Kaeser Kompressoren SE

Postfach 2143, 96410 Coburg
Carl-Kaeser-Str. 26, 96450 Coburg
Germany

Telephone +49 9561 640-0
Fax +49 9561 640-130
produktinfo@kaeser.com

Trade fair hall

  • Hall 18 / G14
 Interactive hall map

Hall map

components 2017 hall map (Hall 18): stand G14

Fairground map

components 2017 fairground map: Hall 18

Our range of products

Product categories

  • 02  Control technology

Control technology

  • 09  Complete automation systems for
  • 09.01  Food processing industry

Food processing industry

  • 09  Complete automation systems for
  • 09.02  Packaging industry

Packaging industry

  • 09  Complete automation systems for
  • 09.03  Pharmaceutical and cosmetics industry

Pharmaceutical and cosmetics industry

Our products

Product category: Others

Energy savings with IE4 motors

Even better!

Outstanding performance and reliability with exceptional efficiency and minimal space requirement: these are just some of the advantages that Kaeser Kompressoren’s new CSD and CSDX fluid-cooled rotary screw compressors have to offer. Now equipped with IE4 motors, these future-fit machines are more efficient than ever before.

Kaeser’s design for this latest generation of compressors far exceeds current norms, including the use of high efficiency IE4 motors as standard. This not only ensures that compressed air stations will meet future legal efficiency requirements, but also brings an additional energy cost saving of approximately one percent. CSD and CSDX systems therefore provide four-way energy savings: First, the airends feature newly-refined Sigma Profile rotors. Together with additional optimisation measures, such as reduced internal pressure losses, the new machines therefore boast between three and six percent better specific power performance compared with previous models. Second, the use of “Super Premium Efficiency” IE4 motors ensures maximum drive motor efficiency. Third, Kaeser’s 1:1 direct drive system eliminates the transmission losses associated with gear or belt drive solutions. Fourth, with five pre-programmed control modes, the Sigma Control 2 industrial PC-based internal controller dynamically adjusts flow rate to match actual compressed air demand thereby assuring further energy savings.

With available motor powers from 45 to 90 kW, the five models of the two series cover flow rates from 8.3 to 16.1 m³/min (at 8.5 bar) and are designed for pressures up to 15 bar.

The Sigma Control 2 also offers further advantages including variable interfaces and - for the first time - plug-in communications modules. These features provide greater flexibility when connecting to computer networks and master compressed air management systems, such as the Sigma Air Manager 4.0, as well as to remote diagnostics and monitoring systems such as Sigma Smart Air. A large, easy-to-read display enables user-friendly on-site communication with the machine, whilst the SD card slot makes machine memory access and software updates via SD memory cards quick and simple. Moreover, an RFID reader enables standardisation of servicing, boosts service quality and assures optimum security. The Sigma Control 2 also provides comprehensive monitoring of the compressor, as well as of any connected refrigeration dryers or frequency converters, for example.

The high-performance cooling system in these new machines allows exceptionally low compressed air discharge temperatures. Over 95 percent of the condensate is removed from the compressed air stream after passing through the condensate separator, which features an automatically monitored condensate drain. The coolers are placed at the rear of the unit, together with a generously-sized cooling air intake opening. As a result, this clever system and its thermal load relief effect significantly increase the efficiency and dependability of downstream compressed air treatment components.

Moreover, the environmentally-friendly system concept extends to the fluid filter element, which is free from metal and is suitable for thermal disposal without the need for any additional treatment.

In addition to the standard models, versions with an integrated refrigeration dryer module are also available that provide compressed air generation and drying within a single compact unit. With considerably reduced energy requirement and using nearly 50 percent less refrigerant than previous models, the refrigeration dryer is dimensioned for high ambient temperatures and operates with minimal pressure loss. The dryer is housed in a separate enclosure and is therefore not affected by heat from the compressor.

The CSD and CSDX are also available with variable-speed control and, as with the standard machines, these models too are optimised for maximum efficiency, dependability and ease of maintenance.

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Product category: Others

New dry-runners from Kaeser

The expanded dry-runner range

Kaeser is proud to introduce its latest range of dry-running rotary screw compressors, the "CSG-2" series. Available with drive powers ranging from 37 to 90 kW, these two-stage machines provide free air deliveries from 5.4 to 13.1 m³/min for pressures between 4 and 10 bar (g). Together with the existing DSG-2 and FSG-2 series, Kaeser‘s dry-runner range now covers free air deliveries ranges from 5.4 to 50.0 m³/min, and 3.2 to 50.8 m³/min for variable speed machines.

