Pfannenberg EB Chillers: Tailor-made Solution for a Rail Component Manufacturer


Customer Requirement

A rail component manufacturer needed a solution to eliminate downtime caused from the overheating of their track drilling unit.  The current system used 2 undersized chillers, unable to keep up with the cooling requirements, especially when the ambient temperatures in the plant rose due to the hot afternoon sun.

The Pfannenberg Solution

An analysis carried out on location with the customer revealed that the cooling capacity of the two chillers no longer corresponded with the current requirements.  The cooling system needed to be redesigned.

Taking the temporarily intermittent high ambient temperature in the factory into account, the choice fell on our high performance EB 90 chiller.  This unit has an integrated control module which allows for precise temperature control of the cooling medium.EB_Chiller_drawing.jpg

The solution excels due to:

  • Separate cooling and hydraulic circuits
  • Control module to program small hysteresis of the oil temperature
  • Use at ambient temperatures of up to +40°C
  • Sturdy steel housing with thick powder coating

Customer Benefits

As a result of our plant audit, the customer was able to invest in a new solution that was tailor-made to meet their current needs instead of spending money on a temporary, expensive and insufficient repair of their old chiller system.  The new solution ensures the desired machine uptime even during those days affected by the hot sun.  A new maintenance contract was signed to support the optimum functionality of the equipment for the long term.


Have a question regarding which equipment is best for your application? Contact our engineering team for more information!


Pfannenberg, Inc. is a global manufacturer of Thermal Management, Liquid Cooling Solutions and Signaling Technologies.

Pfannenberg is proud to provide solutions as a single source to its customers. Our business philosophy – Protection for man, machine and the environment.

Case Study: Pfannenberg Thermal Management Solutions for Harsh Marine Environment


Customer Requirement

An OEM machine builder in the Marine industry needed a thermal management solution that was NEMA Type 4/4X rated, but also resistant to highly corrosive salt spray (fog).  In an industry that encounters very harsh environments, it is crucial to be able to have a product that will be able to withstand such conditions.

The Pfannenberg Solution

To meet the customer’s specific requirements, we provided our PWS Air to Water Heat Exchangerswith the 316 Stainless Steel option.

We offered a unit:

  • Which is very resistant to corrosion and oxidation (316 Stainless Steel) compared to the 304 Stainless Steel
  • That can be configured with a different heat exchanger when salt water is used for the cooling supply water
  • With an “easy to mount” seal, no elaborate reworking of the mounting cut-out
  • With an integrated thermostat and solenoid valve for temperature control

Customer Benefits

The customer was satisfied with these highly resistant units that are perfectly adapted to marine environment. Thanks to Pfannenberg’s Air to Water Heat Exchangers the customer was able to reduce downtime and maintenance costs.


Have a question regarding which equipment is best for your application? Contact our engineering team for more information!


Pfannenberg, Inc. is a global manufacturer of Thermal Management, Liquid Cooling Solutions and Signaling Technologies.

Pfannenberg is proud to provide solutions as a single source to its customers. Our business philosophy – Protection for man, machine and the environment.

Topics: Air Water Heat ExchangersThermal Management

Drinktec 2017: Pfannenberg to exhibit for the first time

Pfannenberg, the specialist for industrial thermal management solutions and signaling technology will be exhibiting for the first time at Drinktec, the world’s leading trade fair for the beverage and liquid food industry to be held in Munich from 11 to 15 September 2017.


Pfannenberg will be at stand 138 in Hall B3 showing tough, efficient thermal management solutions and signaling technology for the beverage and liquid food industry.

Visitors will be able to see the latest signaling technology and thermal management solutions for the food and beverage industry at stand 138 in Hall B3. Exhibits will include cooling units with corrosion resistant stainless-steel covers and robust signaling devices with high IP classifications. These products are designed for the toughest environments and are therefore suitable for use where liquids are processed and in production systems which require frequent cleaning.

