euRECIPE.com Reducing Energy Consumption in Plastics Engineering Issue 3, September 2006 News Welcome … Contact Welcome to the third issue of the RECIPE newsletter. In this edition you will find articles on RECIPE, along with energy and cost saving case studies, websites worth a visit, dates for your diary and energy saving tips. Suzanne Wilkinson RECIPE Project Manager With rising energy costs, soaring raw material prices and the impacts of climate change the need to monitor and reduce energy consumption is more important than ever before in the plastics processing industry. As with most industries, controlling costs is critical to sustainability and profitability. However energy costs can be controlled, and often reduced, by implementing measures that do not require significant investment. Energy efficiency offers short- and long-term benefits and by increasing the efficiency of a business the bottom line can be strengthened. Fax: +44 (0)01939 251118 The RECIPE project has designed materials to provide the plastics processing industry with the information and tools necessary to make energy-wise decisions. Factsheets, benchmarking tools, case studies and best practice guides are available at www.eurecipe.com. Don’t forget to register your details to make full use of the resources available. We really welcome your feedback – if you have any comments or ideas of what you would like us to cover or have an energy saving product or service, we want to hear from you. Please e-mail your comments to info@eurecipe.com. In the meantime, we hope that you find this newsletter informative and useful. Energy Saving Tools ... We Need You! The RECIPE project is currently developing two innovative, interactive software tools for the plastics processing industry. 1. The ‘Total Cost of Ownership Model’ will enable processors to calculate the cost of operating a piece of equipment over its projected lifetime, based on energy efficiency and projected usage 2. The ‘Energy Managers Toolkit’ is an online software tool to help plastics processors understand how energy is being used at their plant and how to save energy and money. The toolkit will give an overview of the energy that a plant purchases and the major systems that consume the energy and provide a report that helps the user understand where the largest opportunities are for energy and cost saving. We are looking for companies to participate in the testing process and provide us with feedback to ensure that the tools fit the needs of the industry. To participate, or to find out more, contact Suzanne Wilkinson at info@eurecipe. com or sign up at www.eurecipe.com. Tel: +44 (0)1939 252435 e-mail: info@eurecipe.com Website: www.eurecipe.com Contents Welcome Page 1 Energy Saving Tools … We Need You Page 1 RECIPE Partners Page 2, 3 Battling Electricity Price Hikes Through Energy Conservation Page 2 Now Available … Design Fundamentals for Energy Efficiency Page 3 Online Services for Europe’s Plastic Manufacturers Page 3 The Smart Way to Reduce Power Consumption Page 4 Peak Energy Savings Through Unique Thermal Insulation at the Die Plate Page 4 In the News Page 5 Case Study: Cooling Plant at LEGO Uses Water as a Refrigerant Page 6 Websites Worth a Visit Page 6 Energy Saving Technologies: Radiant Panels Page 7 Scanning the Potential Energy Reduction at CRIF Page 8 Yamauchi Saves Energy with Maguire’s LPD Vacuum Dryers Page 8 1 RECIPE Partners Rapra Technology (UK) www.rapra.net Part of the Smithers Group, Rapra is Europe’s leading independent plastics and rubber research and technology organisation providing specialist technical, commercial and information services for the polymer industry and end-user industries including the automotive, construction, electrical, medical, offshore, packaging and polyurethane sectors. Battling Electricity Price Hikes Through Energy Conservation Managing operating costs has always been a challenge for managers and business owners alike. Inflation, the economy and fluctuations in consumer demand play a significant part in the equation. Electricity is no different than other variable cost. Electricity rates continue to increase annually meaning the price for the energy needed for production and manufacturing inevitably rises year after year. Business owners are left with tough decisions and few options. Most companies are forced to pass on the increased cost to consumers. Some resort to production schemes aimed at lowering their monthly consumption by running equipment in intervals – which ultimately lowers the efficiency of operations. Others are forced to reduce operating costs by cutting jobs, reducing the hours of operation or sacrificing quality by buying cheaper components or providing fewer services. But