Ensuring ultra-efficient compressed air production at all times, ”CSG-2” systems are the ideal choice for applications where dry-compression is required. Users can choose between air- and water-cooled versions and also have the option of “SFC” variable speed control for applications with fluctuating air demand. 

At the heart of these versatile units lies a quality, two-stage compressor airend. The rotors are equipped with “Ultra Coat”, which is resistant to temperatures up to 300 °C. Because this cost-reducing coating is also highly abrasion-proof, its sealing and protection performance remains virtually unchanged even after years of operation. As a result, compressed air delivery also remains consistent. In other words, dry-running rotary screw compressors from Kaeser consume no more energy after years of use than when first commissioned in order to deliver their rated free air delivery. “Ultra Coat” therefore helps to keep total system costs to a minimum. Air-cooled systems designed for use in ambient temperatures up to 45 °C also provide further significant potential for additional long-term savings.

Dependability and efficiency in ”CSG-2” systems are enhanced by the new PC-based "Sigma Control 2" internal controller: A powerful combination of multiple control modes, a timer and base load sequencing provides additional energy savings. Moreover, a precision electronic pressure sensor keeps switching differential to a minimum thereby saving even more energy. The "Sigma Control 2" also offers added advantages: This advanced system provides greater flexibility through its numerous interfaces and innovative plug-in communication modules. Therefore, connection to energy-saving master control systems, computer networks and/or remote diagnostics and monitoring systems, such as Kaeser's Teleservice facility, couldn’t be easier. The large display located on the control panel also simplifies on-site communication with the system, whilst an SD card slot speeds up data-reading and update processes. Furthermore, the addition of an RFID reader ensures service continuity, increases security and significantly raises service quality. The “Sigma Control 2” is also responsible for compressor monitoring.

As you might expect from a leading compressed air systems provider such as Kaeser, all "CSG-2" compressors are powered by IE3 premium efficiency motors. Standard equipment also includes 'PT 100' sensors for measurement and monitoring of the motor winding temperature. This enables full use of the maximum motor switching frequency and minimises costly idling periods.

These advantages, coupled with numerous other technical refinements, ensure that every unit lives up to the Kaeser quality promise. For example, the use of stainless steel rotors in the second compression stage helps guarantee compressed air quality and significantly enhances service life. In addition, as air intake is regulated via a hydraulically operated inlet valve, there's no need for regular replacement of pneumatic diaphragms. This consequently reduces both service costs and downtime. Furthermore, the use of fibre-free pulse dampers keeps pressure loss to an absolute minimum, maintains consistent air quality and prevents contamination of the compressed air.

Last, but not least, the "CSG-2" series continues the Kaeser tradition of super-quiet performance. Using the very latest in computer-aided measurement technology, Kaeser's development engineers were able to precisely analyse all sound sources and ensure that these versatile systems operate with minimal sound levels.

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Product category: Others

DSD rotary screw compressors

The next generation

In any competitive environment, success comes to those with strengths, the skill to apply them and who have a strong commitment to innovation – the same also applies to the energy efficiency of rotary screw compressors. To become a true efficiency leader therefore, it is crucial to meet both current and future requirements. The new DSD series from Kaeser meets all of these needs and more.

The next generation of DSD-series rotary screw compressors is now available for flow rates from 14 to 25 m³/min. Featuring all-new airends with high efficiency Sigma Profile rotors and IE4 motors, they deliver improved specific power of up to nine percent as well as up to six percent greater flow rates than previous models. These improvements, together with a host of other enhancements, result in significantly reduced energy costs, true to Kaeser’s motto of “More compressed air for less energy”.

Maximum efficiency

The new IE4 Super Premium Efficiency motors, the most efficient currently available, also help to achieve this improvement and therefore enable peripheral losses in compressed air production to be reduced even further. Moreover, the Electronic Thermo Management (ETM) system regulates oil temperature to ensure a safe and consistent differential from the dew point temperature. This strategy also prevents unnecessarily high airend discharge temperatures and provides additional energy savings.

