Modern manufacturing regimes need higher efficiency, more flexibility and greater reliability in their drive systems than ever before - all necessary to reduce manufacturing costs and lower energy consumption. To meet this need, Danfoss has developed the VLT FlexConcept, an integrated conveyor solution ideal for the Food, Beverage and Packaging industries.

The new Danfoss conveyor solution -consisting of the new VLT Decentral Drive FCD 302, VLT OneGearDrive and VLT AutomationDrive FC 302 gives plant engineers and operators a very high degree of flexibility in the choice of components and plant structures. Regardless of whether the plant design is centralised or decentralised and whether the drives are used in dry, wet or aseptic areas, the VLT FlexConcept provides highly efficient components for every conveying task. The concept aims to optimise costs in tailored drive systems as result of high flexibility, high efficiency, reduced version count and an intelligent control concept.

Thanks to the open system architecture of the VLT FlexConcept, plant operators can easily and reliably combine components with existing solutions from other manufacturers, for example when expanding or refitting the plant, to achieve the required optimum configuration.

Furthermore, the VLT FlexConcept is currently the only solution on the market offering EHEDG certified components specifically designed for installation directly in plant areas where hygiene is critical. All components are coordinated with each other to ensure rapid commissioning and optimum efficiency of the overall solution.

The Danfoss components used in this solution, whether for new plants or for retrofitting or modernising existing plants, are highly efficient and comply with the actual requirements of users and the latest EU regulations on motors and motor efficiency. Up to 70% reduction in the overall number of variants in the plant can be achieved by applying the components of the VLT FlexConcept. In many cases we are able to provide end-to-end solutions for conveyor applications with just a few variants, so spare parts stocks can be considerably smaller than is currently the case.

The new VLT Decentral Drive FCD 302 offers the same functionality in a decentralised converter as in the VLT AutomationDrive FC 302, which is designed for centralised plant configurations. Both have the same user interface concept in the form of a graphic message display, which can be connected to the FCD 302 on-the-fly at any time. Both devices can drive standard motors with or without encoder feedback, as well as the compact, energy efficient PM motors in our VLT OneGearDrive series.

The VLT FlexConcept offers the flexible choice of drives for centralized location in control rooms or decentral units for mounting close to or even onto the drive motors, giving you greater flexibility in plant design and maintenance.

The efficiency of these motors exceeds even the premium IE3 class defined in the new EU regulation. With only two motor types and three available gear ratios, the motor concept covers all typical versions for effective conveyor drives commonly used in the food and beverage industry. The system as a whole, comprising motor, gear unit and frequency converter, achieves an efficiency up to 90%; yielding savings of up to 25% compared with conventional systems.

To meet the stringent hygiene conditions necessary in food and beverage plants, the VLT OneGearDrive has a smooth crevice free design that leaves no hiding place for germs or food contamination. The VLT Decentral Drive FCD302 also has a durable coating designed to withstand the harshest cleaning chemicals and processes; ensuring effective wash down with no detriment to system reliability.