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

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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May 9, 2017

Blowers now available with Sigma Control 2

Integrated energy and cost efficiency

Kaeser completes its blower product portfolio with the BBC and FBC series. These compact rotary blowers are now ready to connect with integrated mains power supply equipment and the proven Sigma Control 2 controller for comprehensive system monitoring and communication. Kaeser’s high-efficiency, energy-saving rotary blower range now covers air deliveries from 2 to 72 m³/min at up to 1000 mbar gauge pressure and 500 mbar vacuum. Key applications for these blowers include pneumatic conveying and water treatment.

"Ready-to-connect" means that the units are supplied complete with all sensors, controls and a choice of star-delta starter or variable speed drive.     The complete system packages are CE and EMC certified, which means less work for both the operator and system provider when it comes to planning, installation, certification, documentation and commissioning, because the machines and the electrics are preconfigured and ready-adjusted at the factory.

But that’s not all; these new rotary blowers feature even more integrated intelligence: Highly effective broadband sound and pulsation damping ensure quiet operation at all times, which applies to both the machine and the pipework.

The blower block with its proven Omega profile rotors significantly enhances operational reliability and uptime, whilst adaptive compression reduces energy consumption, and long bearing life minimises maintenance costs.

Moreover, space-saving component layout results in an exceptionally compact footprint. Also, as these blowers have been designed to allow all service work to be carried out from the front of the unit, it is possible with star-delta equipped models to install several blowers side by side. Components such as control valves and exhaust silencers, which would normally be installed externally, are already integrated.

The internal Sigma Control 2 controller makes blower mode selection, such as remote speed control or pressure control, quick and easy with just the press of a button.  Performance parameters relevant for dependable blower performance are monitored by sensors, and warning or fault signals are automatically generated accordingly. Optional communication via databus (multiple databus systems can be connected) allows operational status read out and enables the machine to be remotely controlled.

Of course, operating costs do not just depend on the efficiency and reliability of the individual components within the station. Various other factors play a key role, such as actual pressure and air demand, selection of appropriate and suitably matched blowers and drive systems, as well as tailored sequencing control. This is where an Air Demand Analysis (ADA) can prove invaluable: With help from such detailed analysis it is possible to determine how compressed air demand varies over time, how efficiently a blower station is operating, and to what extent availability and efficiency can be further enhanced. The “Kaeser Energy Saving System” (KESS) is another powerful optimisation tool. This specialised planning software enables different system variants to be simulated and compared with one another, and their respective potential savings to be calculated. Transparency of future servicing and maintenance costs is also essential when considering the total life cycle costs of both individual blowers and stations as a whole. Needless to say, this task requires the kind of knowledge and expertise that only an experienced compressed air system provider such as Kaeser Kompressoren can offer.

By choosing Kaeser, planners and operators not only profit from all of the advantages that Kaeser's latest generation of blowers deliver, but also benefit from the company's decades of experience in system planning and optimisation. As a result, they can enjoy the rewards of enhanced system efficiency and maximum dependability.   

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May 9, 2017

Tomorrow’s technology, today

Controller Sigma Air Manager 4.0

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.

More Less

May 9, 2017

Dryer - 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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May 9, 2017

Filters - Pure compressed air – unprecedented energy efficiency

Corresponding air treatment and filtration is essential for businesses requiring a dependable source of high quality compressed air. Kaeser’s new generation filters not only deliver the necessary performance, but also provide unprecedented energy efficiency. 

Kaeser Kompressoren’s latest generation of filters ensure outstanding efficiency and minimal pressure differential. Low pressure differential means lower energy consumption, but that in itself is not much use if the filter cannot provide the required compressed air quality. Kaeser filters deliver both: Their performance characteristics were determined in accordance with ISO 12500-1, the quality standard for filters, and were tested and verified by an independent body. Accordingly, the new deep-pleat KE (Kaeser Extra) aerosol filter achieves a residual aerosol content of 0.01 mg/m³ with a saturation differential pressure of no more than 200 mbar.

The filter range covers four different element grades for filtration of aerosols, dust and oil vapours. Compressed air can therefore be treated to suit the needs of the specific application in accordance with ISO 8573-1 purity classes. These innovative filters are suitable for pressures up to 16 bar at temperatures of up to 66° C and will be initially available in nine enclosure sizes for flow volumes up to 14.2 m³/min. 