Heat recovery offers yet another key way to boost energy savings: a compressor transforms 100% of its input electrical drive power into heat, of which 96% can be recovered and reused for heating purposes. Kaeser engineers have now expanded the company’s range of heat recovery options with a small yet highly beneficial detail. In systems taking advantage of the heat recovery option, a second electronic Thermo Management system ensures optimised and even more efficient use of the available heat energy. If this heat energy is diverted to heat recovery systems in its entirety, the intelligent Sigma Control 2 controller recognises that it is no longer necessary for the compressor’s cooling system to provide cooling and consequently switches off the fluid cooler fan – effectively saving even more energy.

Energy-saving and environmentally friendly fluid filters

The unit interior also reflects Kaeser’s commitment to resource conservation: the environmentally friendly fluid filter cartridges no longer have a permanently attached sheet metal housing, but rather are simply inserted into an aluminium housing. The filter cartridges themselves feature a metal-free design and are suitable for thermal disposal at the end of their service life without additional pre-treatment.

Controller ensures optimum performance

The Sigma Control 2 controller is responsible for monitoring the compressor and, if equipped, the frequency converter (SFC option). This innovative controller also enables the compressor to connect to a network and facilitates straightforward connection to master control systems, such as the Sigma Air Manager 4.0 or other control centres – thereby making DSD units completely ready equipped for integration into Industry 4.0 environments.

Full range of models

The DSD series includes both air- and water-cooled models. Since variable-speed drive can be advantageous for certain applications, some versions are also available with variable-speed control implemented via a frequency converter (SFC option). As with the standard models, these versions are also designed with maximum efficiency, reliability and ease of maintenance in mind. Naturally as per the EMC Directive, the entire compressor system is tested and certified to EN 55011 Class A1 industrial network standards.

The new DSD series additionally features a range of important design improvements related to the optional integrated refrigeration dryer and system-integrated cooling air circuit (exhaust air). First, the depth of the integrated dryer has been reduced, enabling a corresponding 17% reduction of the T-version footprint compared to the previous version. As a result, the system’s refrigerant requirement has fallen around 30 percent and the power consumption of the integrated refrigeration dryer itself has been reduced by an impressive 25 percent compared to the previous version. Aside from the advantages of lower space and refrigerant requirement, these improvements also translate into significant cost savings.

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Product category: Others

New refrigeration dryer with innovative thermal storage technology

Huge storage density boost

For a refrigeration dryer of its performance rating, the new Secotec TF from Kaeser Kompressoren is incredibly compact and of course delivers an efficient and dependable supply of quality compressed air. Thanks to its innovative thermal storage system and low energy consumption, the Secotec TF pushes the boundaries of compressed air refrigeration dryer performance further than ever before.

Efficient and reliable compressed air treatment is essential when it comes to economical compressed air production. The second generation of Kaeser’s highly successful energy-saving Secotec refrigeration dryers is truly impressive: Not only do they take up only about half the space of comparable first generation dryers despite having a higher specific rating and lower pressure drop, they are also significantly lighter and uses significantly less energy.

The extremely efficient Secotec series thermal storage dryers are now available for air flows up to 34 m³/min and consequently now cover a delivery range from 17 to 34 m³/min. It's all made possible by an innovative thermal storage system, which contains a phase-change material (PCM) that is 98 percent denser than conventional storage media. Thermal energy is stored as the PCM cycles from a solid to a liquid state. The innovative Secotec TF series is therefore considerably more compact compared to conventional models with the same thermal storage capacity. Their footprint is up to 46 percent smaller and they are approximately 60 percent lighter than other thermal storage dryers. It has therefore never been easier to find space for, and install, Secotec TF dryers, particularly as two sides of these units can be installed next to a wall.

The refrigeration dryer includes a Sigma Control Smart microprocessor-based controller, which controls the thermal storage process. It has an alarm and service message memory, as well as remote on/off control capability.

The dryers’ compact design also made it possible to reduce the pressure loss across the dryer to 0.15 bar. Compare this to conventional dryers, where the pressure drop is 0.20 bar and higher.    The low energy requirement of Secotec TF dryers is also remarkable. The meticulously designed new system uses less than 87 Watts per cubic metre of air to be dried per minute, which is a new benchmark in the field of refrigeration dryers; conventional models use on average 200 to 250 Watts. Furthermore, the new design ensures minimal maintenance requirement and service work is made quick and easy. Many practical options are available for the new Secotec TF, including side-mounted compressed air connections.

