TLT-Turbo GmbH & TLT-Turbo India Entrench Successful Cooperation for the Supply of CDQ Fans

TLT-Turbo GmbH is pleased to announce a successful cooperation between TLT-Turbo and TLT-Turbo India for the supply of CDQ fans to clients in Beijing.

TLT-Turbo India has established new channels for fans to be supplied by appointed local suppliers in the region. This provides further support to TLT-Turbo’s existing global manufacturing capacity and additionally, manufacturing in this region offers several advantages that will ultimately benefit TLT-Turbo customers.

Thus far, two orders have been processed thanks to this cooperation and the fans were delivered to two customers in Beijing at the end of May 2020. The scope of work on the order included the rotor hardware and the engineering of the stator as well as a complete fan, with the damper.

“Two manufacturers have been identified to cover quality production of different parts. These India-based suppliers were sourced by TLT-Turbo India and this relationship increases our manufacturing capacity. Both new suppliers are fully qualified to manufacture our components to the required levels of quality. They were provided with technical support and special training at their premises prior to delivery,” explains Rajesh Raut, QA Manager at TLT-Turbo India.

According to Raut, manufacturing in India offers the advantages of cost savings and redundancy in production. “Thanks to these new suppliers, short lead times were also achieved. The cooperation during the manufacturing process was based on strong mutual support between the suppliers and TLT-Turbo. When challenges arose, an efficient problem-solving team was available to ensure a quick and viable solution. Due to this excellent level of cooperation and the quality achieved on the delivered product, these suppliers have qualified for further projects.”

“The success of this project, the extending of our manufacturing capacity and the co-working achieved between our regional offices proves that the TLT-Turbo global team is able to come together to keep driving our business forward even during challenging times. As the effects of the global COVID-19 pandemic are still being felt across the globe, TLT-Turbo is enduring thanks to efforts such as these,” comments TLT-Turbo Global Managing Director, Rainer Redinger.

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TLT-Turbo GmbH Announces Contract for Wuhan Sinter Project

TLT-Turbo GmbH, global ventilation fans and systems manufacturer, today announced its success in winning a contract for the supply of Sinter fans, including complete drive system, to Baosteel for the Wuhan Sinter Project. The announcement comes amid the COVID-19 global health crisis and further indicates improving business conditions in Wuhan.

TLT-Turbo has secured a contract together with consortium partner, TMEIC (Toshiba Mitsubishi-Electric Industrial Systems Corporation) for the supply of two complete fan systems to Baosteel. Headquartered in Shanghai, China, Baosteel is globally recognised as one of the most competitive iron and steel companies with the highest level of modernization in China.

TLT-Turbo’s delivery on the project will include the supply of two sinter waste gas fans as well as the accompanying drive motors, frequency converters, transformers, switch gears and control panels. TLT-Turbo will also fulfil the role of consortium leader for the project and will take the lead on commissioning and final installation of the fan systems.

“This newly secured contract adds to the growing list of projects that TLT-Turbo has been a part of in China recently – each of which reflects our excellent teamwork and long-term success,” says Ma Le, TLT-Turbo Sales Representative based in the region.

Ma Le adds that this is the fourth contract that TLT-Turbo has won since establishing a working relationship with Baosteel in 2013. Since 2013, TLT-Turbo has delivered a total of eight sinter fans to Baosteel – one of which is the largest operational sinter fan in the world.

“The success of this relationship is built completely on teamwork. The fact that Bao Steel always returns to TLT-Turbo to order our fans also speaks highly of our commitment of quality. The resilience shown by the TLT-Turbo global team is evident in their continued success in securing contracts in this region,” adds Ralph Mansius, TLT-Turbo GmbH Sales Liaison.

A Growing Presence in China

In total, TLT-Turbo has won contracts for 18 Sinter Fans since entering the Sinter market in China in 2012. Aside from their continued success with Baosteel, TLT-Turbo also signed an additional two contracts in China’s sinter market this year.

Another notable success coming out of the region is the continued business in the CDQ (Coke Dry Quenching) market. In 2020, TLT-Turbo has won contracts for a total of 10 CDQ Fans. Says Mansius: “This proves that we are a market leader in our field – and that we are committed to working together as a global team to keep up momentum throughout the COVID-19 crisis.”

Enduring Through the COVID-19 Crisis

Ma Le acknowledges that with the COVID-19 crisis still evolving in all parts of the world, it is to be expected that some orders might be coming in slower than usual. “Businesses across the world will all be bracing for its long-term effects. However, we strongly believe that through the combined efforts of the regional TLT-Turbo teams across the world, we will be able to endure through this crisis and for long after it has passed. We are sincerely thankful to every member of the TLT-Turbo global team for the part they have played in our continued success and resilience. We have all risen to the challenge of temporarily changing how we do things – but this is just another example of Ventilation Redefined.”