there are ways to reduce costs and head off such drastic measures – without negatively affecting the operation of a facility. CD Power Saving offers an option that guarantees lower variable costs achievable through the design and implementation of a custom energy conservation system. CD Power Saving ‘systems’ are based on 4 elements: AIMPLAS (Spain) www.aimplas.es AIMPLAS is an innovation and technology centre based in Spain. Founded in 1990, AIMPLAS conducts research within the plastics transformation sector in order to increase the competitiveness of the plastics industry and related sectors. ASCAMM (Spain) www.ascamm.com ASCAMM is a not for profit organisation founded in 1979. It currently has over 200 members comprising of a workforce of over 4000 people. ASCAMM’s activities include specialised training, promotion of the industry and advisory services. British Plastics Federation (UK) www.bpf.co.uk The British Plastics Federation (BPF) is the leading trade association for the UK plastics industry (representing approximately 80% of turnover), a springboard for industry action, existing to exploit common opportunities and resolved shared problems. Membership encompasses producers, suppliers and processors in addition to additive and machinery suppliers and manufacturers. 2 • • • • Focus on using only power quality improving technologies Commitment to only implement projects for entire facilities Unique statistical analysis based savings modelling method 100% guarantee money back if projected savings are not reached The first step in the process requires a CD Power Saving authorised consultant to perform a basic walk-through in a client’s facility to determine if an energy conservation system will be beneficial. The consultant notes the complexity of the electrical system as well as the composition of the loads attributable to lighting, air conditioning, refrigeration and equipment. This data, supplemented with recent electric bill records, enables the consultant to perform an initial analysis. ‘This information helps us to more accurately predict the potential savings that can be achieved by implementing our conservation system,’ says Daniel De Bono, Chairman of CD Power Saving Co. Ltd. – based in Malta. ‘If the customer is interested in the estimated savings percentage, we then conduct a thorough examination of the entire facility noting every bulb, unit and motor – if it uses electricity we record it.’ CD Power Saving are affiliates of Energy Automation Systems, Inc. (EASI), a leading energy conservation design and manufacturing organisation. ‘Working with the preliminary analysis and complete electrical system survey conducted by CD Power Saving we custom design each project to fit the client’s needs and then provide a written warranty guaranteeing the project and the savings,’ states Joseph C. Merlo, founder and CEO of EASI. ‘The customer will realise numerous benefits once the project has been installed including lower operating costs stemming from reduced energy waste, the reduction or elimination of consumption penalties, increased capacity and often reduced maintenance as the electrical system runs more efficiently,’ continues Merlo. ‘While little can be done to curb public utilities from raising their rates, we can ensure that the energy we pay for is used with the highest efficiency possible. By controlling demand without sacrificing operating capabilities, firms can offset rate hikes and keep operating costs in check.’ An EASI system can be implemented in virtually any type of business setting and will significantly lower electricity costs. To learn more about an EASI energy conservation system and how it can effectively reduce a facility’s operating costs and limit the negative effects of public utility hikes, visit www.cdpowersaving.com.mt or contact Mr Daniel De Bono on +356 2148 0500 or ddebono@cdpowersaving.com.mt NOW AVAILABLE … Design Fundamentals for Energy Efficiency A series of factsheets focusing on design issues in plastics processing are now available to download from www.eurecipe.com. The factsheets provide case studies and information that demonstrate fundamental design principals, and highlight how they can lead to significant reductions in energy consumption through the implementation of best practice and the adoption of new technologies. The following factsheets are available as a PDF download: • Water as refrigerant • Energy savings with ground water cooling • Energy savings with optimised water loop design: Background and case studies • Energy savings in plastic processing RECIPE Partners CRIF-Wallonie (Belgium) www.crif.be CRIF-Wallonie started life in 1969 as CRIF Plastics; in order to answer the specific needs of the plastic processing