A demo stainless-steel cabinet demonstrating these features will show a NEMA cooling unit, an air/water heat exchanger including a water jet test, a DTT top-mount cooling unit, a stainless steel rainhood and filterfans in stainless steel design.

“Food production places great demands on manufacturing technology. Our efficient, reliable and tough cooling and signaling technology guarantees maximum machine availability in the fast-cycling and highly dynamic processes in the food and beverage industry, starting with raw material processing through manufacture and quality control to packaging,” explains Annarita Amadei, Industry Group Manager Food and Beverage at Pfannenberg.

IoT-enabled packaged solution
The communication-enabled cooling units in the εCool X series that will be exhibited are ideal for companies wanting to make their production fit for Industry 4.0 and at the same time improve machine availability. These thermal management solutions for electrical enclosures can be integrated directly in the user’s automation systems. If required, they can also provide relevant device parameters via the Cloud for remote maintenance. Users benefit from customized maintenance, cost-efficient service and better machine availability thanks to preventative maintenance.

Reliable cooling
Modern production systems such as filling lines are usually permanently in operation. The cooling units and filterfans from Pfannenberg are fitted with IP 56 housing and corrosion-proof stainless-steel covers which makes them the optimum solution for the economical cooling of electrical enclosure technology.

Exhibits at Drinktec will include the new compact 6301C cooling units from the εCool 6000 series. Their power, and their compact design in particular, make them suitable for use in a wide range of applications.

Despite their space-saving design they offer the same energy efficiency, service friendliness and cut-out compatibility as the standard models: they cut energy consumption compared to traditional cooling devices by up to 43%, with a further 10% reduction in standby operation.

Tailor-made process cooling
In particularly sensitive areas of food and drink manufacture, the maintenance-free air to water heat exchangers and the EB series industrial chillers allow economic system solutions which work independently of the ambient air. Typical areas of application are filling lines and packaging systems. Pfannenberg chillers – with cooling capacities from 3.2 to 148.8 kW – cool sophisticated electronic systems. Both standard ready to-use units and fully customized ones can be provided.

This will be demonstrated at Drinktec with the EB 95 WT. Starting from the compactly designed, highly efficient and easy to service standard unit, this chiller can be equipped with several additional features to match specific applications.

For example, all devices can be equipped with a hydraulic bypass, a SMP55 controller with error messages panel and a ASI communication module enables the unit to be integrated the in the customer’s system. The EB devices are UL certified and can be used at ambient temperatures from -20 °C to +45 °C. All chillers in the range allow users to benefit from lower energy and operating costs, space-saving installation, high reliability and long machine life.

Robust signaling technology
Signaling-2.jpgWith high levels of ambient noise, the manufacture of beverages and liquid food makes serious demands on signaling technology. The status of packaging, laser inscription or filling machines and lines must be permanently displayed so that response times can be optimized and costly downtime minimized. Warning lights and acoustic alarms must signal hazards, risks or technical faults immediately, even in the vicinity of noisy conveyors operating at full capacity. Against this background, combinations of visual and audible signaling devices are the best choice.

Signaling technology suitable for operation in production environments such as these will be exhibited:

  • The BR 50 stacklights: This device is of a modular construction and uses sound and flashing, blinking or solid lights to signal statuses and dangerous situations reliably
  • The QUADRO and LED-HI multi function lights
  • the PYRA sounder/flashing light combinations
  • the PATROL and DS sounders

All of which are suitable for use in the demanding conditions of the drink and liquid food industry, will also be exhibited.

Topics: Thermal Management, Industrial Safety & Signaling Solutions, Trade Show

Reliable Enclosure Cooling for Commercial Bakeries

Customer Requirement

Pfannenberg worked with a bakery end user to develop a cooling solution for their control cabinets.  Most of the OEM equipment installed in the bakery called for air conditioners to cool the drives. PLCs and additional electronics. Most times Cooling units can be a convenient and effective method for cooling electronics, except when located in dusty, humid areas within the plant.

