In 2006, with growing profits and high product demand, German bitter and liqueur producer, Mast-Jägermeister installed a new bottling line at its Linden facility capable of producing 20,000 bottles per hour.

Complete Equipment Solution
The purity of the compressed air used in the bottling process is critical to the finished product quality. After assessing several manufacturers’ systems, Mast-Jägermeister chose two CompAir D75H SR machines from licensed dealer Diehl Drucklufttechnik.

Coupled with the excellent lifetime ownership costs, thanks to the machines’ minimal maintenance requirements, other key deciding factors included completely oil-free operation and high-energy efficiency.

Air Purity Guaranteed
Compressed air is blown into the bottles to remove any dust or impurities before filling. As this is a critical control point in the process, the client placed high demands on the purity of the air, imposing strict quality standards for oil, contaminant and humidity content.

The CompAir units feature PureAir™ technology, meaning that the compressor is water injected and does not contain a single drop of lubricating oil. This assures premium air quality, eliminating any concerns over product contamination.

Werner Struck, mechanical engineer, describes the principles behind the oil-free concept. “Our developers in Simmern combined their expertise in control and drive technology with water injected screw compression…developing an extremely cost effective operation with minimal service costs.”

Energy Efficiency Optimised
It is a fact that for every bar of pressure lost down the line, the compressor will have to use 6% more energy to compensate. Diehl Drucklufttechik was able to retain maximum point-of-use system pressure by using larger 89 mm pipework that is less prone to aerodynamic drag. This results in extremely low network losses of 1.8% compared to an older compressed air network, which, depending on its condition can be between 10 and 15%.

In addition, the D75H SR units use an innovative Switched Reluctance (SR) drive system, which measures the discharge pressure and varies the speed of the compressor accordingly, meaning that only the required energy is consumed. Typically a compressor running at 4,000 hours a year is operating at 50 – 70% of its rated load, with maximum power only needed during short periods. Using SR technology, energy costs can by reduced by up to 25%.

High Performance – Low Maintenance
The design, bearing technology and materials used, make the compressors extremely resistant to wear and also significantly reduce both maintenance and operating costs. Achim Baumbach, Director of Diehl Drucklufttechnik explains further, “The principle behind the compressor is fantastically simple. Completely oil free and energy saving operation coupled with few parts and a slow speed mean that the compressors have a particularly long life cycle.”

The End Result
Mast-Jägermeister is already considering ways to increase productivity. The business could double production, without any additional construction work and the CompAir network could be adapted easily to supply a second bottling line.

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