members of Agoria. The main activities can be split into three areas; engineering of materials, including the design of high tech components in plastics and metal, smart manufacturing and process and rapid manufacturing. • Shortcut to energy reduction and cost savings in the plastic industry: Improved control strategy • Energy savings in the plastic industry: Use of phase change materials for cold and heat storage Danish Technology Institute • Software packages for minimising energy consumption in plastic moulding (Denmark) www.teknologisk.dk • Mould design aspects to minimise energy consumption To receive a copy of the ‘Design Fundamentals’ factsheets visit www.eurecipe.com or email info@eurecipe.com. Online Services for Europe’s Plastics Manufacturers Rapra Technology has added its skills and resources to the multi-national project team developing a Virtual Centre for Plastics (CVP) across Europe. The project, e-SeSME – Electronic Services for SMEs in the Plastics Supply Chain aims to ‘sell high-quality, specialised services in a simple, functional and low-cost manner to companies in the plastics processing supply chain, through the full use of IT facilities, across Europe.’ Suzanne Wilkinson is the Rapra e-SeSME co-ordinator, ‘The central idea is to provide and sell to companies in the European plastics processing supply chain (+85% SMEs) those relevant tools and services that they cannot afford themselves. The project is intended to help the industry develop, innovate and increase its global competitiveness.’ The range of on-line services will include: • e-engineering – products and services such as simulation and design packages all available through the Internet • e-learning – to help increase staff capabilities through courses accessible on the Internet • Technical information – cost-effective research, innovation, access to reports • Digital services – access to databases, links, intelligent software • Interactive software – software accessible through the web that can help with budgets, design, waste reduction The Danish Technology Institute is a not for profit organisation that promotes growth by improving interaction and encouraging synergy between research organisations, businesses and the community. Fraunhofer Institut fuer Chemische Technologie ICT (Germany) www.ict.fraunhofer.de The R & D expertise of the Fraunhofer Institute for Chemical Technology ICT is primarily geared towards products and processes in the fields of polymer engineering, environmental engineering, electrochemistry and energetic materials. Pole European de Plasturgie (France) www.poleplasturgie.com Pole European de Plasturgie (PEP) was founded in 1990 with the assistance of the plastics industry: transformers, mould and die manufacturers, machine manufacturers, plastic producers and toolmakers. It aims to increase the competitiveness of the industry by improving the research and technology developments, from design to finished product. To find out more about e-SeSME visit www.esesme.com or email swilkinson@rapra.net. 3 The Smart Way to Reduce Power Consumption The KM Economiser supplies pump and screw drives directly with magnetic current (reactive current) that would otherwise have to be bought from a utility company. The capital cost of larger dimensioned supply lines falls away because the reactive current no longer flows through these lines. Investment in the KM system pays off within a very short time and large savings can be easily tracked from lower energy costs in regular electricity bills. Semiconductor technology replaces electromechanical systems Conventional compensation systems use electrometrical relays and contacts to energise the capacitors. This has several disadvantages: • Slow, imprecise compensation • Delayed reaction to load changes • Increased wear on capacitors and switching contacts caused by high inrush loads KM uses state of the art semiconductor technology for important benefits • Electronically energised capacitors exactly at line voltage zero, no inrush current peaks • Fast, precise compensation, reaction to load ramps within 100ms. • Immediate reaction to load changes Advantages of power supply with compensation (KM-Economiser): • Extra capacity for system expansion • Reduced energy costs (no charges for reactive consumption) • Cutting power consumption is good for the environment! In fixed compensation schemes, the compensation is defined for a specific motor performance (e.g. 0.92 of rated load). In an injection-moulding machine, however the actual motor performance changes with the injection cycle (30 to 120%). The advantage of dynamic compensation is that the compensation is continuously matched to actual motor performance. This ensures that reactive