These AC units failed regularly and had to be replaced. This was not a sustainable solution as the customer had constant issues with clogging coils and overheating panels.

Once a panel overheated they had to either: not operate the machine, or operate the cabinets with the doors open. This would let all the contaminants that were hurting the AC units into the cabinet, damaging the drives and other components.

The Pfannenberg Solution

To use the chilled Glycol that was already present for other machine processes to provide the cooled liquid source for our PWS Air to Water Heat Exchangers.

The solution included:

  • A reliable cooling solution designed for harsh environments
  • Reduced maintenance.  Once installed the units only have just one moving part, so regular maintenance is not necessary
  • Eliminating equipment failures, means greater uptime
  • Reduced energy costs with the PWS units
  • UL Tested NEMA Type 4/4X – washdown

Customer Benefits

Pfanneneberg’s PWS Series Air/Water Heat Exchanger was the precise solution for the problems our customer experienced. Incorporating Air/Water Heat Exchangers improved performance, reduced maintenance, was energy efficient, and prevented unplanned repairs.

 

Case study: Pfannenberg Cooling Units to meet Wood Manufacturing needs

An end user turned to Pfannenberg for assistance with managing their enclosure temperatures in a particularly harsh environment. The company produces high-quality construction and installation materials from wood fiber.

Customer Requirement

The customer current system was facing system failures and downtime due to severe soiling from wood dust and rust particles from diesel-powered fork lift trucks and heavy equipment. The current thermal management solution used conventional point-of-entry filters and top-mounted filterfans. The current cabinet system had to be completely changed as it needed to be reliable despite severe air contamination from wood dust and exhaust gas, plus provide energy savings and service friendliness.

The Pfannenberg Solution

As a first step, all the switch cabinets were wet cleaned, both inside and outside.  To rule out any repeat soiling, the top-mounted fan combination was replaced by partially recessed cooling units: DTI 6301 Model.

Special features of the cooling units are:

  • Uniquely high energy-efficiency rating (EER)
  • Significant energy savings/operating costs reduction
  • Condenser with wide fin spacing for highly effective protection against contaminated ambient air
  • Large distance between intake and exhaust vents (to eliminate hot spots)
  • Perfect ease of servicing
  • New service interface for easy retrieval of parameter settings/history (Pfannenberg Plant software necessary)
  • Optional filter can be retrofitted in a few seconds
  • Energy-savings mode in the Multi Controller integrated as standard

Customer Benefits

Use of the new DTI 6301 cooling units led to reliable system operation and to the highest possible amount of machine up time. The environmental and cost balance sheets demonstrated considerable reductions with regards to energy costs and CO2 emissions, as well as reduced service requirements and repair times.


Have a question regarding which equipment is best for your application? Contact our engineering team for more information!


Pfannenberg, Inc. is a global manufacturer of Thermal Management, Liquid Cooling Solutions and Signaling Technologies.

Pfannenberg is proud to provide solutions as a single source to its customers. Our business philosophy – Protection for man, machine and the environment.

Topics: Enclosure CoolingCooling UnitsThermal Management

Pfannenberg Top-Mounted Cooling Units meet the need of OEM Milling Component Manufacturer

Customer Requirement

An OEM Milling component manufacturer which develops processing centers for the precision boring and milling high-precision components needed critical thermal management for their machine’s control electronics. The systems are designed using relatively tall electrical enclosures to minimize that installation space. This compact design fosters the development of heat pockets.

 

The customer needed a space-saving thermal management solution to keep the manufacturing footprint compact. To minimize the formation of heat pockets, the solution needed to promote very efficient air circulation. Another requirement was absolute protection against condensate and assurance of top-level machine availability – even under difficult environmental conditions.  Thermal management with compact cooling units proved to be unreliable so far because of the problems with condensate.

The Pfannenberg Solution

Our revolutionary DTT series top-mounted cooling units met the requirement for maximum reliability, space savings design and 100% protection against condensate.