The new and efficient TF models are available now as air-cooled versions.

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Product category: Control technology, Others

Sigma Air Manager 4.0

Tomorrow’s technology, today

Industry 4.0, or the ‘Internet of Things,’ promises to be a far-reaching revolution in production. The new Sigma Air Manager 4.0 (SAM 4.0) makes it all possible: the ability to make predictions far in advance, know today what the future holds, network components and exploit much larger data volumes than ever before – whilst also ensuring significant energy cost savings and delivering a reliable, consistent and efficient compressed air supply.

The latest generation of the Sigma Air Manager (SAM 4.0) - the master control system for all of your compressed air production and treatment components – is now available. Amongst many other key benefits, the new system optimises pressure values, automatically adjusts compressor system air delivery to accommodate fluctuating air demand and optimises system efficiency through constant analysis of the relationship between control losses, switching losses and pressure flexibility. Moreover, the SAM 4.0 enables your compressed air station to take advantage of future services such as predictive maintenance. All of these features not only boost operational reliability and efficiency, but also significantly reduce energy costs.

Best possible pressure quality, tailored to specific needs

This is largely made possible by Kaeser’s advanced 3-D Control, which takes into account other factors - aside from switching losses (start/stop) - that influence compressed air system energy efficiency. These include control losses (idling and frequency conversion) and pressure flexibility (average increase above required pressure). This innovative control strategy predictively calculates the optimum achievable configuration and adjusts the connected components accordingly – all based on the specific pressure required by the user.

When machines talk

The SAM 4.0 supports operation in 30 languages, while the easy-to-use 12-inch colour touchscreen shows at a glance whether the station is operating in the “green zone” from an energy management perspective. Operating status, pressure history, free air delivery, power consumption, as well as maintenance and any error messages can be easily displayed and analysed – both in real-time and retroactively. Using a PC and network connection, this data can be accessed conveniently from anywhere, not just at the machine itself. This not only provides users with peace of mind, but also lays the foundation for predictive maintenance and enables energy management in accordance with ISO 50001.


 

Sigma Network

The far-reaching benefits of the SAM 4.0 are expanded even further when users also take advantage of Kaeser’s Sigma Network. Based on Ethernet technology, the powerful Sigma Network is a closed and secure network that has been specially developed to support optimal monitoring and coordinated control of compressed air stations.

Remote diagnostics and predictive maintenance

The SAM 4.0 offers additional powerful features. For example, maintenance and error messages can be immediately sent via email to a pre-set personal address and the remote diagnostics option allows for predictive maintenance and service based on actual use. Both of these elements increase compressed air availability and reliability and also help keep lifecycle costs to an absolute minimum.

SAM 4.0: Future-ready

The SAM 4.0 is ready-designed to accommodate potential future compressed air system expansion. A straightforward software upgrade allows for expansion with no need for additional investment in new hardware.

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Company news

Date

Topic

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Apr 20, 2017

Kaeser at Interpack

Outstanding reliability

Compressed air supply systems for the packaging industry must be safe, efficient, economical and ready to accommodate future technological developments. At Interpack, Kaeser Kompressoren is showcasing innovative concepts and individually tailored solutions that meet these requirements and more.

The packaging industry requires excellent solutions for a highly varied range of compressed air applications – solutions capable of reaping the myriad benefits of Industrie 4.0 systems. With highly efficient components, a compressed air management system and predictive maintenance services, systems from Kaeser deliver a highly reliable supply of compressed air at all times – the right amount, treated to the proper quality standards and always supplied precisely where it is needed. Kaeser compressed air systems operate with maximum cost-effectiveness and efficiency whilst also providing a previously unimaginable scope of data processing and monitoring. Aside from the benefit of reduced costs, users can also depend on enhanced availability and reliability.

SAM 4.0 delivers efficiency and transparency

The Sigma Air Manager 4.0 (SAM 4.0) is the most important component for maximizing the efficiency of the compressed air supply and it’s also the key to compatibility with future Industrie 4.0 innovations. This comprehensive compressed air management system perfectly coordinates operation of all compressed air system components whilst also guaranteeing maximum availability and energy efficiency at all times, thanks to its improved 3D Advanced Control technology. The SAM 4.0 also acts as the central node and basic requirement for taking advantage of Industrie 4.0 services such as continuous energy management and predictive maintenance.