current compensation is always optimised. For further details contact: Krauss-Maffei Kunststofftechnik GmBH, KS1/Service, Injection moulding machines, D-80997 Munich. Tel: +49 89 8899 3121, Fax: +49 89 8899 1721, e-mail: meiserj@krauss-maffei.de “ Making good use of daylight in a typical small office can reduce lighting costs by up to 15% ” Peak Energy Savings Through Unique Thermal Insulation at the Die Plate In normal underwater granulators there is a great difference between the process water temperature and the die plate temperature (up to 250K). This can lead to the danger of individual holes ‘freezing’ over during the granulation process. In addition, the running surfaces are usually made of hard metal with high thermal conductivity and these are attached to the supports of the die plate. This results in high heat energy losses and cooling of the die plate. A new technology has been developed by ECON to avoid these unwanted properties. A ceramic (or CECONID®) with low thermal conductivity was selected as the material for the die plate and mounted on the supports with heat engineering insulation. This arrangement leads to minimum heat energy transfer into the process water, reducing the energy required for heating the supports by more than 70%. Additionally, this energy is not diverted into the process water, which would require cooling during production, and increase energy consumption. The plastic melt is kept at the melt temperature until output through all the nozzles is complete and is only cooled when it enters the process water. The result is extremely uniform, round, high quality granulate while maintaining working temperatures at the supports (melt protection). In addition, the system is user friendly and process stability is increased by several factors. For further information contact ECON Future Systems at www.econ.co.at 4 In the News … First BASF Plastic with Eco-efficiency Label Energy Facts Just one year after its market introduction, Ultradur® High Speed, BASF’s new especially easy-flowing PBT (polybutylene terephthalate), has become the company’s first engineering plastic to receive the so-called eco-efficiency label. Studies have demonstrated that products made of Ultradur® High Speed are considerably more eco-efficient than products made of a standard PBT. The good flowability of this new material not only makes the production of injectionmoulded plastic components cheaper but also helps to save energy, thus protecting the environment. • A typical window left open overnight in winter will waste enough energy to drive a small car over 56 kilometres. Processors benefit from the flowability of Ultradur® High Speed, which has been improved by incorporating a nano additive, since the processing temperature as well as the injection and holding pressures in the injection moulding machine can be lowered. Energy savings of up to 20 percent can be realised here. As an alternative, the cycle time can be reduced by up to 30 percent. The mould can have a simpler design and new parts can have thinner walls, thus saving a considerable amount of material. The number of rejects also drops as it is now easier to fill the mould with this easy-flowing plastic. The eco-efficiency label is awarded to products or methods that perform better from an environmental and financial standpoint than comparable products or methods. Additional information regarding the new Ultradur® High Speed is available at www.ultraplaste.infopoint@basf or www.basf.de/ultradur. Information about the eco-efficiency analysis is available at www.oeea.de. Technologies to Fight Climate Change With its CO2 Emissions Trading Scheme in place, Europe has resolutely opted for a ‘market pull’ approach to bring clean technologies onto the market in the short run. However, politicians realise new breakthrough technologies are also needed if deeper emission cuts are to be achieved in the long run (2020-2050 and beyond). This ‘technology push’ approach is currently being championed by the US, which has put in place large-scale R&D programmes with impressive budgets. However, in the absence of a viable long-term alternative (e.g. hydrogen), it appears that a mix of solutions, including energy efficiency, alternative fuels and nuclear power will be called into play. The question now is how to roll out these technologies to developing nations. Source: http://www.euractiv.com/en/energy/technologies-fight-climate-change/ article-150076 New Wind Power Record The year 2005 saw another record in wind power developments with 11,3000 MW of capacity added worldwide, of which 6,174 was in Europe, mostly in the 15 ‘old’ countries. Both the global and the European developments are records. At the end of 2005, the global