Tailored compressed air purity with maximum efficiency
The filters’ impressive performance has been made possible by the completely redesigned element head. This patented in-house development is the result of Kaeser’s decades of compressed air engineering expertise. The new design gently redirects the air flow so that it is evenly distributed across the innovative filter media. In addition, especially large filter surfaces ensure optimum filtering rates, which results in high filter efficiency with minimal pressure loss.

Faultless element replacement
A bayonet fitting is used to connect the filter head and housing. An innovative integrated positive positioning guide ensures that the housing and element are always automatically correctly joined following filter element and seal replacement. A stop screw fixes the housing in its final position and seals it at the same time. If improperly assembled, the connection does not close and compressed air can be heard escaping.

Durable, easy-to-install housing
The Kaeser filter housings are made of corrosion resistant aluminium and are coated with a passivation layer to ensure long, dependable service life. They are available with compressed air connection flanges of various nominal sizes to make installation as easy as possible. Numerous options and a comprehensive selection of accessories are also available.

Kaeser's finely graded filter range ensures reliable and efficient compliance with all ISO 8573-1 quality classes. The filter models are precisely matched to the compressors and air treatment components and can be combined to suit the specific needs of the application.

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May 9, 2017

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.

More Less

May 9, 2017

Compressor - 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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May 9, 2017

Compressors - 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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May 9, 2017

Compressors - Compact design with exceptional efficiency

Compressed air users have always benefited from cost-effective and reliable compressed air production with KAESER’s ASD series rotary screw compressors. Covering free air deliveries from 3.16 to 5.53 m³/min at 7.5 bar, and capable of 15 bar maximum operating pressure, these compact compressors are the perfect choice for users who require smaller volumes of quality compressed air.

At the heart of every ASD compressor is a high performance Kaeser rotary screw airend equipped with flow-optimised ‘Sigma Profile’ rotors. The ‘D’ in ASD stands for Direct Drive, which means that the airend and the drive motor are directly coupled and turn at exactly the same speed. The drive power is transmitted from the motor to the airend without the losses incurred by gearing or drive belts. The use of premium efficiency IE3 electrical motors also contributes to additional energy savings.

Another important efficiency-enhancing component is the new “Sigma Control 2” internal controller: This advanced system not only enables demand-oriented performance matching and dependable monitoring, but ensures even 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 addition of an integrated RFID reader ensures service continuity, increases security and significantly raises service quality.

‘Sigma Control 2’ equipped ASD compressors can also be connected to a second machine of the same specification to provide co-ordinated base load operation - a master control system is therefore not required. One of the units assumes the 'Master' role and thereby precisely co-ordinates performance of both compressors to suit specific compressed air demand. It also ensures that both machines are evenly loaded.

Featuring a radial fan and optimised cooling-air flow, the ASD’s clever cooling system ensures low compressed air outlet temperatures. The fan’s power reserve is sufficient for long lengths of ducting and, as a result, eliminates the need for installation of an additional exhaust fan. Moreover, it consumes less power than a comparable axial fan. In conjunction with exceptional sound insulation, the high performance ventilation system enables low sound levels of only 65 to max. 69 dB (A), depending on model.

Furthermore, ASD compressors are optionally available with an integrated refrigeration dryer and / or frequency control module. This versatile modular design therefore allows the compressor system to be precisely tailored to meet the user's exact requirements.

The electronic thermal management feature controls the oil temperature to maintain a consistent and reliable differential with respect to the condensation temperature; it also prevents unnecessarily high compression discharge temperatures to ensure even greater energy savings.

Energy- and eco-friendly filters
Resource conservation was also top a priority when it came to interior design of the machine: the eco-friendly fluid filter elements no longer have a permanently attached sheet metal housing; rather, they’re simply inserted in an aluminium housing. The filter elements themselves contain no metal, making them ready for easy thermal disposal at the end of their service life – without the need for any additional pre-treatment.

Advanced controller for optimal performance
The advanced Sigma Control controller masterfully coordinates a full range of monitoring functions to track the performance of the compressor – and a frequency converter, if applicable. Furthermore, the Sigma Control allows Teleservice capability and enables straightforward connection to master control systems and data networks, thereby providing seamless integration of the compressors within an Industry 4.0 environment.

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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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