Shrink Tunnel Standby Mode Energy Optimization
Solution Overview
Problem
Shrink tunnels in bottling and packaging plants have high energy consumption, particularly in generating the shrink medium, leading to significant operational costs, and existing methods for reducing energy consumption in stand-by mode are not optimized enough.
Innovation Solution
The method involves transferring a shrinking device from production mode to stand-by mode by reducing the interior temperature, partially or completely switching off the supply of shrinking agent from below, and adjusting the lateral supply of shrinking agent to specific areas, while also reducing conveyor speed and chain cooling capacity, and closing inlet and outlet openings to minimize energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the shrink tunnel is operated in production mode with full heating and cooling capacity, then the packaging quality and processing speed are maintained, but the energy consumption is high
Solution Approach 1:
The shrink tunnel dynamically adjusts its operating parameters (heating power, cooling capacity, conveyor speed) based on the actual production requirements. During stand-by periods, the system transitions from full production mode to reduced stand-by mode, continuously adapting energy consumption to match the current operational state rather than maintaining constant high-power operation
Solution Approach 2:
The system changes key operational parameters when transitioning between production mode and stand-by mode. The desired temperature is reduced to a stand-by temperature, heating power is decreased, cooling is reduced or switched off, and conveyor speed is lowered. These parameter changes enable the system to maintain packaging capability when needed while minimizing energy consumption during low-demand periods
2Use of energy by stationary object
If the shrink tunnel is switched to stand-by mode to reduce energy consumption, then the operational costs are reduced, but the readiness for production is compromised
Solution Approach 1:
The system performs preliminary actions during stand-by mode to ensure rapid transition back to production. The conveyor remains operational at reduced speed, maintaining basic motion and positioning readiness. The system is pre-configured with stored production parameters that can be quickly restored, and critical subsystems remain in a state that allows immediate resumption of full production capabilities when demand arises
3Use of energy by moving object
If the cooling capacity is reduced in stand-by mode, then the energy consumption is reduced, but the packaging strength and stability are compromised
Solution Approach 1:
The cooling system operates periodically rather than continuously during stand-by mode. Cooling is activated only when packaging units are present and require stabilization, and deactivated during extended stand-by periods. This periodic operation maintains packaging strength when needed while minimizing energy consumption during idle periods when no packaging is being processed
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach further optimizes energy consumption by reducing the overall energy requirement of the shrinking device, leading to lower operational costs and more efficient energy management in different operating modes.
Implementation Method 1
The articles wrapped with shrink film are subjected to a shrinking medium or shrinking agent, in particular hot air. The shrink film shrinks and attaches itself to the article or assembly of articles.
Implementation Method 2
A cooling area with fans immediately adjacent to the shrink tunnel ensures rapid cooling of the packaging units or bundles produced in this way
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The invention relates to a method for converting a shrink-wrapping device (1) from a production mode (PM) to a standby mode (SM) and to a shrink-wrapping device (1). The shrink-wrapping device (1) comprises a conveyor section (3) for articles (20) at least partially encased with a shrink material (23) and shrink material injection devices (6) for supplying shrink material into the interior of the shrink-wrapping device (1). In production mode (PM), shrink material is supplied via laterally arranged first shrink material injection devices (7) and from below via at least one second shrink material injection device (8) arranged below the conveyor section (3).In standby mode (SM), the internal temperature (T2) of the shrink device (1) is reduced compared to an internal temperature (T1) in production mode (PM) by reducing or switching off the supply of shrinking agent from below and/or in a lower area associated with the conveyor line (3), at least in some areas.