reopened the site after extensive conversion and renovation. The Group invested round 85 million euro in the constructing and state-of-the-art know-how at this site in a small town in northern Lower Saxony, between Oldenburg and Osnabrück. The slaughtering, butchering and ending processes are based on the newest cooling technology, machine-based butchering and highly automated choosing and shipping traces.
Several hundred tons of meat depart the positioning every single day and 95% of the animal – virtually every thing – is utilized. This allows Tönnies to fulfill different consuming habits around the world: While German customers favor lean beef, meat with a thick layer of fats is well-liked in Scandinavia and other European nations, according to the manufacturer’s web site.
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 various major customers. For this function, Tönnies has put in several packaging strains within 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 nice 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 4 small boosters that decrease the strain even further to three mbar. One of the screw pumps provides the forming vacuum for the thermoforming roller machines, which solely require round one hundred to one hundred fifty mbar for the forming course of. The different vacuum pumps in this station are related to the boosters. One of the pumps is redundant at any given time: This can additionally 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 traces. “The size of the cuts of meat is automatically detected by our systems,” explains Waldemar Metzger. “ Manifest packaging machines then automatically insert the cuts of meat into the tubular luggage, which are cut to the right size under a vacuum bell.” Under the hood, all ambient air is then evacuated in two levels till the stress is around 3 mbar (fine vacuum).
“With the forming vacuum – or thermoforming vacuum, as it’s additionally called – the plastic tray is formed by slicing the foil roll,” says the Technical Manager. After filling the shell with smaller items of meat, the shell is “wed” to the duvet film: The device closes and seals the packaging hermetic at 3 to 5 mbar utilizing the nice vacuum. Sorting machines assign the individual trays and tubular baggage to larger boxes, which are then used to select custom packing containers for buyer orders.
Efficient velocity regulation reduces energy requirements by a 3rd or extra
Waldemar Metzger has been working in Badbergen for 20 years and has been a part of the planning and execution phases of converting the blended 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 technology is concerned, having the power to differ the velocity of the GHS vacuum pumps is crucial to us and saves energy,” stresses the Tönnies worker. “Compared to fixed-speed machines, you can reliably reduce down energy necessities by round a 3rd – even perhaps by half, relying on the variety issue.”
The controls on the vacuum pumps have a user-friendly plain text show, which additionally signifies the working hours and maintenance intervals. Since the Atlas Copco pumps can be connected on to an exhaust system, it was attainable to make use of air-cooled pumps. According to the producer, this improves the climate of the room; it is not essential to have the extra room cooling usually required when using central vacuum methods.
The project 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 use – together with a four hundred m pipeline within the converted slaughterhouse, measuring in locations to a diameter of DN 300. His firm, Eugen Theis GmbH, was based in 1984 and focuses on vacuum know-how. 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 youngsters are pursuing different profession paths,” he says. Best selling stays Managing Director even after the corporate was sold to Atlas Copco and is looking ahead to important development underneath 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 within the south and Halle (Saale) in 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 hold up the machines.
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