The DTT top-mounted cooling units provide unique, four-fold condensate protection:

  • Zero sweat guarantee
  • No overflow of condensate into the electrical enclosure
  • Managed water droplet control
  • No air hoses, which are otherwise at risk of condensation

Further benefits:

  • High-volume air delivery via the integrated nozzles to accelerate cold air movement right down to the bottom of the cabinet
  • Filter media for any area (contaminated ambient air)
  • Controller with energy-saving mode to maximize energy-efficiency (optional feature)

Customer Benefits

Switching to the DTT series top-mounted cooling units successfully allowed the OEM to provide a competitive design to their customers. The units are compatible with all makes of electrical enclosures and are available in 3 sizes and 6 performance levels. Because of its cUR approval and versions with 230V and 400V voltages, the milling processing centers can be used worldwide.


Have a question regarding which equipment is best for your application? Contact our engineering team for more information!


Pfannenberg, Inc. is a global manufacturer of Thermal Management, Liquid Cooling Solutions and Signaling Technologies.

Pfannenberg is proud to provide solutions as a single source to its customers. Our business philosophy – Protection for man, machine and the environment.

Topics: Cooling UnitsThermal Management

How to Choose the Best Heater for your Electrical Enclosure?

Condensation is one of the biggest dangers for electrical enclosures. As long as the components operate under load, their own warmth prevents water from condensing. If the process is switched off, the electronics cool down. This is where Pfannenberg control cabinet radiant heaters and fan heaters provide additional protection for your electronics.

 

How to Choose the Best Heater for your Electrical Enclosure?


Radiant Heaters
Pfannenberg PRH-M Mini Radiant Heaters (10 to 30 Watts) are ideal for smaller enclosures or for the heating of isolated spots in sensitive areas. These heaters use natural convection to heat the cabinet and prevent condensate formation. FLH series of Radiant Heaters (up to 150 Watts) are used in combination with a thermostat or hygrostat, mainly to avoid excessively low temperatures or high humidity into the enclosure.


Fan Heaters
Ideal for use in larger electrical enclosures with higher heat requirements, Pfannenberg FLH series of Fan Heaters (250 to 400 Watts) have an integrated fan that assists the natural convection and provides fast distribution of the heat in the electrical enclosure. The fan heaters are used in combination with a thermostat or hygrostat, and are designed to protect electronics from moisture or corrosion caused by high humidity, low temperatures or condensation caused by rapid temperature change.

Need more than “just” a Heater?


Pfannenberg also offers a range of fan heaters with an  integrated thermostat: PFH-T (200 – 1200 Watts) dedicated to larger enclosures and with flexible mounting options. These fan heaters with adjustable thermostat are especially designed to protect electronics from the effects of low temperatures such as corrosion, freezing or condensation, which can damage critical components within a control enclosure.

To provide the best Thermal Management for your electronics, using a thermostat or hygrostat results in greater reliability of your production process:

  • Pinpoint distribution and constant temperature in the control cabinet
  • Reduced energy consumption and optimization of the efficiency of the heaters.
  • Additional savings on energy, materials and time.

Pfannenberg’s heaters, thermostats and hygrostats  detect and keep ambient conditions above dew point to avoid the harmful effects of condensation on your electronics. They can be used as a standalone product or in partnership with our Filterfan® and Cooling Unit product lines for a complete Thermal Management of your electrical enclosures.

Topics: Thermal ManagementHeaters

How Pfannenberg Thermal Management & Signaling Solutions Save the Holidays


Pfannenberg products ensure that manufacturing operations are up and running – especially during the holidays when many manufacturing lines are always online. Read below on just a few example applications on how Pfannenberg supports these product lines and keeps them running.

Candy Canes:

The go-to holiday candy.  As a child, they are passed out and enjoyed by many, and as adults they are necessary for almost any holiday decoration.  This peppermint candy involves very delicate care when being processed.  There are many differences in temperature to heat up or cool down – just enough that it maintains flavor and will not ruin the product quality.  All throughout the manufacturing process of candy canes, temperatures are critical.  At certain stages, the temperature needs to be increased to help form the canes, then at other parts it needs to be cooled so that it can be mixed to perfect flavor and coloring.

