The overall aim of the project in hand is to improve the energy-efficiency of a current machine program. The manufacturer Cincinnati Extrusion targets the market leadership for energy-efficiency.
Therefore as a first step the current energy consumption status of different facilities has to be examined. Subsequently, the drawing of energy balances, analysing any energy-saving potentials, proposing a catalogue of measures for further actions and planing the implementation are further steps within the optimisation process.
Project data and goals:
Project duration: 6 months
Energy measurement of all product groups
Proposing a measures for the implementation
Presenting the results at the K`07 fair in Oc. 2007
Developing energy services
Energy Services for the industry
(November 4th, 2007)
PROFES in cooperation with Cincinnati Extrusion presented their energy services at the world's largest plastics processing fair K'07 in Düsseldorf (GER). PROFES offers services ranging from energy measurement of industrial processes and energy concepts to managing ECODESIGN for energy-efficient products.
(October 22nd, 2007)
The project ended with a presentation at the world´s largest plastics fair K´2007 on energy-efficient measures. The presentation of two machines awarded with the energy-efficiency label and the presentation of the PROFES energy services as a partner of the exhibitor Cincinnati Extrusion attracted a great deal of attention and got a remarkable positive feedback.
Public Relation and Marketing
(October 20th, 2007)
"Energy saving comes naturally" was the theme of the energy-efficient program presented to the public. PROFES was in charge of preparing the technical input for the marketing campaign. Energy-efficiency was included in brochures and presentations becoming an important sales point.
(October 15th, 2007)
The change to the significantly more efficient AC drives was an essential step for the success of the project. Savings of 12-15% where realised. Additionally auxiliary components have been optimised , an internal cooling has been initiated and an integrated energy measurement has been established.
Thermography implementation
(October 5th, 2007)
After finalising the insulating, additional thermographic examinations have been conducted. The outcome was an energy saving of up to 60%. The surface temperature could be reduced from 80-150 °C to 40-60 °C as a result (the picture on the right shows the status after the optimisation has been implemented).
Thermography current status analysing
(June 6th, 2007)
During the construction process changes in the short-term run can be undertaken. One element of the current status analysis was a thermographic analysis of the production unit's radiation, having temperatures usually up to 220 °C. (the picture on the right displays the status before the optimisation has been done).
Efficiency criteria and catalogue of measures
(June 1st, 2007)
The development of energy balances is an essential tool for analysing test results, see the picture on the right hand side for an example. The developed energy criteria have been examined on economic efficiency and listed in a catalogue of measures chronologically according to their feasibility.
Current status analysis
(May 1st, 2007)
For analysing the current status energy tests of different machine types have been conducted in cooperation with the customer: Individual measurements at the manufacturer's pilot plant stations.
Overall measurements of already exisiting plants at selected customer's sites. These data where the basis for the development project.
