Conveyor upgrade brings Coca-Cola HBC one step closer to net zero
ITALY: Coca-Cola HBC has set the goal of achieving net-zero emissions across its entire value chain by 2040 with the NetZEROby40 program, making steady progress toward this goal every year. At the Coca-Cola HBC plant in Nogara, a targeted conveyor upgrade based on Danfoss FlexConcept delivers significant energy savings and reduces maintenance requirements, demonstrating how greater efficiency can be achieved with the right technology.
The Coca-Cola HBC plant based in Nogara, in the province of Verona, is the largest Coca-Cola HBC production site in Italy. it is the first in Europe in terms of production capacity and operates 24/7 under strict hygiene requirements.
After many years of continuous operation, the conveyor belt system had reached a point where ageing gearboxes and worn components were taking a toll. The crate and conveyor sections were running with reduced efficiency, and the maintenance workload had become unnecessarily heavy.
The previous setup relied on decentralized 0.75 kW variable frequency drives (VFDs) paired with legacy geared motors drawing approximately 0.5 A at no load and 0.6 A under load. This translated into unnecessarily high energy consumption and frequent service needs, impacting both operating costs and environmental footprint.
To reduce maintenance demands and improve energy efficiency, Coca-Cola HBC Italy partnered with Danfoss to upgrade selected conveyor sections.
With Danfoss FlexConcept®, the old VFDs were replaced by VLT® Decentral Drive FCD 302, and the legacy gear units were exchanged for VLT® OneGearDrive® units. The new VFDs match the 0.75 kW rating of the previous equipment, while the VLT® OneGearDrive® units deliver super premium efficiency (IE5 class), significantly outperforming the earlier technology.
The new system also features a hygienic design and IP66/IP69K options, making cleaning simpler and supporting the stringent sanitary standards of the Nogara plant.
Energy measurements taken at the drive input side show a substantial reduction in electricity consumption:
• ~40% less energy intake at no-load current
• ~33% less energy intake at loaded current
These figures are based on two adjacent conveyor sections performing the same function — one upgraded, one left unchanged — providing a clear, like-for-like comparison.
Scaling the upgrade across multiple conveyor sections multiplies these savings while further reducing heat losses to the surrounding environment.
With Danfoss FlexConcept®, the number of VFD and motor variants is significantly reduced, lowering spare parts requirements and minimizing training and commissioning time.
Maintenance needs are also notably lower in the new setup. The VLT® OneGearDrive® offers extended service intervals, including an oil-change interval of approximately 35,000 operating hours.
Easy asset management: DrivePro® 360Live
As part of the upgrade, all assets were registered in DrivePro® 360Live: an app that allows Coca-Cola HBC and Danfoss to track equipment condition, ensure timely maintenance, and keep operations running smoothly
By introducing Danfoss FlexConcept® on our conveyor lines, we have achieved a clear reduction in energy use and maintenance effort. The system runs more cleanly, quietly, and more efficiently – perfectly supporting the sustainability goals of our plant.
Discover how to maximize uptime with the Danfoss FlexConcept® system
Danfoss FlexConcept® combines modern motor technology with the most advanced inverter drives. This flexible unified drive system offers cost savings via high efficiency, robust reliability and variant reduction.
Read more about Danfoss FlexConcept®
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Optimize your variable-frequency drive (VFD) maintenance with DrivePro® 360Live, an advanced solution for managing your entire installed base at every plant globally. With it, you get customized dashboards and reports to forecast and schedule maintenance, repairs, and upgrades, all tailored to your specific maintenance strategy plan and operational needs.
A highly efficient combination of a permanent magnet motor and optimized bevel gearing.
Thanks to its rugged design, the FCD302 drive can be mounted close to motors in demanding applications.
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