GMG 1302

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Three Simple Ways to Reduce Energy Consumption WIDIA & partners Fastenal & Hi-Speed Corp. join the team February 2013

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Green Manufacturing Guide for February 2013

Transcript of GMG 1302

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Three Simple Ways to

Reduce Energy Consumption

WIDIA & partners

Fastenal & Hi-Speed Corp. join the team

February 2013

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Green Manufacturing Guide™ is published twelve times a year on a monthly basis by H&F Media, Inc., 2070 Valleydale Rd, Hoover Al 35244 USA. Green Manufacturing Guide™ is distributed free to qualified subscribers. Non-qualified subscription rates are $57.00 per year in the U.S. and Canada and $84.00 per year for foreign subscribers (surface mail). U.S. Postage paid at Birmingham, Alabama and additional mailing offices. Green Manufacturing Guide™ is distributed to to qualified owners and managers in the industrial industry. Publisher is not liable for all content (including editorial and illustrations provided by advertisers) of advertisements published and does not accept responsi-bility for any claims made against the publisher. It is the advertiser’s or agency’s responsibility to obtain appropriate releases on any item or individuals pictured in an adver-tisement. Reproduction of this magazine in whole or in part is prohibited without prior written permission from the publisher.

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Company Pg. Website

Continentail Pipe & Tube 29 www.continentalcutoff.com

Dee Zee IBC www.deezee.com

Eagle Bending 32 www.eaglebendingmachines.com

Gorbel BC www.gorbel.com

Greaves 21 www.greaves-usa.com

Jesco 25 www.jescoonline.com

Jet Edge 19 www.jetedge.com

Johnson Bros 11 www.johnsonrollforming.com

Krenz Vent 10 www.krenzvent.com

LEDtronics IFC www.ledtronics.com

Phase-A-Matic 17 www.phase-a-matic.com

Provent 31 www.proventilation.com

Quick Screws 7 www.quickscrews.com

Ram Mount 15 www.ram-mount.com

Revere Controls 5 wwww.reverecontrol.com

Rigid Lifelines 1 www.rigidlifelines.com

Shopbot Tools 27 www.shopbottools.com

Shop Data System 9 www.shopdata.com

Steelman Industries 10 www.steelman.com

Tractel 23 www.tractel.com

Warehouse Equipment 6 www.warehouseequipment.com

Inside This Issue:

Electrical Cable Tray Fire Protection in Chemical and Petroleum Refineries

Three Simple Ways to Reduce Energy Consumption

WIDIA & partners Fastenal & Hi-Speed Corp. join the team

SETCO EXPANDS GLOBAL SPINDLE SERVICE NETWORK INTO ASIA

Lincoln Electric Welding Technology Takes Center Stage at Siemens Mobility Division’s Green Manufacturing Facility

Our Advertisers:

412242830

Three Simple

Ways to

Reduce Energy

ConsumptionWIDIA &

partners

Fastenal &

Hi-Speed Corp.

join the team

February 2013

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Protection By Separation American Petroleum Industry (API) 2218, Fireproofing Practices in Petroleum and Petro-chemical Processing Plants, provide guidelines for “selecting, applying, and maintaining fire proofing materials that are designed to limit the extent of fire-related property loss in the petroleum and pet-rochemical industries.” Separating refinery opera-tions into fire zones that can be isolated and safely shut down is a key objective, so if a fire breaks out, the flow of the product being refined doesn’t feed the fire.

The API 2218 guidelines include a variety of protective measures, including fireproofing to improve the capacity of equipment and its sup-port structure to maintain their structural integrity during a fire. Shielding essential operating systems when they are exposed to fire is another important measure.

To protect the refinery and its components, the standard requires control valves that turn off the flow in the event of a fire, along with control cables that signal when to shut off the fuel. Under the API standards, this control valve and cable must itself be able to withstand a fire, usually for 20 minutes, but in some circumstances for 30 minutes or more. Examples of cable tray systems

designed to protect the cables from fire include: •Vendor-certified fireproofed cable tray systems

•Standard cable trays completely enclosed with insulating, fire-resistant fiber mats, or endothermic mats

•Cable trays encased with calcium silicate insulat-ing panels with calcium silicate sleepers to hold cables away from bottom of the cable tray

•Trays with exterior surfaces made of galvanized sheet metal coated with mastic or intumescent fireproofing material.