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TLT-Turbo GmbH Response to the Coronavirus

TLT-Turbo GmbH is closely monitoring developments around the spread of coronavirus (COVID-19), and our priority remains the safety of our employees and our clients. Importantly, our employees remain dedicated to ensuring we deliver on our commitment to our clients amid these challenging times.

TLT-Turbo, Global Co-Managing Director, Rainer Redinger: “TLT-Turbo is closely monitoring developments around the spread of Coronavirus (COVID-19). As a company with a global footprint, our priority remains the safety of our employees and our clients. Importantly, we remain dedicated to ensuring that we deliver on our commitment to our clients amid these challenging times. TLT-Turbo is taking our response to the developing Coronavirus outbreak seriously and we have put measures in place to ensure ongoing production and remote assistance for clients. Ensuring that TLT-Turbo is operationally resilient is of paramount importance to our clients and organization. As the number of Coronavirus cases continues to climb, we are taking steps to ensure that we are, in fact, resilient.”

Specific arrangements for each of TLT-Turbo’s 15 offices located worldwide will be based on local legislation and government responses but plans are in place to ensure our operational continuity.

Thanks to intensive and coordinated efforts, the COVID-19 situation in China is improving with the number of confirmed cases decreasing from last month. TLT-Turbo has received reports from our office in Sichuan stating that as of 25 March 2020 no TLT-Turbo employees in the region have been infected with the Coronavirus and that they are now once again operational. Stringent hygiene and prevention protocols are in place for all employees and while sales discussions are still limited to electronic platforms, these developments are encouraging.

Currently, TLT-Turbo manufacturing facilities in the USA, Korea and Germany are also operational. The staff present at these sites have been provided with personal protective equipment (PPE) as advised by global health organizations and all recommended hygiene measures are in place. The number of staff on site has been reduced where required along with the number of suppliers and external persons allowed on site. All suppliers are required to comply with TLT-Turbo’s prevention protocols on arrival.

The closures affecting manufacturing and delivery currently include TLT-Turbo Africa and TLT-Turbo India who are subject to government mandated national shutdowns – although this only for a period of 21 days. For sales offices and smaller branches, TLT-Turbo has implemented remote working arrangements to ensure that administrational, sales and consulting processes continue as normal.  

Additional measures taken by TLT-Turbo to protect the health and safety of our staff include cancelling all work-related travel, restricting client and internal meetings to electronic platforms, and complying with client hygiene and prevention protocols if and where field services are conducted.

TLT-Turbo Global Co-Managing Director, Minggang Wan: “As your trusted ventilation partner, we are taking every necessary step to continue to provide the high-quality service and stability you rely on, while safeguarding the health and wellbeing of our employees and our clients. We have and will continue to take prudent, precautionary actions that allow us to provide the excellent support you have come to expect from us – including a focus on leveraging electronic platforms as far as possible, and flexibility to accommodate client needs and ensuring we proactively engage with you to gather real-time feedback. Importantly, TLT-Turbo remains as fully functional as this global crisis allows and we are prepared to provide continuity of service as the environment around us evolves. We take tremendous pride in being trusted suppliers to your business and will do everything in our power to deliver on that promise. Accordingly, we encourage you to contact your client service teams who are ready to offer assistance in any meaningful way possible and answer any further questions.”

TLT-Turbo will continue to monitor this evolving situation in each of our regions of operation and will ensure swift and decisive responses as the situation changes.

Mr. Wan extends his gratitude to the agencies, organizations and professionals who have provided guidance to the company during this challenging period. “In our 145-year history TLT-Turbo has overcome numerous challenges to our business and survived global events that have threatened the livelihood of our employees. We have overcome these and emerged stronger. In the crisis we face today we will take every possible measure to ensure our continuity and to safeguard the wellbeing of our team along with our clients’ operations. Although this may be a time of business as ‘un-usual’ we remain agile in our delivery of ventilation solutions.”

We encourage concerned clients and suppliers to reach out their TLT-Turbo representatives in the various regions. Locate your nearest point of contact here.

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Pursuing Air Flow Perfection: 90 Years of Wind Tunnel Innovation

TLT-Turbo have a long-standing tradition of supplying wind tunnels especially for the motor vehicle and aerospace industry. TLT-Turbo were among the first to focus on aero-acoustic wind tunnel fans. As a supplier for some of the world’s most prominent car manufacturers, TLT-Turbo aims to become renowned as a global leader in wind tunnel fans and systems through continual innovation and a deeply ingrained passion for performance.