The sugar kneading machine is very large and very powerful.  Right after the sugary mixture is heated up and completed its first round of mixing, it is dumped onto a liquid cooling table, where the candy has its flavoring added and mixed. The amber liquid when being first mixed is heated up to around 300°F.  Once being transferred to the kneading machine, this large machine will mix in the flavoring by pushing and folding the candy – slowly cooling the product from its hot temperature. Pfannenberg’s CC Chillers can play a key role in supplying the cool liquid to the table which kneads the candy.  If the table is left uncooled or heated, it will change the look, consistency, and taste of the final product.  Not only is it crucial to have Pfannenberg Compact Chillers to cool the table, it is also import to utilize Pfannenberg’s PWS Air to Water Heat Exchangers to cool the electrical panels controlling the entire process.


Wrapping Paper:

The wrapping of gifts dates back to the ancient Chinese, but here in the US  it hit its popularity in 1917 when Joyce Clyde Hall and Rollie Hall (founders of Hallmark) decided to modernize it. Wrapping paper is a staple item.  When it comes to holidays and special occasions, there are many steps that go into the manufacturing of wrapping paper.

Artists have to create such artwork which is then etched onto copper cylinders that are bathed in a liquid bath of chromium, which galvanizes the copper to protect it from wear and tear.  From here these rolls each have a various piece of the final wrapping paper artwork.  Each color has its own roller. The paper will go through a series of various printers where it encounters the artwork on the copper rolls for the different colors.  These metal rolls need to be highly controlled with temperature.  Too hot or cold could cause the paper to stick to these rolls and cause a paper jam which leads to loss revenue and downtime. As part of a complete solution  Pfannenberg’s CC Series Chillers help to control the temperature to the print rollers and Pfannenberg’s Air to Water Heat Exchangers provide proper cooling for the control equipment operating these large machines. To complelent our full product line,  Pfannenberg’s Signaling products are needed at every stage of the manufacturing process to alert employees of a problem. Pfannenberg’s Signaling Solutions help the employees to be able to hear and see exactly where the problem is occurring (which machine) and what problem is occurring (what action is need).

Wrapping paper leads to the excitement and mystery of the gift. Without the proper cooling and operation of the equipment that are used to produce the paper, it would be difficult to wrap the gifts.  Pfannenberg aids in the manufacturing process of wrapping paper.


Champagne:

The holiday season concludes with celebrating New Years.  New Years is a time to reflect on the past and perhaps try new things in the upcoming year. Celebrations are had with friends old and new, and champagne is typically the drink of choice. One crucial aspect in champagne manufacturing is the inspection and bottling stages of the process. The champagne bottle undergoes many cleanings and inspections prior, during, and after bottling.  Each stage will monitor and check various aspects.  The final inspection step will make sure that the champagne bottle is not cracked or damaged and to check the champagne to make sure that there are not fragments of cork or metal casing. A bright light will shine through the bottles where a machine will scan and take pictures for an employee to monitor/double check that the inspections are all being passed.

Pfannenberg has proven experience in working directly with food and beverage inspection OEMs to provide complete engineering solutions for the cooling of x-ray tubes and the internal cavity of their inspection machines. The Pfannenberg team has come up with a complete solution to utilize a CC Chiller in conjunction with a small PWS Air to Water Heat Exchanger to cool the x-ray tubes and internal cavity.  By combining products and eliminating a compressor based air conditioning unit, the Pfannenberg liquid cooling solution requires less maintenance and is far more cost effective by eliminating dependencies on different competing products and eliminating downtime.

