飲料行業(yè)智能灌裝機的自動潤滑（中英文）
升級到自動潤滑系統(tǒng)可以為食品和飲料制造商帶來諸多好處，包括經(jīng)濟效益和其他方面。
Upgrading to an automated lubrication system can bring food and beverage manufacturers a score of benefits, economic and beyond.
只需觀察在當(dāng)?shù)厣痰甑娘嬃蠀^(qū)，就會發(fā)現(xiàn)瓶裝飲料已成為日常消費品，而且種類繁多，令人眼花繚亂。全球城鎮(zhèn)化趨勢推動著人們在工作場所、學(xué)校、健身房、交通等便利場所（例如工作場所、學(xué)校、健身房、交通工具）對飲料的需求日益增長，而人口的持續(xù)增長又進一步加劇了這一趨勢。不可避免地，滾雪球式的消費給制造商及其所依賴的機器帶來了更大的壓力。
難怪飲料行業(yè)的競爭日益激烈。制造商通常要求24小時不間斷生產(chǎn)，幾乎沒有時間進行維護，并且需要在設(shè)備仍在運行時進行保養(yǎng)。機器故障會嚴(yán)重影響可用性；80%或更高的整體設(shè)備效率 (OEE) 目標(biāo)往往與60%左右的現(xiàn)實情況相沖突。
在飲料制造過程中，決定整體OEE的最關(guān)鍵應(yīng)用之一是灌裝機本身。制造商需要將水、茶、冰沙、酸奶等各種液體灌裝到玻璃瓶、罐、袋、管、PET 或其他容器中，因此他們尋求的是精準(zhǔn)、多功能、衛(wèi)生可靠的灌裝設(shè)備，即使在連續(xù)高速運行且無需計劃內(nèi)維護的情況下也能保持穩(wěn)定。
自動潤滑系統(tǒng)為飲料灌裝機提供了一種全新的解決方案。
You need only stroll down the beverage aisle of your local store to know that bottled drinks have become a consumer staple and that the range of products is overwhelming. The growing demand for drinks at convenient locations – work, school, gym, transport– is being driven by the global trend towards urbanization, fuelled in turn by inexorable population growth. Inevitably, snowballing consumption increases the pressure on manufacturers as well as on the machines upon which they rely.
Small wonder then that the beverage industry is becoming increasingly competitive. It is common for manufacturers to demand 24-hour production, leaving little time for maintenance and requiring that upkeep be performed while the equipment is still in operation. Machine failures have a dramatic impact on availability; the goal of overall equipment effectiveness (OEE) at 80 percent or higher often clashes with a reality of around 60 percent.
One of the most critical applications determining overall OEE in beverage manufacture is the filling machine itself. Faced with the need to fill glass bottles, cans, pouches, tubes, PET or other containers with anything from water or tea to smoothies and yoghurt, manufacturers look for filling equipment that is accurate, versatile, hygienic and reliable, even when operating continuously, at high speeds and without planned maintenance breaks.
Automated lubrication systems offer a new approach in beverage filling machines.
遞進式自動潤滑系統(tǒng)是食品飲料行業(yè)最常見的潤滑系統(tǒng)。該系統(tǒng)適用于潤滑點分散、需要不同量潤滑脂或潤滑油的中小型機器。
Progressive automatic lubrication systems are the most common lubrication systems in the food and beverage industry. They can be used on small to medium-sized machines with dispersed lubrication points that require varying quantities of grease or oil.