The development of wind tunnel production at TLT-Turbo started with their ancestral company, Dinglerwerke, who built their first wind tunnel back in 1936. Decades later, the company now known as TLT-Turbo, would be responsible for some of the world’s most notable wind tunnel installations. “From the start we set out to establish a tradition of being pioneers and innovators in this field of ventilation as we recognized the significance of these systems for vehicle testing,” says Volker Szemskat, Vice President of TLT-Turbo.

TLT-Turbo’s first wind tunnel installation for the motor vehicle industry was built in 1940 for FKFS (Research Institute of Automotive Engineering and Vehicle Engines) in Stuttgart. It was a low speed wind tunnel designed for wind speeds of up to 72 m/s. This wind tunnel was later taken over by Daimler.

Testing vehicles in wind tunnels started with projects such as Peugeot’s passing a car through the Eiffel Wind Tunnel at the rue Boileau, in Paris in 1914. The goal was to gain information on how to modify the shape of models to decrease aerodynamic drag. Since then these types of tests have advanced significantly and today, they are becoming more and more relevant as a means of testing for reducing pollutant and noise emissions. “Even the smallest gain in the aerodynamic drag leads to a decrease in consumption of fuel,” Szemskat explains.

In total, over the past 90 years, TLT-Turbo have supplied around 70 wind tunnels and test stands, of which about 30 were delivered for the automotive industry. This includes more than 70 customized fans ranging from 100 kW to 88.000 kW with diameters from 1 to 15 meters. Among these are some of the most notable facilities in the world – such as the ONERA (French Aerospace Center) Transonic Wind Tunnel S1 in Modane, France, being installed in 1949, with a 2-stage counter-rotating fan measuring 15 m in diameter with a drive power of 88.000 kW. This colossal fan remains to this day the largest wind tunnel fan in the world being in continuous operation since 1952.

Another example of the longevity of TLT-Turbo’s fans is the wind tunnel installed for Volkswagen in 1965. Its 9-meter diameter fan has been in operation in operation for over 50 years.

“The combination of our experience, with the field-proven performance and long operational life spans of these fans has made us a trusted supplier across the globe,” says Szemskat.

(Above) Diffuser section of a TLT-Turbo Aero-acoustic Wind Tunnel Fan

This status has been well maintained over the years with clients including Volkswagen, Ferrari, Ford and Audi coming back to TLT-Turbo for repeat orders.

TLT-Turbo’s 145 years of experience in ventilation design and supply has contributed to the innovations and new methods they have been able to apply to their wind tunnel designs. In 2010, TLT-Turbo supplied a fan for an aero-acoustic wind tunnel for the DLR (German Aerospace Center) which features a special blade and guide vane design for particularly low noise generation as well as composite material for the fan blades. Since then, this innovation has been applied to most of their automotive wind tunnel fans.

“Most often the development of innovations in the application of wind tunnels is guided by the needs of a particular client or the project itself. We need to think on our feet to come up with new approaches to solving challenges that arise as a project unfolds. This then informs future designs and installations and ensures that our offering is constantly evolving.”

Some of TLT-Turbo’s latest field-driven innovations include the application of their ‘Cut-off’ and ‘Lean/Sweep’ design that they have applied to their low speed aero-acoustic fan design to reduce blade tone and broadband noise. “We have also been working with the use of composite materials which has allowed us to apply 3D-geometry on the guide vanes which increases efficiency and overall performance,” Szemskat says.

The use of composite materials is also being applied in their current projects for the CAERi and CATARC automotive research institutes in China. These projects are currently in installation and commissioning phase.

For the past 12 twelve years, TLT-Turbo have changed their focus to the centerpiece of wind tunnels; the fan. “In the past, TLT-Turbo supplied turn-key wind tunnel solutions. From 2007, this offering changed to focus solely on the fan itself as the key component of a wind tunnel system. Our clients still benefit from our extensive experience and expertise in complete wind tunnel systems. This allows us to provide a tailored solution because we understand how the separate components interact with each other,” Szemskat reports.

(Above) TLT-Turbo now focuses solely on the fan itself as the key component of a wind tunnel system

“This gives us greater scope for customization. Every fan and its project planning is adapted to its specific installation. Stand-alone drive systems with local operation, control and monitoring systems and their connection to the parent digital control system also form part of our portfolio. Our experience with the supply and installation of turn-key wind tunnels means that we are able to recognize the significance of specific wind tunnel features to the design of the fan.”

