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Good practices in CP: 40. Reduction of energy consumption, waste generation and noise emissions by changing the technology of cutting metal bars and pipes (TEDGUM Sp. z o.o.)

Written By Polski Ruch Czystszej Produkcji on czwartek, 27 października 2022 | 10:00


photo by: TEDGUM Sp. z o.o.

 

Good practices and investments related to Cleaner Production

Example No. 40
Reduction of energy consumption, waste generation and noise emissions by changing the technology of cutting metal bars and pipes

Company:
TEDGUM Sp. z o.o.

Industry branch: automotive

Resources in question:

  • Electrical energy
  • Materials
Pollution, waste in question:
  • Waste
  • Emissions into the atmosphere (indirectly)
  • Noise
Cost (implementation of good practice): Medium
(PLN 13,500)

Description of the problem:

Among other things, the company used a worn-out frame saw of the old type (OH253/254) in its processes. The device was characterized by, among other things, reciprocating motion (with the back motion being a work motion and the forth motion being an “empty run” – a non-work motion, increasing energy consumption and machine running time). Since there are newer, better, more economical machines on the market that do not generate “empty runs”, it was decided to select a new machine.

Applied solution:
 
As part of the project, a new machine based on more modern bar and pipe cutting technology was selected and incorporated into the production process. Consideration was given to frame and band saws operating automatically (the device itself measures the successive lengths of the cut pieces based on the preset settings) and semi-automatically (the operator himself/herself measures the needed length of the cut piece, and then sets the cutting parameters – the device, however, does not require constant supervision of an employee).
A semi-automatic band saw was selected as the most suitable for the company's current needs (also from an economic point of view – taking into account purchase and operating costs). The new device consumes much less energy, is quieter, and produces less waste (thanks, among other things, to a reduction in cutting width from 2 mm to 0.9 mm), which contributes to better use of raw material (e.g., 1 or even 2 more sleeves can be cut from a single pipe, depending on its length).

Obtained benefits and effects of the implementation:

  • Reduction in electricity consumption by about 1,200 kWh/year (i.e., by about 72%).
  • Reduction of post-production waste (filings and material end sections) by about 50%.
  • Better utilization of raw material (savings of 2.2% of the input material weight due to the ability to cut more elements from a single pipe or bar)
  • Reduction of noise emissions from 80-85dB to 45-50 dB
  • Reduced operating time of the saw from 6h/d to 2 h/d (thanks to the more powerful motor, the new device is able to make 3 times as many cuts), which, among other things, reduces the time of noise caused by the device
  • Increased work comfort by reducing emission of noise and vibration as well as heat energy in the production room
  • Savings: about PLN 3,000/year (payback period: about 4.5 years)

 


Old frame saw
photo by TEDGUM Sp. z o.o.
 
 
 
New semi-automatic band saw
photo by TEDGUM Sp. z o.o.

 
Sources:
  • Report on the Cleaner Production Project No. 49.806, developed within the framework of the Cleaner Production Academy at TEDGUM Sp. z o.o.: “Reduction of noise emissions, production waste and energy consumption by changing the technology of cutting metal bars and pipes”
  • Materials (including photos) submitted by TEDGUM Sp. z o.o.


Polish version:



This material has been subsidized by the National Fund for Environmental Protection and Water Management. The Polish Cleaner Production Movement Association is solely responsible for its content.









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