灌裝機與潤滑
Filling machines and lubrication
SKF食品飲料行業(yè)的客戶可以列舉許多影響灌裝機性能的潤滑挑戰(zhàn)。
? 潤滑脂過少：潤滑脂不足會縮短軸承和機器的使用壽命。潤滑不足和過度都可能是由于計量不精確，也可能是因為一些潤滑點被遺忘，尤其是那些難以觸及或在機器運轉(zhuǎn)時無法觸及的潤滑點。
? 潤滑脂過多：這里最大的風(fēng)險是產(chǎn)品污染，造成高昂的成本。但同樣嚴(yán)重的問題是，潤滑脂可能會進入用于清潔機器的水中，需要水處理工藝符合環(huán)保法規(guī)。
? 復(fù)雜性：一臺灌裝機可能有多達 80 個潤滑點，其中許多位于旋轉(zhuǎn)的機械部件內(nèi)部，因此在機器運轉(zhuǎn)時無法觸及。出于安全考慮，手動操作可能會變得復(fù)雜。部件種類繁多，其高效潤滑可能非常復(fù)雜。例如，齒輪的潤滑對機器的性能至關(guān)重要。
? 腐蝕：潤滑系統(tǒng)的設(shè)計可能不適合在飲料行業(yè)的惡劣條件下運行，例如高濕度，這會導(dǎo)致計量裝置、油嘴和管道腐蝕。裝瓶生產(chǎn)線必須頻繁進行高壓沖洗，這對裝瓶機械裝置的完整性及其潤滑構(gòu)成了真正的挑戰(zhàn)。簡而言之，腐蝕對飲料生產(chǎn)基地具有破壞性。
SKF customers in the food and beverage sector can cite a number of lubrication challenges that affect the performance of filling machines.
? Too little grease: Lack of lubricant shortens the lifetime of the bearing and that of the machine. Both under- and over-lubrication can be due to imprecise metering and also because some lubricating points are simply forgotten, especially those that are difficult to reach or cannot be accessed while the machine is in motion.
? Too much grease: The paramount risk here is costly contamination of the product. But an equally critical problem is that grease can enter the water used to clean the machine, requiring water treatment processes to meet environmental regulations.
? Complexity: A filling machine can have as many as 80 lubrication points, many of which are located inside rotating mechanical parts and therefore impossible to access while machinery is running. Manual access can be complicated by safety concerns. Components vary, and their efficient lubrication can be complex. Gear wheels are an example, and their lubrication is fundamental to a machine’s performance.
? Corrosion: Lubrication systems may not be designed to operate under the aggressive conditions of the beverage industry, such as high humidity, which can lead to corroded metering devices, grease nipples and piping. Frequent high-pressure washing is mandatory on bottling lines and poses a real challenge to the integrity of bottling mechanisms and their lubrication. In short, corrosion is damaging for beverage manufacturing sites.
自動化解決方案
Automated solutions
集中式自動潤滑系統(tǒng)(ALS)能夠提高機器可用性，同時減少對稀缺人才的依賴。這些系統(tǒng)能夠以正確的間隔提供適量的潤滑，最大限度地減少摩擦和磨損，并優(yōu)化軸承和機械的使用壽命。ALS專為潤滑單臺機器以及整個工廠而設(shè)計，能夠為所有需要的點提供適當(dāng)、精確的潤滑劑補充，從而在生產(chǎn)過程中帶來一系列優(yōu)勢。
因此，采用防腐蝕材料制成的智能機器能夠消除上述常見問題。通過在正確的時間將正確的潤滑劑以正確的量輸送到正確的潤滑點，自動化系統(tǒng)可以消除人為錯誤，極大地簡化潤滑管理，減少潤滑劑消耗，并提高裝瓶流程的整體效率。
選擇哪種系統(tǒng)？
在為特定灌裝機選擇正確的解決方案時，需要考慮以下幾個主要因素：
? 尺寸：灌裝機的尺寸決定了潤滑點的數(shù)量，從而決定了潤滑劑的總消耗量。
? 變化：所選系統(tǒng)必須能夠向每個潤滑點輸送精確量的油脂或潤滑油，具體量可能因機器中需要潤滑的部件而異。
? 技術(shù)參數(shù)：系統(tǒng)必須考慮潤滑點的背壓、工作溫度范圍、潤滑劑本身的選擇以及供油泵的驅(qū)動能量、控制和監(jiān)控。
? 需要潤滑的機構(gòu)類型：包括軸承、齒輪、選擇螺釘?shù)取?/p>
? 工廠環(huán)境：在大多數(shù)情況下，不銹鋼部件對于避免腐蝕至關(guān)重要。然而，并非所有自動潤滑系統(tǒng)都使用防腐蝕材料。
Centralized automatic lubrication systems (ALS) have the potential to increase machine availability while reducing reliance on scarce talent. These systems provide the appropriate quantity of lubrication at the correct intervals, minimizing friction and wear and optimizing bearing and machinery service life. Designed to lubricate individual machines as well as entire plants, ALS provide proper, precise lubricant replenishment to all required points, enabling a range of benefits in the process.