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TLT-Turbo Fan Range Redesigned to Meet Specific Mining Industry Needs

Global ventilation fans and systems manufacturer, TLT-Turbo GmbH, has announced the redesign of its Auxiliary and Booster fan range. Developed in close collaboration with clients, the new designs address both efficiency and cost effectiveness, in a versatile product range that meets the specific ventilation requirements of the mining industry.

Development of the new fan range concept began in early 2015. Following a lengthy global market study to gain an understanding of the market requirements, the range was defined in mid-2017, with fabrication of the first units taking place shortly thereafter. “The development of the Auxiliary and Booster fan range would not have been possible without the input of clients. This ensured that we focused on key market driven requirements including energy efficiency, noise reduction, cost effectiveness and turnaround time,” says Michael Minges, Technical Director at TLT-Turbo Africa, who headed up the fans’ designs.

“To sell these products we needed to ensure close customer relationships and visibility. We are striving to change the industry’s mindset on the use of such fans to ensure proper fan selection for the ventilation required. In optimizing mine ventilation, efficient, high quality Auxiliary and Booster fans can add as much value as surface fan installations.”

(Above) The new TLT-Turbo Auxiliary and Booster fan range addresses both efficiency and cost effectiveness

TLT-Turbo started commissioning of the first iterations of the fan range towards the end of 2017 within the Sub-Saharan market through its Africa office. From there, they based the development of the various fan sizes of the new range on market interest. The fan designs and their performance validation was completed at the end of July 2019. They aim to complete product roll out, with all supporting documents and certification, by the end of September 2019.

Minges explains that meeting identified market demands was the main focus of the improved designs. “As energy efficiency is one of the main drivers of industrial equipment usage, and minimum efficiency requirements on certain equipment are often legislated, TLT-Turbo identified the need and opportunity in the market for more efficient mining fans compared to what is currently in use.”

The new designs include several innovative additions to enhance performance in order to provide exceptional underground ventilation. The fan range was developed using the latest in engineering flow technology which allowed TLT-Turbo to improve the aerodynamics, and thus efficiency of the fans. A unique stator design and aerodynamic fairings, all manufactured from wear resistant composite materials, result in improved efficiencies and reduced noise levels. The modularity of the fan casings allow for quick and easy assembly with interchangeable ancillary fan parts.  The motor mounting in coherence with a machined impeller track ensures low and controllable blade tip clearances for improved performance and efficiencies. Pad mount motors are used for all fan sizes and help reduce vibration levels in the axial direction of the motor significantly which leads to longer motor bearing life and lower maintenance requirements.

(Above) The first orders for the new range were received at the end of 2017

Minges says that all possible measures are taken to ensure the highest quality and best possible performance of every fan supplied by TLT-Turbo. “All fans are ISO 5801 tested, unless the client agrees to type testing on higher volume orders. We ensure the client quoted performance is met before the fans leave the factory. Test certificates on both raw data and calculated performance can be provided on request. Fan efficiency is determined with the performance test and this quality check ensures we deliver on what we promised the client. Clients are regularly invited to witness the performance tests to sign off on acceptance. The fans also come with pressure ports that can be hooked up to a calibrated handheld measuring device to measure performance in-situ.”

In addition to performance and efficiency, ease of maintenance was also a major consideration in developing the new Auxiliary and Booster range. The modularity of the product design and the interchangeable standardized parts allows for quick turnaround time on parts supply. “For example, we only have two blade types for the full product range and generally only one motor barrel per fan size accommodating various motor sizes and types. Standardization on the product is the key to successfully managing maintenance and repair as it allows ample supply of spares for companies certified to do the repair work. The design track record has indicated a longer mean time between failure (MTBF) than previous products,” Minges explains.

(Above) The new TLT-Turbo Auxiliary and Booster fan range is available to clients worldwide

The fan range is being rolled out in phases. The preliminary testing at sites located in Sub-Saharan Africa has been launched successfully. The next phase is globalization as the new range will be rolled out in the USA, Canada, Europe, Russia and Australia. Following this, product supply and support will be extended to TLT-Turbo offices in South America and India. In the interim though, Minges says that these fans can be supplied to clients worldwide from TLT-Turbo Africa.

TLT-Turbo Africa has received a number of orders for these fans since the end of 2017. These orders include South African clients seeking a solution for deepening a gold mine, and for Kamoa Copper in the DRC as an exclusive supplier. “The feedback that we have received thus far has been that the fans are meeting our and client expectations. I am proud to say that one EPC consultant used the phrase ‘super fan’ to describe the new range and indicated that he has not heard a fan of this size so quiet before,” says Minges commenting on the reception of the new range.