Vacuum Turkey Packaging – Thanksgiving Edition

Tis’ the season – for we have many things to be thankful for this year!  With the holiday season quickly approaching, we are taking the time to reflect on all of our blessings.  Common dishes for most Traditional American Thanksgivings include turkey, cranberry sauce, stuffing, green bean casseroles, fresh baked rolls, and pumpkin pie. Most of us look forward to this holiday all year, for it is a time to be thankful and gather with loved ones.

Turkey processors themselves have to really work all year to meet this spike in demand around the holidays.  Innovation in new packaging technology allows these processors to be able to serve a fresh Turkey that has a longer shelf life without chemicals.  Pfannenberg’s thermal management and chiller products are a perfect fit for aiding in the packaging side of Turkey processing.

Vacuum packaging is the most popular form of packing and food preservation for full turkeys. The process reduces the amount of oxygen from the package by utilizing a vacuum and completely sealing it, removing the extra oxygen to prevent contamination. The removal of oxygen allows the product to have a longer shelf-life. The packaging material protects the meat from the passage of various gases and outside moisture.

When it comes to the vacuum packing machines they operate at very high speeds, processing many turkeys in a short amount of time.  It’s critical that the control enclosure electronics  do not overheat. Proper cabinet temperature control is essential to keeping production on schedule. To keep these electrical enclosures cool, the processing facility has several options. If using traditional enclosure air conditioners (cooling units) then our washdown NEMA Type 4/4x DTS 3000 Series Cooling Units would be a good solution. For a more economical and maintenance free solution our stainless steel PWS Air to Water Heat Exchangers could be used with existing water lines or a Pfannenberg Packaged Chiller. These both would be perfect options to protect the electronics and  drives that are so important to keep everything online and running.

Besides the electronics in the electrical panel, the motors (servo motors) need a chiller to maintain the cool liquids running through the machines.  Pfannenberg’s CC Series Chillers are ideal for quick setup and trouble free operation.  Packaged and ready-to-use, Pfannenberg’s chillers require piping and power to install a solution for process cooling applications.

Pfannenberg’s enclosure cooling solutions and chillers aid in meeting the high demands of poultry processing equipment during the peak season helping to ensure there is not a turkey shortage on the biggest turkey day of the year!


Happy Thanksgiving to you and your family!

Pfannenberg – Global Solutions and Support for OEMS


When it comes down to the final decision on whether or not to purchase new equipment for a plant, the decision tends to fall down to three major concerns:

  1. What preventative yearly/monthly/weekly/daily maintenance is required?
  2. Is it able to withstand the environment?
  3. How much time and money will it save?

For OEMS to be competitve and meet the needs of their end use customers, there are 3 main areas that are looked at when choosing the supporting components for their equipment.

Components that are Built to Last

For more than 60 years, we have been helping guarantee production safety for OEMs and end users throughout the world.  Sensitive control technology needs to be protected from many environmental conditions. With NEMA Type 4/4X, IP 56 protection, our cooling units satisfy the toughest environments.

Support and Accessibility

Pfannenberg innovation has made it one of the largest globally operating manufacturers of thermal management and process cooling equipment today.  Our wide product range includes complete system solutions for machine and enclosure cooling along with visual and audible signaling devicesfor events that require alarm, warning or indication notifications.

Support… when and where it’s needed – In addition to manufacturing facilities location on three continents, Pfannenberg has developed a worldwide network of local subsidiaries and sales/service partners eager to meet your service needs and help you select the correct solution.

If maintenance of your enclosure cooling system is required you can expect immediate assistance from Pfannenberg. Our repair service affords you the fastest possible response – nationally or internationally. We ensure that your cooling system is returned to optimal condition – even if it’s not a Pfannenberg product.  Our on-site service gets you back on-line faster, eliminating the transit time associated with factory repair programs.

Experts in Industry Group Solutions

As a leading thermal management solutions
company, we can develop products quicker than the competition while optimizing the solution for that specific industry group’s requirements. The high performance of our products comes from years of research and design experience. Trust us to be the experts in your industry to provide you  with the proper cooling solution.


Have a question regarding which equipment is best for your application? Ask Us Here.