An intelligent machine, made from non-corrosive materials, therefore has the potential to eliminate the common problems listed above. By delivering the correct lubricant, in the right quantity, at the right time and to the correct lubrication point, automation removes human error, hugely simplifies lubrication management, reduces lubricant consumption and enhances the overall efficiency of the bottling process.
What system to choose?
There are several main factors at play in determining the correct choice of solution for a particular filling machine:
? Dimensions: The size of the filling machine determines the number of lubrication points, and thus total lubricant consumption.
? Variation: The chosen system must have the capacity to deliver an exact quantity of grease or oil to each lubrication point, which may vary according to the part of the machine to be lubricated.
? Technical parameters: The system must consider back pressures at the lubrication points, operating temperature range, the choice of lubricant itself and the feed pump’s drive energy, control and monitoring.
? Types of mechanisms to be lubricated: These include bearings, gears, selection screws, etc.
? Factory environment: In most circumstances, stainless steel components are essential to avoid corrosion. However, not all automated lubrication systems use corrosion-free materials.
自動潤滑系統(tǒng)的類型
Types of automated lubrication systems
? 單線自動潤滑系統(tǒng)
泵將潤滑劑輸送到可調(diào)節(jié)的計量裝置，該計量裝置為潤滑點提供精確的油脂或潤滑油量。單線潤滑系統(tǒng)可用于為多臺獨立的機器、一臺機器，甚至一臺機器上的不同區(qū)域提供服務(wù)。監(jiān)控由傳感器完成，這些傳感器監(jiān)測系統(tǒng)壓力，并在預(yù)設(shè)的臨界值時向控制單元發(fā)送信號。控制單元可按預(yù)定的時間間隔自動觸發(fā)潤滑。單線潤滑系統(tǒng)可為機器中多達 900 個潤滑點提供服務(wù)，潤滑距離可達 100 米。小型系統(tǒng)由緊湊型泵組（包括潤滑劑儲液罐）供油；大型系統(tǒng)由桶泵供油。安裝比漸進式油脂潤滑系統(tǒng)更容易，但單線油脂潤滑系統(tǒng)的初始投資可能更高。
? 漸進式自動潤滑系統(tǒng)
這是食品和飲料行業(yè)最常見的潤滑系統(tǒng)。它適用于潤滑點分散、需要不同用量的油脂或潤滑油的中小型設(shè)備。遞進式潤滑系統(tǒng)由一臺連接到主計量裝置的泵組成，主計量裝置的出口通過管道或高壓軟管連接到加注機的潤滑點。泵將潤滑劑輸送到計量裝置，計量裝置將潤滑劑分成預(yù)定的量。然后將潤滑劑泵送到潤滑點，或者泵送到二次計量裝置的入口，從而可以潤滑更多的點。遞進式潤滑系統(tǒng)可以向大約15米范圍內(nèi)多達150個潤滑點分配精確計量的潤滑劑。
? Single-line automatic lubrication systems
A pump delivers lubricant to an adjustable metering device that services the lubrication points, delivering a precise amount of grease or oil. Single-line lubrication systems can be used to service several separate machines or a single machine or even different zones on a single machine. Monitoring is done by sensors that monitor system pressures and send signals to the control unit at preadjusted critical values. The control unit enables lubrication to be triggered automatically at predetermined intervals. Single-line lubrication systems can serve as many as 900 lubrication points in machines over distances of up to 100 metres. Smaller systems are fed by compact pump units, including lubricant reservoirs; bigger systems are fed by barrel pumps. Installation is easier than with a progressive grease lubrication system, but the initial investment in a single-line grease lubrication system may be higher.