“The Auxiliary and Booster fan range was developed to enhance TLT-Turbo’s mining ventilation product portfolio. The product is based on historic innovative designs by the TLT-Turbo Africa R&D team. Continual product development and keeping up to date with the latest technologies is ingrained within the engineering teams of TLT-Turbo. Ensuring that innovations are market and client driven with the end result being a benefit to the industry, puts us in the forefront of advancement in ventilation solutions,” Minges concludes.

– ENDS –

MEDIA CONTACT                                                       TLT-TURBO GLOBAL CONTACT

Oxigen Communications                                            Global Marketing Office

Nicola Weir                                                                 Anna Renner

nicola@oxigencomms.com                                        a.renner@tlt-turbo.com

About TLT-Turbo

TLT-Turbo GmbH builds radial and axial flow fans for virtually any application. First-rate engineering, tradition and progress in air handling technology and a worldwide support network have been the cornerstones of their excellent global renown as a fan and systems manufacturer for more than 140 years. TLT-Turbo GmbH fans and the associated system components are deployed successfully all over the globe. To date over 10,000 fans have already been installed. Their subsidiaries, branches and agencies span the globe including TLT-Turbo offices in Germany, China, Austria, Russia, South Korea, USA, Chile, Hungary, Australia, India and South Africa.

Visit www.tlt-turbo.com for more information.

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TLT-Turbo On-site Test Lab Advances Product Quality

Global ventilation fans and systems manufacturer, TLT-Turbo GmbH, has spent the past five years investing in and equipping its on-site test lab. The test lab now provides streamlined processes for research, advancing product quality and expanded capabilities for material testing. With a focus on particle impact wear testing, the test lab is driving innovation forward at TLT-Turbo as the results help improve product reliability, quality and performance in their final operating environment.

Patrick Baumgärtner a Research and Development Engineer – and expert in wear and corrosion protection – at TLT-Turbo, has played an instrumental role in building up the test lab – located at the TLT-Turbo Development Centre in Zweibruecken, Germany – to its current capabilities. Together with Sabine Groh, Industrial Fans Product Manager at TLT-Turbo, they have been spearheading the current research.

Currently, the core field of research at the test lab is the testing of new wear-resistant materials and coatings for fan components. Baumgärtner says that the testing takes place in the lab’s solid particle impact wear test bench. There, various types of dust or abrasive particles are blasted onto the test material, varying the angle and speed of the blasting to observe the resulting wear. “We also carry out caking tests in which we select, for example, anti-adhesive layers for our fans, in order to find suitable solutions for customer applications. A further main focus is the analysis of process residues that can have an abrasive or corrosive effect. Here the composition, size distributions, pH value and conductivity in the eluate are determined,” Baumgärtner explains.

(Above) Part of the materials testing laboratory in Zweibrücken

TLT-Turbo’s approach is to continuously test materials, coatings and components in order to produce fan components that are designed for performance excellence in any operating environment – no matter how abrasive. This testing is applied to current and new products in development but also to samples that are brought in from client sites in order to establish the wear patterns caused by their specific environment. In this way, TLT-Turbo is able to provide each client with a customized solution that will last longer and require less maintenance. 

The test lab now offers facilities for metallography, a stereomicroscope, a pycnometer for determining the density of materials and coatings, and an automated solid particle impact wear test bench. “The capabilities of the test lab open a lot of doors for advanced research that will make a positive contribution to the engineering community at large as well,” says Baumgärtner. “Under my supervision, studies and thesis research takes place in the laboratory in cooperation with local colleges and universities. For me, this is the basis for successfully researching and developing new solutions in our field.”

According to Groh, the test lab has almost endless possibilities for the improvement of product delivery to clients. “Our customers are often operating TLT-Turbo fans in abrasive and/or corrosive environments. To develop suitable solutions that match the wear resistance against particle impact we use our automated solid particle impact test bench. Compressed air accelerates a defined mass flow of abrasive particles to velocities up to 300 m/s and propels them onto a piece of sample material. This leads to material loss and wear that we can examine.  It is even possible to use original dust from a customer’s plant to evaluate the most suitable solution for them. By varying the impact angle we can observe system characteristic wear curves. With this knowledge we can provide customized solutions for many processes.”

(Above) Exchangeable impeller blade exposed to massive wear

These customized solutions can be best illustrated in the selection of coatings. This, says Groh, has an immensely positive impact for TLT-Turbo clients. “If we were to propose a new coating for a customer, the wear rate of the coating would be determined first. That is the main scientific-based decision criteria for wear resistant coatings. If the coating has a superior wear rate compared to other coatings or at least a wear rate that is on par with other coatings and another beneficial quality such as anti-stick effect, corrosive resistance or a cost advantage it will be implemented into TLT´s coating portfolio.”