capacity reached 58,982 MW, of which more than 40,000 MW are installed in the EU, reaching the EU 2010 target five years ahead of time. The development is spread among more countries and regions than before, while the installation rates in the ‘old’ wind power leaders of Germany, Denmark and Spain have decreased. In Denmark, only 4 MW was added to the capacity, similar to the installations in 2005 on the tiny Faroe Islands. The largest installation was in the USA (2424 MW of capacity added), followed by Germany (1,799 MW added), Spain (1,764 MW), India (1,430 MW), Portugal (500 MW), China (496 MW), UK (465 MW), Italy (452 MW), France (371 MW), Canada (239 MW), Austria (213 MW) and Australia (196 MW). (Source: Carbon Trust, www. carbontrust.co.uk) • The world’s annual consumption of plastic materials has increased from around 5 million tonnes in the 1950s to nearly 100 million tonnes today. (Source: www.wasteonline.org.uk) • World energy consumption in projected to increase by 59% from 1999 to 2020. Much of the growth in worldwide energy use is expected in the developing world. (Source: International Energy Outlook, EIA) • Two billion people in the world have no access to electricity. (Source: www.solarbuzz.com) • Over the last century there has been an increase in the global average temperature of nearly 1ºC. Projections show that if this trend continues, global temperatures could rise by a further one to 4 degrees by the end of the 21st century. (Source: World Business Council for Sustainable Development) • For many businesses, a 20% cut in energy costs represents the same bottom line benefit as a 5% increase in sales. (Source: www.defra.gov.uk) • Most users of compressed air can save up to 30% of the energy by simple measures such as identifying and fixing leaks. (Source: www.defra.co.uk) Source: http://www.inforse.dk/doc/SEN52.pdf 5 Case Study: Cooling Plant at LEGO Uses Water as a Refrigerant As a result of a research and development project initiated by the Danish Technological Institute, a 2MW cooling plant was built at the LEGO factory in Billund, Denmark. The plant, built in 1994, uses only water as refrigerant for process cooling water. The installation cools process water from 600 injection moulding machines producing LEGO bricks on a roundthe-clock basis. Energy savings are estimated to be approximately 50% compared to traditional technology. The Principle The process resembles a normal gas compression cycle (evaporation, compression, condensation and expansion), but the process is an open cycle whereby the water is used as both primary and secondary refrigerant. Process water at a temperature of 13.5° is fed to the evaporator where it expands to approximately 11mbar, corresponding to a saturation temperature of 8°C. Of this water, 1% evaporates and the remaining 99% is cooled to 9°C. The evaporated water, acting as the primary refrigerant (working fluid), is compressed in a two-stage turbo compressor system with intermediate cooler. The water vapour is condensed directly in the stream of injected water from the cooling tower, which is heater by some 4 – 5°C. The condenser pressure is very close to the saturation temperature of the water and the temperature difference on both sides is less than 1°C. All noncondensable gases must be removed from the cooling water before it enters the condenser. This takes place in an efficient two-stage de-aeration system. Measurements show that the power consumption of the new plant is less than half that of a conventional R22 refrigeration plant installed at LEGO Systems A/S, however, compared to a traditional plant, costs would currently be higher. Further development is still ongoing to reduce the overall production costs of the plant. For further information, contact the Danish Technological Institute at www.danishtechnology.dk 6 Websites Worth a Visit Intelligent Energy – Europe Programme Intelligent Energy – Europe (IEE) is a main means of converting EU policy for smart energy use and more renewables into action on the ground, addressing today’s energy challenges and promoting business opportunities and new technologies. IEE supports European projects, one-off events and the setting up of local/regional energy agencies with a total budget of €250 million covering up to 50% of the costs. The programme currently supports more than 200 international projects, 30+ local/ regional energy management agencies and almost 40 European events in the areas of • new and renewable energy sources • energy efficiency, notably in buildings and industry • energy aspects of transport • co-operation with developing countries A new call for proposals has been published in May 2006. For further information, visit http://ec.europa.eu/energt/intelligent/index_en.html