Can High Output and Low Energy Consumption be married? Reifenhäuser says: Yes they can

Size: px

Start display at page:

Download "Can High Output and Low Energy Consumption be married? Reifenhäuser says: Yes they can"

Johnathan Shaw
6 years ago
Views:

1 2009 Flexible Packaging Symposium Mumbai / New Delhi Can High Output and Low Energy Consumption be married? Reifenhäuser says: Yes they can Reifenhäuser Extrusion GmbH & Co.KG, proprietary information, all rights reserved

2 Cast Film Lines combined with REItruder Twin - Screw - Technology

3 Improving your ROI High Output low Energy Consumption Saving on Resin Cost Higher Productivity by minimizing of down times High Flexibility - Only one Production Line for different Products Saving on Energy Cost 3

4 Savings on total Production Cost Key Elements of production costs resin down time interest energy labour costs 4

5 Technical overview Twin Screw Technology Dosing Dosing screw Vacuum Domes P1 P2 P3 P4 P5 Intake Zone Mixing Zones Pump 1 Pump 2 Protection screen Backflush screen Die Vacuum Pump

6 6 Technical overview Twin Screw Technology

7 Improving your ROI High Output low Energy Consumption Saving on Resin Cost Web width adjustment During Production without Die deckling possible Why? Dosing Up to 40% Refeeding possible Vakuum Domes P1 P2 P3 P4 P5 Intake Zone Mixing Zones Pump 1 Pump 2 7

Improving your ROI High Output low Energy Consumption Dosing Higher Productivity by minimizing of down times Dosing screw Vacuum Domes P1 P2 P3 P4 P5 Intake Zone

8 Improving your ROI High Output low Energy Consumption Dosing Higher Productivity by minimizing of down times Dosing screw Vacuum Domes P1 P2 P3 P4 P5 Intake Zone Mixing Zones Pump 1 Pump 2 Why? Absorbing of monomers direct during Extrusion Process! Vakuum Pump Production Stops for Cast Roll cleaning can be minimized!!!!! 8

9 Improving your ROI High Output low Energy Consumption High Flexibility - Only one Production Line for different Products PP PE, PET EVA, TPU Filler Ca Co

10 Improving your ROI High Output low Energy Consumption

11 Improving your ROI High Output low Energy Consumption Saving on Energy Cost Copper cooling rolls for cast film process 11

12 Improving your ROI High Output low Energy Consumption Saving on Energy Cost Copper cooling rolls for cast film process T [ C] Outer sheel made from steel or copper 20 λ Kupfer λ Stahl α ΔT steel or copper 10 α Cooling water Plastic film 12

13 Improving your ROI High Output low Energy Consumption Saving on Energy Cost Advantages of copper shelled cooling rolls Cooling water of higher temperature can be used with identical heat transfer times The total energy consumption of the chilling unit can be reduced The Line speed can be increased Haze and transparency of the film can be better influenced The line capacity can be increased 13

14 Optimizing of cast film lines concerning energy consumption EAP: Extrusion heat-up program An intelligent heat-up program copes with individual heating-up times of the extrusion section

501-1-60-33D Conventional drive technology RT 501-1-60-33D-ht REItorque

15 Optimizing of cast film lines concerning energy consumption REItorque drive technology (EP ) Comparsion of extruder construction RT D Conventional drive technology RT D-ht REItorque direct drive motor 860 mm 520 mm 1 = Motor 2 = coupling 3 = gearbox 1 = drive motor

16 Optimizing of cast film lines concerning energy consumption REItorque drive technology Advantages: no need for a mechanical gearbox due to the lack of gearbox, the extruder screw can be removed from the back through the drive unit vibration-free operation (no mech. gearbox) low noise level backlash-free running no need for an external fan free of mechanically wearing parts the extruder is almost maintenance-free due to the lack of gearbox and power transmission belts space-conserving design (approx. 30 % smaller footprint) small space requirement especially for coextrusion lines water cooling (heat recovery is possible) efficiency increased by approx. 8% (mean value)

17 Optimizing of cast film lines concerning energy consumption Return on investment direct drive extruder from customer s viewpoint: Ø Nm = 8,33 Cent / kwh (Energy price) = 1,23 Cent / kwh (Energy tax) = 8000 h / a (production hours per year) = Nm (Motor torque) = 125 min -1 (Motorspeed) = 0,98 (cos φ Motor) = 0,92 (cos φ gearbox) K K K St t a M t2 n t2 η ϕ η G K K K + K St = 8,33 + 1,23 = 9,56 Cent / kwh ges = = 0,0956 / kwh M n P V = t2 t2 (1 η ) 9550 η G ϕ P V = (1 0,92) =11,75 kw ,98 W = t 11, = kwh a K V = P V a = K W a ges = 0, K V =8.986 = / a / a

18 Please remember! Savings on total Production Cost Key Elements of production costs resin down time interest energy labour costs 18 CF -V

19 Improving your ROI High Output low Energy Consumption Can High Output and Low Energy Consumption be married? Reifenhäuser says: YES they can

20 Thank you for your attention For more details on improving your ROI, your Fexibility Please contact your Extrusioneers

Advances in Twin Screw Compounding Technology

Advances in Twin Screw Compounding Technology Extrusion technology from micro to production scale Ing. Manfred Dobersberger 19.08.2011 Labor- and Pilotanlagen für die Kunststoffverarbeitung, Dr. Collin