SAVING COST IN 3P WAY

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Lawrence Lee
6 years ago
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1 SAVING COST IN 3P WAY KAMAL AGARWAL CEO TECHNOVATION INTERNATIONAL

2 3 P s PLASTICS Material and Processing (Screw-Barrel, Die, Design) POWER EFFICIENT Power Management (Motor and Heaters) PRODUCTIVITY Automation (QMCs and Robots)

5 PLASTICS

6 PLASTICS BIMETAL SCREW BARREL

7 PLASTICS BIMETAL SCREW BARREL

8 POWER

9 POWER REDUCE POWER CONSUMPTION EFFICIENT MOTOR AND PROCESS OPTIMISATION POWER SAVING HEATERS

10 POWER HOLDING PRESSURE 30~60% POWER CAN BE SAVED COOLING 90~100% POWER CAN BE SAVED

11 POWER MOLDING CYCLE

12 POWER Power Consumption Sheet Activity Time(s) Flow(%) Pressure 80T Normal 80T Servo Power KW 1. Cycle: 18sec 2. = actual system pressure during motion. 3. Power-consumption (KW) : average of motion as input data.

13 POWER HOW The output flow of fixed pump is 100% all the time no matter flow requirement of each motion is different that cause the power-consumption more. The unused flow of each motion goes back to the oil tank according the setting pressure. All the waste power transfers into the heat that increases the oil temperature. Motor Motor SERVO Motor Fixed Pump Fixed Pump GEAR Pump 100% Flow 100% Flow 50% of power wasted 50% Flow 100% 0% Oil Tank Motion 50% 50% Oil Tank Motion 50% 0% Oil Tank FULL LOAD HALF LOAD HALF LOAD

14 POWER Case Study 650T 1 Economic Benefit Analysis Power unit price 10RS./KWH 650T Before (JSW) 650T After (JSW) Cycle Time Sec Injection Time Sec Refilling Time Sec Cooling Time Motor Power Consumption Heater Power Consumption Total Power Consumption/day Savings/day 318 units Savings INR/Month Rs 95,400 Savings INR/Year Rs 11,44,800

15 POWER Case Study 2200T

16 POWER 2200T Car Bumper

17 POWER POWER CONSUMPTION CHART RUNNING COST AFTER SERVO 0.3~0.5 UNIT/KG PF PLASTIC PROCESSING BEFORE SERVO 0.8~1 UNIT/KG OF PLASTIC PROCESSING PAYBACK IS WITHIN YEARS OF PRODUCTION AT 20HOURS/DAY

18 PRODUCTIVITY

19 PRODUCTIVITY HYD QUICK MOLD CHANGE SYSTEMS

20 PRODUCTIVITY HYD QUICK MOLD CHANGE SYSTEMS

21 PRODUCTIVITY HYD QUICK MOLD CHANGE SYSTEMS

PRODUCTIVITY HYD QUICK MOLD CHANGE SYSTEMS QMC System allows Machine User to Clamp and Declamp Mold within few minutes by means of Hydraulic Pressure

22 PRODUCTIVITY HYD QUICK MOLD CHANGE SYSTEMS QMC System allows Machine User to Clamp and Declamp Mold within few minutes by means of Hydraulic Pressure With the push of one Button, clamping and declamping becomes very easy and turn reduce production down time It provides Hydraulic and Mechanical Safety

23 PRODUCTIVITY HYD QUICK MOLD CHANGE SYSTEMS Vs TRADITIONAL CLAMPING Traditional Way Waste Time and Manpower Manual Operation can result in heavy or Loose tightening of Bolts and hence cause accident Bolts are usually broken Possibility of thread/tslot damages on the platen It needs skilled operators to change Mold QMCS Timeand Manpower can be saved by 70% Operators can just press buttons to change mold QMCS sets safe Hydraulic workin pressure and interlock with the machine Only one time installation of Clamps so No possibility of damages Only one General Operator can change mold

24 PRODUCTIVITY CASE STUDY - QMCS TOSHIBA 1300TON MACHINE (ONE MOLD CHANGE EVERY DAY) JOB INCOME AS RS 1950/HR ATLEAST (RS 1.5/TON) COST OF CLAMPS RS 11 LAKH APPROX PRODUCTION DOWNTIME SAVING 90 MINS (FOR 1 MOLD) PRODUCTIVITY INCREASED 90 MINS INCOME INCREASED RS 2925/DAY I.E. RS 87,750/MONTH BREAK EVEN ACHIEVED IN NEARLY 1 YEAR 1 MONTH. AFTER BREAK EVEN EVERY MONTH EXTRA INCOME IS RS 87,750 AND WE HAVE NOT INCLUDED THE SAVING OF ONE OPERATOR

25 PRODUCTIVITY Video Comparisions

26 PRODUCTIVITY Auto Slide QMCS Video

27 Check Points to Ask Which BiMetal Coating on Screw and Barrel? For upto 40% Glass, It must be WC 30% For Transparent Material, It must be Chrome Plated What is the Power Cost per KG of Material Processed? It should not be more than 0.5 Unit/KG Ideally should be 0.3 Unit/Kg How Much time consumed in one Die Change? If Consuming more than 10 Min, Think of QMC How Much is Operator Take Out Time? If more than 4 sec, Consider for Robots

28 Contact KAMAL AGARWAL CEO TECHNOVATION INTERNATIONAL MOBILE : WORKS : PLOT NO 11, NEPCO COMPOUND, 20/4, MATHURA ROAD, FARIDABAD, HARYANA REGD OFFICE : EXCEL 502, IMPERIAL ESTATE, SECTOR 82 FARIDABAD, HARYANA

29 THANKS QUESTIONS PLEASE

ORIGINATED FROM CLASSIC. TRX Series Injection Molding Machine

ORIGINATED FROM CLASSIC. TRX Series Injection Molding Machine TRX Series Injection Molding Machine ORIGINATED FROM CLASSIC TRX SERIES IMM IS ONE CLASSIC PRODUCT DELEVOPED METICULOUSLY BY TEDERIC AND THROUTH CONTINOUS IMPROVEMENT, LARGE FIELD PRODUCTION LINE, CLAMPING