European Environment Agency The aim of the European Environment Agency is to establish a seamless environmental information system. This is done to assist the Community in its attempts to improve the environment and move towards sustainability, including the EU’s efforts to integrate environmental aspects into economic policies. The EEA supports sustainable development and to help achieve significant and measurable improvement in Europe’s environment through the provision of timely, targeted, relevant and reliable information to policy making agents and the public. To find out more, go to http://www.eea.europa.eu/ EuPC EuPc is the professional representative body of plastics converters within Europe whose activity embraces all sectors of the plastics converting industry including recycling. The Association focuses its activities on market development as well as on the issues management and the common problems affecting plastics converters such as Health and Safety, environment, raw materials, trade or communication. For further details, visit http://www.eupc.org Arbeitsgemeinschaft Verstärkte Kunststoffe Technische Vereinigung e.V. is the professional agency representing suppliers of raw materials and processors of reinforced and filled plastics. AVK is a member of the European Composites Industry Association (EuCIA), the European parent organisation of the national industrial associations for reinforced plastics. AVK’s activities include: • Workshops offering help to solve primary questions affecting the industry, e.g. technology and marketing reinforced and filled plastics • Professional seminars in collaboration with inspection departments and other scientific institutes, as well as an annual international conference and exhibition To find out more about AVK’s activities, visit http://www.avk-frankfurt.de/ www_avktv/home_1_1_1_f.htm Energy Saving Technologies: Radiant Panels The Product The radiant panels (or Catalytic flameless heaters) are devices that transform the calorific energy of gas fuels into infrared energy. The oxidation can occur in different conditions of temperature, speed and reaction. Flame combustion takes place at high speed, whereas catalytic reaction is a low speed and creates an infrared spectrum, which is absorbed by most materials used in industry. The Technology The principle of the technology is to convert gas through a ceramic medium at below ignition temperature into infrared energy without flame. This ensures that there are no harmful by-products with the exception of CO2 and H20, which is also minimised in the conversion process. The important factor is that the wavelengths produced fall within the absorption spectrum of the majority of materials used in industry today so that these materials will absorb the emitted infrared energy ultimately leading to the required process curing of the product. Characteristics The panels can be regulated within a range of surface intensities from 1.5 Kcal/h per sq. cm. The surface temperature ranges from 250 °C to 400 °C. The emission intensity can be calibrated between 3 – 6 microns. The complete absence of flame makes the apparatus intrinsically safe in environments where there are explosive risks. Effects The panel fuel requirements are only 30% or less against a conventional burner to achieve the same result in energy output. EST panels are flameless catalytic burners, and are risk free of fire or flame propagation. • The catalytic panels are intrinsically safe and explosion proof, as the surface absorbs and oxidises VOC’s without provoking explosion. • Unlike flame combustion, the catalytic panels are not sensitive to atmospheric variations as there is only gas in the feed chamber, not a mix of gas and air. • The panels used under the manufacturers guidelines are not subject to transformation, degradation or deterioration. • The panels transform all gases into useful calorific value so that its performance is practically 100/100. About EST Energy Saving Technologies Ltd. has spent many years researching and designing solutions related to energy conservation and environmental concerns. They have cooperated with major industrial outlets throughout Europe in the design of systems using Catalytic infrared for curing processes. This has resulted in comparison of energy usage against conventional systems, and CO2 emission testing. Case studies have shown that EST systems have saved over 70% in energy and reduced emissions by up to 84%. The product and technology has achieved a successful characterisation study by the Department of Particle Science and Engineering at Leeds University. Research work has also focused on the curing of polymer-based materials and by matching the infrared