Groh says that they have also conducted tests that have led to the development of completely new proprietary coatings. “During the manufacturing process, coatings were tested to see the influence of welding heat on coating qualities – such as the development of cracks – to ascertain how to avoid damage caused by heat or weld splashes. We conducted research and testing on combining welded coatings and thin layer coating into a Hybrid Coating which can dramatically increase the operational lifespan of TLT-Turbo fans at their clients’ plants.”

This is one of numerous examples of how TLT-Turbo’s testing capability can positively impact ventilation systems across all applications. “Due to the broad database of wear tests on various materials and coatings, we are able to offer tailor-made wear protection solutions for various processes of our customers,” Baumgärtner acknowledges.

(Above) Blasting nozzle and sample holder of test bench

Groh agrees, adding that the wide variety of chemical compositions and coating conditions such as acceleration of coating powder and heat development make it extremely difficult to objectively find the best coating by carrying out testing at a customer plant. “The process of reaching just initial findings in these conditions is very time consuming. In addition to this, there is a broad variety of conditions to contend with at different customer plants that hinder an accurate comparison of different coatings at different plants. If you test different coatings on one machine you might get a rough estimation what coating is superior, however different wear rates of coating cause imbalances in the impeller and vibrations at the fan.”

She elaborates by explaining that finding a precise comparative measurement on different coatings is impossible without being able to analyse how the wear rate changes at different angles. “At the test lab we can control the conditions to find precisely what we are looking for in a shorter timeframe. Additionally we are able to replicate the fan’s operating environment. We can run tests using dust collected from the client site while simulating particle speeds that match the client’s environment to precisely simulate wear rates.”

In the laboratory environment, the TLT-Turbo team is also able to determine additional coating properties as they have the capability to run additional experiments, e.g. corrosive resistance, anti-stick effect, robustness, heat resistance, suitable application methods, and combination possibilities like hybrid coatings.

The test lab has afforded TLT-Turbo engineers a deeper understanding of the mechanisms behind wear and the effects of specialized solutions. This has led to new approaches in product advancement and development that are grounded in providing solutions that meet market requirements.

“The analysis of residues from plants has a great influence on product development as we are making more informed decisions when choosing materials for corrosive and abrasive environments,” says Baumgärtner.

This has also had an impact on TLT-Turbo’s aftermarket service offering. The test lab, has allowed for new customer services can be generated, such as the performance of specific tests for customers. “The development of new solutions for specific customer problems is now much faster and more accurate. Also the suitability of low cost approaches or solutions that allow for wear induced damages to be repaired on-site integrate effortlessly into TLT-Turbo’s existing solutions,” Groh concludes.

The test lab enables TLT to continuously improve their solution portfolio for different customer problems with a focus on wear. The combination of understanding the client’s exact requirements and challenges and having a tool that allows engineers to find the best solutions from a scientific basis are a key factor for success in the market and play an important role for TLT-Turbo’s on-going product development and quality client delivery.

– ENDS –

MEDIA CONTACT                                                       TLT-TURBO GLOBAL CONTACT

Oxigen Communications                                            Global Marketing Office

Nicola Weir                                                                 Anna Renner

nicola@oxigencomms.com                                        a.renner@tlt-turbo.com

About TLT-Turbo

TLT-Turbo GmbH builds radial and axial flow fans for virtually any application. First-rate engineering, tradition and progress in air handling technology and a worldwide support network have been the cornerstones of their excellent global renown as a fan and systems manufacturer for more than 140 years. TLT-Turbo GmbH fans and the associated system components are deployed successfully all over the globe. To date over 10,000 fans have already been installed. Their subsidiaries, branches and agencies span the globe including TLT-Turbo offices in Germany, China, Austria, Russia, South Korea, USA, Chile, Hungary, Australia, India and South Africa.

Visit www.tlt-turbo.com for more information.

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TLT-Turbo Introduces the Next Generation of Mechanical Vapor Recompression

TLT-Turbo GmbH, a global ventilation fans and systems manufacturer, has launched a new range of mechanical vapor recompression fans, with ceramic hybrid bearings that provide an exceptionally long operational lifespan. Integrating the latest ventilation technologies, this fan offers numerous advantages regarding performance efficiency, minimal maintenance and high reliability.

The TLT-Turbo fan for mechanical vapor recompression (MVR) has been in development since 2012 since the first case studies were carried out. Following intensive discussions with clients, TLT-Turbo established that a need existed for low maintenance MVR fans. This was followed by four years of intensive research, product testing and consultations with clients. The first MVR fans were rolled out in 2016 while continual product improvement has remained a focus area for TLT-Turbo.