DSD features increased efficiency

To defend the title of efficiency champion, it’s necessary to continually adapt to higher standards: precisely like the next generation of DSD-series compressors. Now available for flow rates from 14 to 25 m³/min, these new machines feature a range of improvements, including completely overhauled airends with the efficient Sigma Profile, as well as IE4 motors. The result: specific power gains of up to nine percent as well as up to six percent higher flow rate compared to previous models. This significantly reduces energy costs, true to Kaeser’s motto of “More compressed air for less energy consumption”.

Oil-free compressed air

The CSG series delivers excellent performance for applications requiring oil-free compressed air. With drive power of 37 to 90 kW, the flow rates of these two-stage machines range from 5.4 to 13.1 m³/min with pressures ranging from 4 to 10 bar(g). The durability of CSG-series compressors enables them to deliver a highly-efficient compressed air supply with guaranteed high cost-effectiveness over their entire service life – and consistently provide significant energy cost savings.


  • SAM 4.0: the Sigma Air Manager 4.0 (SAM 4.0) enables highly efficient monitoring and control of all components in a compressed air station as well as laying the necessary foundation for Industrie 4.0 applications.
  • The new dry-compression CSG rotary screw compressors are durable, energy-efficient and environmentally-friendly.
  • The new DSD rotary screw compressors are now more efficient than ever before.

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About us

Company details

Kaeser Kompressoren

Established in 1919 as a mechanical engineering workshop, Kaeser Kompressoren is a family-owned business and today is one of the world's leading compressor manufacturers and compressed air systems providers. Kaeser's production centres are located in Coburg (main plant) and Gera, Germany. The company has approximately 5500 employees worldwide.

Kaeser's comprehensive product range comprises stationary and portable rotary screw compressors, stationary and mobile reciprocating compressors, dental compressors, vacuum pumps, rotary blowers, filters, dryers, air tools and accessories. Furthermore, Kaeser's state-of-the-art compressor control systems with advanced IT technology take compressed air efficiency to the next level and beyond. Both users and the environment therefore benefit from the consequent energy-savings.

Subsidiaries and authorised partners in over one hundred countries ensure that users are able to enjoy all of the benefits that the very best in compressed air engineering has to offer.  Key markets include the EU, the United States, Latin America and the Asia-Pacific region. Kaeser owes its enviable reputation not only to the exceptional efficiency and quality of its products, but also to its reliable field service. More recently, the other industry-leading services offered by the company - such as operator models for compressed air stations, concepts within the framework of Industry 4.0 and predictive maintenance - have increasingly moved to centre stage.

Kaeser's many years of strong growth and expansion are directly attributable to its passion for innovation and strict quality standards. Both are driven by the hard work and dedication of its employees, whose expertise, combined with ongoing professional development, keep them attuned to the very latest technology. The company's opening-up of key global markets in recent years has also created many additional jobs and secured existing ones, both in Germany and around the world.

The company is headed by Thomas Kaeser, Dipl.-Wirtsch.-Ing, grandson of the company's founder, and Tina-Maria Vlantoussi-Kaeser, Dipl.-Wirtsch.-Ing.

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Brief company history:

Founded: Coburg 1919

Trade name: Kaeser Kompressoren

Founder: Carl Kaeser senior

Executive management: Thomas Kaeser, Dipl.-Wirtsch.-Ing.,
Tina Maria Vlantoussi-Kaeser, Dipl.-Wirtsch.-Ing.

Products: Reciprocating and rotary screw compressors ranging from 0.18 to 515 kW, portable rotary screw compressors, high-pressure and dry-running compressors, dental compressors, compressor control systems, vacuum pumps, rotary blowers, air filters and tools, refrigeration & desiccant dryers, as well as compressed air system accessories and services.

Turnover (2015): Approximately EUR 800 million

Employees:

Worldwide: Approx. 5500

Apprentices: Approx. 300

Apprentice positions per year (since 2016): 120

Production centres: Coburg (main plant), Gera

Branch offices: 8 regional offices throughout Germany

Worldwide sales partners: Represented in over 100 countries by Kaeser-own branch offices and exclusive authorised partners

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