? Progressive automatic lubrication systems
This is the most common lubrication system in the food and beverage industry. It can be used on small to medium-sized machines with dispersed lubrication points that require varying quantities of grease or oil. Progressive lubrication systems consist of a pump connected to a primary metering device, outlets from which are connected via pipes or high-pressure hoses to the lubrication points of the filling machine. The pump supplies lubricant to the meter, which splits the lubricant into predefined amounts. The lubricant is then pumped to the lubrication points or – alternatively – to the inlet of a secondary metering device, thereby enabling more points to be lubricated. Progressive lubrication systems can dispense a precise, metered amount of lubricant to as many as 150 lubrication points over distances of approximately 15 metres.
集中自動潤滑系統(tǒng) (ALS) 可以提高機器可用性，同時減少對稀缺人才的依賴。
Centralized automatic lubrication systems (ALS) have the potential to increase machine availability while reducing reliance on scarce talent.
99.5% 的飲料灌裝機采用手動潤滑。
99,5% of operated beverage filling machines are manually lubricated
雖然安裝自動潤滑系統(tǒng) (ALS) 需要一定的初始成本，但其投資回報速度可能比預(yù)期更快。首先，人工成本顯著降低。其次，停機時間減少，部件壽命延長，也帶來了可觀的節(jié)省。無需停機潤滑，只需保持系統(tǒng)潤滑和維護，從而提高效率。軸承旋轉(zhuǎn)時進行的潤滑還能改善潤滑劑的分布。少量潤滑脂保持流動，即使在惡劣環(huán)境下運行，也能有效防止污染。
Although there is an initial cost to installing an ALS, the return on investment can come faster than might be assumed. Firstly, labour costs are significantly reduced. And there are also considerable savings from reduced downtime and extended component life. There is no need to stop the machine for lubrication, only to keep the system filled and maintained, so efficiency is enhanced. Lubrication that takes place while the bearings are rotating also improves the distribution of lubricant. A small amount of grease remains flowing, keeping out contamination even when the machine is operating in a harsh environment.
投資回報
Return on investment
智能傳感器和數(shù)字測量設(shè)備還能持續(xù)監(jiān)控整個潤滑過程。監(jiān)控和控制對于潤滑系統(tǒng)的高效運行至關(guān)重要。與智能監(jiān)控設(shè)備配合使用，自動潤滑系統(tǒng)可以實現(xiàn)經(jīng)濟高效的潤滑。生成的數(shù)據(jù)可以提前預(yù)警潤滑或機器故障，從而采取預(yù)防措施。
SKF發(fā)現(xiàn)，自動潤滑系統(tǒng)在灌裝機中的應(yīng)用潛力可以用經(jīng)濟角度來衡量：
? 提高資產(chǎn)可用性：自動潤滑系統(tǒng)帶來的可靠性，可以大幅降低因機械故障導(dǎo)致的停機頻率和停機時長。SKF擁有豐富的應(yīng)用經(jīng)驗，停機時間減少了高達 80%。
? 降低備件消耗：消除潤滑故障后，軸承、鏈條和齒輪等備件的年消耗量平均可減少約50%。
? 降低維護成本：精準(zhǔn)合理的潤滑可以消除機器故障的主要原因之一。
? 速度更快：裝瓶廠可將螺旋輸送機的速度提高一倍，因為自動潤滑的傳動鏈可以更快地運行而不會損壞瓶子。
自動潤滑系統(tǒng)還具有許多其他優(yōu)勢：
? 更高的生產(chǎn)力：除了增加機器正常運行時間外，自動化還能減少日常潤滑所需的勞動力，從而顯著提高效率。
? 改善健康和安全：工人在機器運行過程中無需再承受手動潤滑帶來的潛在危險。
? 降低產(chǎn)品污染風(fēng)險：自動化消除了過度潤滑導(dǎo)致飲料污染的危險。
? 快速投資回報：以上所有因素共同作用，使飲料灌裝機自動潤滑系統(tǒng)的投資能夠快速獲得回報。
Smart sensors and digital measuring devices also make it possible to constantly monitor the entire lubrication process. Monitoring and control are essential to the efficient operation of lubrication systems. Installed in conjunction with intelligent monitoring devices, automatic lubrication systems can facilitate economical and optimal lubrication. The resulting data can give operators advanced warning of lubrication or machine failure, enabling preventive action to be taken.