“MVR fans have been available on the market for some time but instead of just following the trend, TLT-Turbo took time to ensure that we came to the market with a completely new, state of the art MVR solution,” says Mario Schmidt, Head of TLT-Turbo’s Vapor Fans business segment. “And we continue to have on-going discussions and feedback exchanges with our clients worldwide in order to continuously adapt and improve our MVR offering to their requirements.”

According to Schmidt, the features of TLT-Turbo’s MVR fan, such as the lower maintenance requirements and the introduction of hybrid ceramic bearings, underscores their commitment to developing products in close alignment to their clients and their needs, and also speaks to TLT-Turbo’s key objective for continual innovation.

(Above) The new TLT-Turbo fan for Mechanical Vapor Recompression

The implementation of hybrid ceramic bearings is a key differentiator of the TLT-Turbo MVR fan. “Our clients are amazed by the possibility of a hybrid bearing operating at high speed without circulating oil. Conventional roller bearings do not provide the required support for operating the fan in a broad operational speed range without running into harmful resonance frequencies (under critical operation). Thanks to continuous enhancement in recent years, especially through the use of ceramic materials, more effective roller bearings are available today. The use of hybrid bearings with steel rings combined with ceramic rollers has been established in many industrial applications and in the case of the TLT-Turbo MVR fan, hybrid ceramic bearings mean significantly lower maintenance requirements and better operational performance,” Schmidt explains.

The hybrid ceramic bearings used in TLT-Turbo MVR fans are life time greased and can be operated for up to 10 years without requiring maintenance. To enhance this benefit for clients, TLT-Turbo introduced an additional device to the fan’s design that allows for the bearing to be re-greased from the outside in order to further simplify maintenance and to increase the fans’ service life.

High motor speeds, a wide range of optimized impellers and the allowance for high temperature and pressure increases complement the lifetime greased hybrid ceramic bearings to ensure that clients benefit from the enhanced performance and efficiency that they have come to expect from TLT-Turbo products. These factors allow for operation of the fan below critical speed which ensures both reliability and safe operation.

(Above) A high efficiency will be achieved with an optimized impeller design

“Reliability and safety are key concerns for our clients and TLT-Turbo has addressed this in the MVR fan by using high quality components. Thanks to the use of the hybrid bearings, no oil supply or oil pump is necessary which means that no oil can contaminate the product. In addition to this, the fan also features temperature and vibration monitoring and remote monitoring of the bearing is possible as well. Our entire manufacturing process is carried out according to all major quality standards, including DIN ISO 9001,” says Schmidt.

The TLT-Turbo MVR fan is suited to numerous applications in the chemical, pharmaceutical, waste water treatment, and the organic natural product production industries as well as in the food and beverage process and manufacturing sectors. “Since 2018, we have received 35 orders for MVR fans across the globe with one installation completed. Thus far, the feedback from clients has been very positive. We have received reports that the bearing temperature is considerable lower than that of other comparable MVR fans and that our fan runs with less vibration than other MVR fans,” Schmidt affirms.

“Overall, TLT-Turbo’s objective was to offer our clients a mechanical vapor recompression solution that would outperform what was currently available on the market. We have delivered a fan that requires less maintenance while providing high efficiency and reliability. This is exactly what clients would expect from TLT-Turbo as a world class fan manufacturer and global service organization.”

– ENDS –

MEDIA CONTACT                                                       TLT-TURBO GLOBAL CONTACT

Oxigen Communications                                            Global Marketing Office

Nicola Weir                                                                 Anna Renner

nicola@oxigencomms.com                                        a.renner@tlt-turbo.com

About TLT-Turbo

TLT-Turbo GmbH builds radial and axial flow fans for virtually any application. First-rate engineering, tradition and progress in air handling technology and a worldwide support network have been the cornerstones of their excellent global renown as a fan and systems manufacturer for more than 140 years. TLT-Turbo GmbH fans and the associated system components are deployed successfully all over the globe. To date over 10,000 fans have already been installed. Their subsidiaries, branches and agencies span the globe including TLT-Turbo offices in Germany, China, Austria, Russia, South Korea, USA, Chile, Hungary, Australia, India and South Africa.

Visit www.tlt-turbo.com for more information.

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ACHEMA 2018 – Strong visitor Interest at the
TLT-Turbo Booth

At this year’s ACHEMA 2018, we once again presented our MVR Turbo Fan for mechanical vapor recompression. This year, we demonstrated the fan to the audience with a sanded and highly polished impeller, as an example of how it is applied for use in the pharmaceutical industry.

The TLT-Turbo Mechanical Vapor Recompression (MVR) fan attracted a large number of visitors to the booth. Our engineers presented the energy-efficient process in detail to interested visitors representing the process, chemical and pharmaceutical industries.