The material used to provide 30-minute fire protection against a hydrocarbon pool fire for grouped electrical cables inside conduit or a cable tray must be tested before installation, using the ASTM E 1725-95 method, Standard Test Methods for Fire Tests of Fire-Resistive Barrier Systems for Electrical System Components. The method is based on a model of the type of fire that could happen at a refinery; one that gets to 1500°F at 3 minutes, and between 1850 to 2150°F after 5 minutes. Testing is carried out in accordance with hydrocarbon pool fire temperature-curve condi-tions outlined in ASTM E 1529 (50,000 +/-2,500 BTU/ft2hr).

The test is run at positive pressure over at least half the test assembly. Thermocouples are

Electrical Cable Tray Fire Protection in Chemical and

Petroleum RefineriesFinding the best option for

protecting cables and valves

By Clay Booth, Fire Protection - Market & Sales Manager,

Morgan Thermal Ceramics

One of the most significant fire protection requirements for refineries and other offshore locations is the need to protect con-trol cables and control valves in the event of a fire. Several alter-natives are on the market, including fire blanket systems, calcium silicate board, and flexible mats that absorb heat in the event of a fire. Each has its benefits and refinery operators need to weigh up the pros and cons of the available cable fire protection solutions to ensure that they select one that is the best for a particular application.

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arranged in sets, with thermocouples peened every 6 inches on both rails of the cable tray, and every 6 inches on a bare copper wire centered in the tray. The cable tray is intended to be run empty of cables, which provides approval for zero to 100 percent cable loading. Failure is determined when one “set” reaches an average temperature rise of 250°F, or any single thermocouple reaches a temperature rise of 325°F.

Options for meeting fire protection standards

A wide range of options are available to protect control valves and grouped electrical cables against extended exposure to fire and maintain control of equipment operated by the cables.

One option involves wrap-ping cable trays and conduits with a nonflammable high temperature resistant insulating blanket. The fire exposure period is rated in propor-tion to the wrap thickness and the material is typically weatherproofed in the field.

For example, FireMaster® 607 Blanket (Figure 1) produced by Morgan Thermal Ceramics is a flexible blanket composed of high temperature fibers classified for applications to 2192°F. The core fibers are manufactured using the patented Superwool® fiber technol-ogy, which uses a low bio-persistent insulating wool, reducing the risk for installers. The blanket wrap system consists of a single layer of 2-inch, 8 pound per cubic foot material, and is designed for up to 12-inch cable trays and conduits. The lightweight flexible blanket wrap is easy to cut, reducing installation problems in

Figure 1

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complex designs. A simple wrap design allows easy re-entry for cable modifications. The insula-tion is supplied with full encapsulation in a glass fiber reinforced foil and polypropylene (FSP) facing as standard, to provide superior handling strength for installation. Optional weather and mechanical abuse protection may be added. The FireMaster® fire protection system results in signif-icant material cost and labor savings compared to composite products or rigid board installations. It is also lightweight, preventing the need for addi-tional support structures and associated costs.

The blanket wrap system has achieved third-party certification through Factory Mutual (FM) Approval, a global program that includes objectively testing property loss prevention prod-ucts and services and certifying those that meet rigorous loss prevention standards.

Figure 2 shows the material used in a cable tray application. Figure 3 shows a close-up of an application, demonstrating the material’s versatili-ty.

Another available option is calcium silicate board, an inorganic, noncombustible high tempera-ture insulation. The material can offer some weath-er resistance and durability in many environments, but it can be heavy (around 54 pounds per cubic foot), which together with the cutting and fasten-ing methods required, makes it relatively difficult to install.

In addition, while the board itself is rela-tively inexpensive, the waste from cutting and the additional labor required for cutting and fastening, makes it expensive to install. It is also less adap-tive to complex cable tray runs.

A third option is an endothermic mat

Figure 2- Cable fire protection using FireMaster Blanket Wrap

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Figure 3- Installations in complex designs

(e-mat), which protects structural steel, cable trays, and conduit circuits by chemically absorbing heat energy, blocking heat penetration. The product requires the installation of between three to five layers, resulting in increased weight and material costs – up to five to ten times higher than insulation or board alternatives. These multilayer solutions also have additional labor costs. On the plus side, flexible mat solutions are not as insulating, so they can often be used to protect power cables, which generate heat. The other options discussed are more appropriate for use to protect control cables, which do not generate a significant amount of heat.

The intent of petroleum industry standards is to separate refinery fire zones by enough distance so that if a fire breaks out, it is possible to turn off the flow of chemicals, oil, or gas to the affected area so the fire does not feed itself. In that sce-nario, the cables and valves controlling the shut-off valves must be adequately protect-ed. When selecting the most appropriate options to maintain control over these components, be sure to evaluate the total material costs, labor and installation costs, durability under the particular facility’s location, and any associated differences in long term maintenance and replacement costs.

