Success Story: Hybrid Hydraulic Power Unit for Single-Dose Packaging – Pharmaceutical Sector

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Hybrid Hydraulic Power Unit for Packaging Machines: Application Case in Single-Dose Packaging

Hydraulics and High-Cycle Packaging: a Critical Combination

In the single-dose packaging and thermoforming machine sector, the performance of the hydraulic system directly affects productivity, cycle stability, energy consumption, and thermal management of the system.

For high-cycle applications such as these, operating temperature, noise level, and motion control are not secondary variables: they determine process quality and long-term operating costs.

For the customer VALMATIC, together with our distributor Mekoil Oleodinamica Srl of San Prospero (MO), we developed a solution designed to control the cylinders dedicated to the forming, sealing, and cutting phases.

In this application case, we describe how we designed the transition from a traditional hydraulic power unit to a hybrid solution using the Daikin SUT00D6021, achieving concrete and measurable results.

 

The Traditional Configuration: Functional but with a Clear Critical Issue

The solution previously adopted for this type of machine was based on a traditional hydraulic power unit composed of:

• 100-liter oil tank

• 3 kW three-phase asynchronous motor and 25 cc/rev vane pump

• Solenoid valve manifold for managing hydraulic actuators

• Air-oil heat exchanger for controlling operating temperature

• 1.5 kW accumulator unit

This was a well-established and functional configuration designed to control the cylinders during the forming, sealing, and cutting phases.

However, a critical issue clearly emerged during continuous operation: after only a few hours of work, the oil temperature reached values close to 60 °C, making forced cooling necessary. This condition generated several significant side effects:

• higher energy dissipation

• increased overall noise level

• greater thermal stress on components

• lower overall system efficiency

 

The Hybrid Solution: Daikin SUT00D6021

Selection Criteria and Design Objectives

Starting from these operating conditions, the Mekoil Oleodinamica technical team proposed adopting a Daikin SUT00D6021 hybrid power unit. The objective was not limited to energy efficiency alone: the project also aimed to improve the dynamic quality of motion and the overall stability of the machine cycle.

Daikin SUT technology stands out for its ability to adapt the delivered flow rate to the actual demand of the machine, avoiding constant maximum flow even during phases where the machine cycle does not require it (a typical continuous operation characteristic of traditional power units).

This results in lower pressure losses, consequently reducing heat dissipation, improving the thermal balance of the circuit, and making the overall system more efficient.

 

Results Achieved: Efficiency, Dynamics, and Thermal Control

The introduction of the hybrid power unit produced tangible results on multiple fronts:

• increased production speed

• significant noise reduction

• improved cylinder motion management through proportional acceleration and deceleration ramps

• drastic reduction of heat generated in the hydraulic circuit

• reduced energy consumption with the same operating hours

 

Dynamic Behavior: An Often Underestimated Aspect

One of the most significant aspects of this application concerns system dynamics. Controlled management of acceleration and deceleration phases makes cylinder motion smoother and more stable, reducing mechanical stress, pressure peaks, and unwanted oscillations during the most delicate phases of the cycle.

 

Thermal and Energy Advantages

From an energy perspective, reducing losses that are normally converted into heat leads to a lower need for forced cooling and a better thermal balance within the circuit. These two factors directly affect operational continuity and component lifespan.

 

High-Cycle Packaging: When to Choose a Hybrid Power Unit

For packaging applications characterized by high cycle rates, continuous operation, and strict requirements for speed and repeatability, a hybrid power unit represents a concrete technical evolution compared to a conventional hydraulic solution.

Key parameters to consider during evaluation include:

• operating temperatures reached with the current configuration

• daily operating hours and cycle continuity

• required motion quality in critical phases (forming, sealing, cutting)

• reduction targets for energy consumption, noise, and maintenance

Do you have a similar situation in your hydraulic system?
Tell us about your application: our technicians will analyze your configuration and evaluate possible optimization opportunities together with you.
 

WATCH THE FULL VIDEO!

CONTACT US: sales.exp@duplomatic.com

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