The innovative bearing concept – a hybrid ceramic bearing that is grease-lubricated at the factory and requires neither regular oil changes nor an oil supply – aroused great interest. With this concept, maintenance and thus operating costs can be reduced significantly.

The units are available in two different versions: the basic version includes the fan on a base frame with monitoring sensors whereas the complete package contains a motor and frequency converter. Depending on the application, different stainless steel housings and impeller types can be selected. In addition to the standard impellers made of duplex stainless steel, and models made of super duplex or titanium are also available.

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TLT-Turbo at Drinktec 2017

Drinktec 2017 held in Munich, with over 76,000 visitors, was a special highlight for TLT-Turbo GmbH. It was TLT’s first participation at Drinktec and at our booth we presented the TLT-Turbo fan for mechanical vapour recompression – MVR for short.

In a relaxed atmosphere with pretzels and TLT-Turbo wheat beer, trade visitors were able to see the outstanding technology of the MVR fans for themselves. The innovative storage concept in particular was met with great interest from numerous visitors. Both plant constructors and plant operators see the TLT-Turbo Hybrid Ceramic Bearing as a major advantage over conventional oil-lubricated bearing arrangements.

Come and see TLT-Turbo’s quality and innovation for yourself. Visit us at the ACHEMA 2018 in Frankfurt. You will find us in Hall 5.1 at Stand A90.

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New Service Workshop Now In Operation

Repairing up to 40 tons in four weeks! Our new service workshop enables cost-effective and fast overhauls of industrial fans.

Sustainability is becoming increasingly important for industrial ventilation systems. Significantly fewer new investments are being made in this area and old systems are used and maintained for as long as possible instead. In order to support its customers, TLT-Turbo GmbH, one of the world’s largest fan manufacturers, commissioned a new service workshop in Bad Hersfeld at the beginning of November 2017. In this workshop, all types of large industrial fans – both radial and axial –with weights of up to 40 ton will be overhauled and repaired in the future. In addition, the production area was expanded by 1500m² and the production and assembly areas were updated to meet new requirements.

“With regard to revisions, our customers increasingly make their decisions based on price and leadtime, which can be explained by growing cost pressure,” explains Matthias Adamy, Sales Director for After Sales Services at TLT-Turbo GmbH. “This increases the need for cost-effective and fast revisions. This is why we have decided to set up a service workshop that supports our customers with fast, flexible and uncomplicated service. Rapid processing in particular is an essential requirement here as the rapid replacement of defective or maintenance-needy rotors is crucial. Downtime can be shortened and system availability increased thanks to a short throughput time. For this reason, three types of revisions will be offered in the service workshop in future, which are characterized by a standardized procedure for diagnosis and repair. In addition to the standard and findings-oriented overhauls, there is now also a so-called rapid overhaul. This only takes four to six weeks, which means a time saving of about six months compared to conventional maintenance and repair. The reduction in processing time is also accompanied by a reduction in costs.”

Despite the short duration, TLT Turbo can guarantee the highest quality with the aid of component tests, functional tests for rotors, quality and surface crack tests. For this purpose, the specialist workshop has qualified personnel, all the necessary machinery and testing equipment for disassembly, cleaning, diagnosis, repair and assembly, as well as close links to the specialist departments, such as design and quality assurance. “In contrast to a repair on site, it is more advantageous to have a diagnostic report made in the service workshop, as the equipment, workshop and personnel support at the location where the fans are used are often not ideal,” Adamy explains. “An inspection directly at the customer should therefore always be an exception due in special circumstances”.

Process optimisation for smooth handling

In order to ensure that orders can be processed smoothly in the workshop even at full capacity, separate sections for dismantling and final assembly were set up and route and transport optimisation was implemented. “Due to the greatly reduced processing time, the new concept requires continuous improvement of internal processes and external communication. Through efficient cooperation and communication with subcontractors, for example, spare parts can be delivered and installed more quickly,” Adamy confirms. Especially for components with comparatively long delivery times, TLT-Turbo offers its customers consulting appointments with regard to spare parts stocking, so that revisions can be carried out as quickly as possible. The spatial extension also allows significantly more flexibility and space for handling workpieces of all kinds. For this purpose, several storage racks were installed in which up to 450 pallets can be accommodated. TLT-Turbo attaches particular importance to the transparency and traceability of the orders: This means that the status of the revision can be queried online at any time.

The new service workshop was presented to selected business partners at a Customer Day on 8 November 2017. “We want to signal to the industry that our focus is on service. To this end, we deploy highly qualified personnel who are familiar with diagnostic findings, repairs and the replacement of parts,” concludes Adamy.

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