field (absorption spectrum) of the materials the curing and process times are reduced dramatically. Aluminium Extrusion Project Diary Dates PU China 2006 5th–7th September 2006 Shanghai, China http://www.puchina.nl ENERGY 2006 7th–8th September 2006 Solihul, UK http://www.energy2006.co.uk TIPREX 2006 14th–17th September 2006 Bangkok, Thailand http://www.tiprex.com/ the_event.html PDM 06 26th–28th September 2006 Telford, UK http://www.pdmevent.com/ FAKUMA Fair 17th–21st October 2006 Friedrichshafen, Germany http://www.fakuma-messe.de/ de/fakuma Iran Plast 06 7th–11th November 2006 Tehran, Iran EuroMold 2006 29th November– 2nd December 2006 Frankfurt, Germany http://www.euromold.com Plast Eurasia 2006 29th November– 3rd December 2006 Istanbul, Turkey http://www.plasteurasia.com/ For further information contact Stephen W Webb at swwebb@btconnect.com 7 Scanning the Potential Energy Reduction at CRIF At the Belgium Research Centre for the Manufacturing Industry (CRIF), a new method of energy consumption testing is being tested. The aim is to first, reduce their own energy consumption and see if the method can be generalised and adapted for the plastics processing industry. The CRIF method is based on an exhaustive report of all equipment and facilities that consume energy and fluids, (electricity, water, gas, oil etc.). An initial evaluation is made based on the consumption over a twelvemonth period, taking into account every process and product. It will then be possible to assess which are the most energy consuming processes and/or products and highlight potential energy reductions. Following the Energy Consumption Analysis (ECA) the equipment responsible for most of the energy consumption will be identified. This will then be ‘scan’ the potential energy reduction and estimate the relevance of difference solutions to improve the energy efficiency. All possible solutions identified are assessed in terms of feasibility and financial viability to assist the decision makers within an organisation and provide a method of verifying the results obtained. Computer software processes the consumption data and attributes an ‘energy efficiency index’ and a ‘CO² emission index’ to the product. This ‘Energy Potential Scan’ (EPS) method analyses the changes in the index from one year to the next, demonstrating immediately if the organisation has successfully reduced their energy consumption. The main advantage of this method is that the index is completely independent of level of production and outside temperature; therefore the comparison is made on a sound basis. For further information regarding the EPS method at CRIF, contact Jacky Lecomte, Tel: +32 43618700, e-mail: jacky.Lecomte@crif.be 8 Yamauchi Saves Energy with Maguire’s LPD Vacuum Dryers The Yamauchi Corporation’s production subsidiary in Hasselt, Belgium has recently installed Maguire vacuum drying technology to improve drying performance of their polyamide-based materials and dramatically reduce the Company’s expenditure on energy supply. Yamauchi Belgium, a global producer and supplier of moulded plastic components for the audio, video, car and battery industries, optimized production by introducing a cell based system that utilises 3 Maguire LPD 100 dryers each feeding a series of injection moulding machines. The installation, supplied by Maguire’s distributor in Belgium PME of Zottegem, replaced12 hot air dryers previously employed to do the same job. An expensive by-product of the previous drying system was the excessive air temperature released into the factory. This air needed to be cooled down to acceptable working temperatures, greatly increasing the Company’s energy consumption and costs, particularly in the summer months. Energy Saving Hot Dryers LPD 100 12 3 5664 hours 5664 hours 6 kW 2 kW €0.041925 €0.041925 Consumption - 24hrs 1728 kW 144 kW Cost - 24hrs €72.44 €6.03 Cost – 1 year €17097.35 €1424.77 No. of machines Usage (hours/year) Consumption (kW/hour) Cost (kWh) €15672.57 (92%) Yearly Saving Rudi Vermeulen, Technical Manager, says that the investment in LPD 100 Vacuum Dryers will give full return on investment within 2 years. He adds that not only is the cost saving coming from increased productivity, reduced scrap and energy cost saving, but the simplicity of having 3 dryers instead of 12. For further information contact the Yamauchi Corporation at www.yamauchi.be Supported by the European Commission under the Intelligent Energy - Europe Programme The sole responsibility for the content of this newsletter lies with the authors. It does not necessarily reflect the opinion of the European Communities. The European Commission is not responsible for any use that may be made of the information contained therein.