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
Cast Film Lines combined with REItruder Twin - Screw - Technology
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
Savings on total Production Cost Key Elements of production costs resin down time interest energy labour costs 4
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 Technical overview Twin Screw Technology
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 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
Improving your ROI High Output low Energy Consumption High Flexibility - Only one Production Line for different Products 1 2 3 PP PE, PET EVA, TPU Filler Ca Co3 1 2 3 9
Improving your ROI High Output low Energy Consumption 1 1 2 2 3 3
Improving your ROI High Output low Energy Consumption Saving on Energy Cost Copper cooling rolls for cast film process 11
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
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
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
Optimizing of cast film lines concerning energy consumption REItorque drive technology (EP 1 182 027) Comparsion of extruder construction RT 501-1-60-33D Conventional drive technology RT 501-1-60-33D-ht REItorque direct drive motor 860 mm 520 mm 1 = Motor 2 = coupling 3 = gearbox 1 = drive motor
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)
Optimizing of cast film lines concerning energy consumption Return on investment direct drive extruder from customer s viewpoint: Ø 80 11000 Nm = 8,33 Cent / kwh (Energy price) = 1,23 Cent / kwh (Energy tax) = 8000 h / a (production hours per year) = 11000 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 11000 125 P V = (1 0,92) =11,75 kw 9550 0,98 W = t 11,75 8000 = 94.000 kwh a K V = P V a = K W a ges = 0,0956 94.000 K V =8.986 = / a / a
Please remember! Savings on total Production Cost Key Elements of production costs resin down time interest energy labour costs 18 CF -V
Improving your ROI High Output low Energy Consumption Can High Output and Low Energy Consumption be married? Reifenhäuser says: YES they can
Thank you for your attention For more details on improving your ROI, your Fexibility Please contact your Extrusioneers