SKF has found that the potential of automatic lubrication systems for filling machines can be measured in economic terms:
? Increased asset availability: With the reliability that comes with automated lubrication, the frequency and duration of downtime because of mechanical failures is sharply reduced. SKF has experience of applications in which downtime reduction has been as much as 80 percent.
? Lower consumption of spare parts: With lubrication failures eliminated, annual consumption of spare parts such as bearings, chains and gear wheels is reduced by around 50 percent on average.
? Reduced maintenance costs: Accurate and appropriate lubrication removes one of the main causes of machine failure.
? Higher speed: A bottling plant can as much as double the speed of a spiral conveyor, because automatically lubricated transmission chains can run faster without damaging the bottles.
Automated lubrication systems offer a number of additional benefits:
? Higher productivity: Apart from the increase in machine uptime, the reduction in labour necessary to carry out routine lubrication makes automation an obvious route to increased efficiency.
? Improved health and safety: Workers are no longer exposed to potential hazards during manual lubrication of machines during operation.
? Lower risk of product contamination: Automation eliminates the danger of contaminating beverages through over-lubrication.
? Rapid return on investment: All the above factors combine to deliver a swift return on investment in automated lubrication systems for beverage filling machines.
潤滑對于灌裝機的性能至關(guān)重要。
Lubrication is critical to the performance of filling machines.
遵守食品安全法規(guī)
Compliance with food safety regulations
法規(guī)對全球食品和飲料生產(chǎn)的影響日益加深，越來越嚴(yán)格的規(guī)定要求食品加工商改變其工藝流程或改造其設(shè)備。在一些國家，關(guān)鍵的機器部件必須采用不銹鋼材質(zhì)。在潮濕區(qū)域使用的部件必須防腐蝕，并能承受高壓清洗。在食品和飲料生產(chǎn)過程中使用不合適的潤滑劑也引發(fā)了越來越多的健康擔(dān)憂。潤滑劑本身必須經(jīng)過認(rèn)證，確保不會與人類食用的物品偶然接觸，并且必須符合世界主要宗教的飲食規(guī)范。升級到自動潤滑系統(tǒng)還可以帶來額外的好處，即符合現(xiàn)有或預(yù)期的法規(guī)要求。部件必須采用不銹鋼涂層或置于不銹鋼機柜中，以確保污染物的遷移量（即使發(fā)生）完全無害。
Regulation is increasingly affecting global food and beverage production, with stricter rules that require food processors to change their processes or modify their machines. In some countries, stainless steel is already obligatory for critical machine parts. Components for use in damp areas must be corrosion-free and amenable to high-pressure cleaning. Health concerns are also rising with regard to the use of inappropriate lubricants in the manufacture of food and beverage products. Lubricants themselves must be certified safe for incidental contact with items to be consumed by humans, and they must be compliant with the dietary specifications of the world’s major religions. Upgrading to automated lubrication can bring the additional benefit of compliance with existing or anticipated regulations. Components must be coated in stainless steel or housed in a stainless steel cabinet, ensuring that migration of contaminants takes place, if at all, in completely harmless amounts.
結(jié)論
Conclusion
SKF及旗下Lincoln潤滑產(chǎn)品、系統(tǒng)和服務(wù)通過全球分銷商網(wǎng)絡(luò)提供，并由遍布全球的統(tǒng)一銷售機構(gòu)提供支持，提供交鑰匙解決方案和廣泛的售后支持，包括針對飲料行業(yè)量身定制的食品級潤滑劑。致力于通過優(yōu)化潤滑管理來助客戶取得成功。
SKF and Lincoln lubrication products, systems and services are available through a global network of distributors, supported by a unified sales organization around the world to offer turnkey solutions and extensive aftermarket support, including food-grade lubricants tailored to the beverage sector. We are committed to your success through optimizing your lubrication management.
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