Can High Output and Low Energy Consumptionbe married ?

2009 Flexible Packaging SymposiumMumbai / New Delhi

Reifenhäuser says:

Yes they can

© Reifenhäuser Extrusion GmbH & Co.KG, proprietary information, all rights reserved

Cast Film Lines combined withREItruder Twin - Screw - Technology

3

Improving your ROIHigh 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

Savings on total Production Cost

4

Key Elements of production costs

resin

down time

interest

energy

labour costs

Dosing

Die

Mixing ZonesIntake Zone

VacuumDomesDosing screw

VacuumPump

P1 P2 P3 P4 P5

Protection screen

Pump 1

Backflush screen

Pump 2

Technical overview Twin Screw Technology

6

Technical overview Twin Screw Technology

7

Improving your ROIHigh Output low Energy Consumption

Saving on Resin Cost

Dosing

Mixing ZonesIntake Zone

VakuumDomes P1 P2 P3 P4 P5

Pump 1Pump 2

Web width adjustment

During Production

without Die deckling possible

Why ?Up to 40% Refeedingpossible

8

Improving your ROIHigh Output low Energy Consumption

Higher Productivity by minimizing of down timesDosing

Mixing ZonesIntake Zone

VacuumDomesDosing screw

Vakuum Pump

P1 P2 P3 P4 P5

Pump 1Pump 2

Why?Absorbing of monomers

direct during Extrusion Process!

Production Stops for Cast Roll cleaning can be minimized !!!!!

9

Improving your ROIHigh Output low Energy Consumption

High Flexibility- Only one Production Line for different Products

1

2

3

1

2

3

PP

PE, PET

EVA, TPU

Filler Ca Co3

Improving your ROIHigh Output low Energy Consumption

1

2

3

1

2

3

11

Improving your ROIHigh Output low Energy Consumption

• Saving on Energy Cost

Copper cooling rolls for cast film process

12

Improving your ROIHigh Output low Energy Consumption

• Saving on Energy Cost

T [°C]

20

10

Stahlλ

α

Kupferλα

Outer sheel madefrom steel or copper

ΔT steel or copper

Cooling water

Plastic film

Copper cooling rolls for cast film process

13

Improving your ROIHigh Output low Energy Consumption

• Saving on Energy Cost

Advantages of copper shelledcooling rolls

Cooling water of higher temperature can beused with identical heat transfer timesThe total energy consumption of the chillingunit can be reduced

The Line speed can be increased

Haze and transparency of the film can bebetter influenced

The line capacity can be increased

Optimizing of cast film lines concerningenergy consumption

EAP: Extrusion heat-up program

An intelligent heat-up program copes with individualheating-up times of the extrusion section

Optimizing of cast film lines concerningenergy consumption

REItorque drive technology (EP 1 182 027)Comparsion of extruder construction

520

mm

860

mm

Conventional drive technology REItorque direct drive motorRT 501-1-60-33D-ht

1 = Motor 2 = coupling3 = gearbox

1 = drive motor

RT 501-1-60-33D

• 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 transmissionbelts

• 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 concerningenergy consumption

REItorque drive technologyAdvantages:

Return on investment “direct drive extruder“ from customer‘s viewpoint: Ø 80 – 11000 Nm

Optimizing of cast film lines concerningenergy consumption

= 8,33 Cent / kWh (Energy price)= 1,23 Cent / kWh (Energy tax)= 8000 h / a (production hours per year)

kW11,75=)92,01( 98,0 · 9550

125·11000−VP =

a/ €8.986=94.000 · 0,0956 W· K ages =VK =

8000 · 11,75 t· P aV =aW = kWh94.000=

= 11000 Nm (Motor torque)= 125 min-1 (Motorspeed)= 0,98 (cos φ Motor)= 0,92 (cos φ gearbox)

kWhCent / 9,561,238,33K K StK =+=+gesK = kWh/ €0,0956=

StKKK

att2nt2M

ϕηGη

VP = )1( · 9550 · t2t2

GnM ηηϕ

−

a / € 8.986 KV =

Please remember!Savings on total Production Cost

CF -V18

Key Elements of production costs

resin

down time

interest

energy

labour costs

Can High Output and Low Energy Consumptionbe married ?

Reifenhäuser says: YES they can

Improving your ROIHigh Output low Energy Consumption

For more details on improving

your ROI, your Fexibility

Please contact your Extrusioneers

Thank you for your attention