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Three Simple Ways...

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by Matt Albright, Product Manager

The Lincoln Electric Company

in Your Welding

Operations

...to Reduce Energy

Consumption...

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Today’s manufacturers face a daunting challenge: Running a production line that not only delivers quality product on time and on budget but also meets various demands for energy efficiency and savings. Welding operations in any manufac-turing facility are no exception. In fact, welding annually consumes at least $15 million worth of electricity in the United States and about $99 mil-lion worldwide.

Today’s manufacturing environments need an energy-efficient, reliable welding program that not only produces quality welds using multiple processes but also saves on operating and elec-tricity costs. If you’re ready to boost the overall efficiency and reduce energy requirements of your facility’s welding operations in efforts to achieve this goal, consider following these three, easy steps:

1) Assess your existing equipment’s efficiency

Take a hard look at your welding shop and de-termine a time to make crucial upgrades that will increase overall productivity and quality as well as energy efficiency.

Welding equipment is no exception, seeing that it can be a major power consumer on the shop floor. Rather than living by the old adage, “If it’s not broken, don’t fix it,” ask yourself this: “Are our current welding power sources maximizing energy savings and efficiency?”

Chances are if they are more than even five years old, they’re not. Even if they’re running in like new condition, older welding power sources lack the energy-saving capabilities of newer technol-ogy. While the upfront cost of upgrading might seem a bit daunting, the payback on upgrades may be faster than you think.

The latest welding power sources offer many bene-fits on the production line – from increased weld quality and deposition to increased energy efficien-cy. New software-driven production monitoring capabilities are also available.

To determine if your existing equipment is putting a dent in your bottom line, follow these

steps:

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•Step 1 – Calculate output power Take the output voltage, which is given as volts on your welding power source, and then multiply it by the output current, found on your power source in amps. The total is known as output power.

•Step 2 – Calculate input power Divide the total output power by the power source’s efficiency, which is provided by the welding equip-ment manufacturer to yield input power in kilowatts (KW).

•Step 3 – Calculate daily operating costs during welding To calculate KW hours used in one day, take the input power and multiply it by the hours per day that the power source is actively welding. Now, take this total and multiply it by the price per KW hour.

•Step 4 – Calculate the daily operating costs during idle periods To calculate the idle consumption per day, first take the input power, multiplied by the idle hours per day. You’ll need this number later in your calculations. Now find your power source’s input power idle number provided on the rating plate or in the instruction manual in watts and multiply it by the idle hours. Then, multiply by the price per kilowatt hour of power.

•Step 5 – Calculate the total operating costs Take the daily operating costs for welding as determined in Step 3 and add the daily oper-ating costs for idle periods as calculated in Step 4. This equals the daily operating costs in dollars.

By comparing this final number for an older welding power source with the es-timated daily operating costs of newer, more efficient power source, you can easily tell which machine will provide cost savings and an ultimate return on investment.

To calculate energy savings between a modern inverter-based welding power source and conventional welding power sources in your plant, try this handy calculator: http://content.lincolnelectric.com/products/calcula-tor/inverters/inverter-energy.html.

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2) Consider switching to inverter technology

Inverter-based power sources allow man-ufacturers to deliver more power output from new power electronics technology, resulting in a better performance-to-size ratio. These models also de-liver smooth operation with greater efficiency than many older, conventional welding power sources. In the past, welding power sources were based on conventional transformers. The power supply took in 60 Hz 230, 460 or 575 volt power. A metallic transformer changed it from the rel-atively high input voltage to 60 Hz current at a lower voltage. This current then was rectified by a device known as a rectifier bridge to get a DC welding output, which was controlled by relatively slow control systems. Older industrial power sources built on this technology are typically heavy and large, weigh-ing in at 400 pounds or more. All tend to heat up during use and have limited ability to pulse any faster than 120 pulses per second due to control inefficiencies.

With inverter technology, the incoming 60 Hz power is first rectified to DC and then is fed into the power supply’s inverter section where it is switched on and off by solid-state switches at frequencies as high as 120,000 Hz. This pulsed, high-voltage, high-frequency DC then is fed to the main power transformer, where it is transformed into the low-voltage DC that’s suitable for weld-ing.

Some of the newest welding power sourc-es, rated at 650 amps at 100 percent duty cycle with a range of 10 to 815 amps, weigh in at only 165 pounds vs. over 700 pounds for a single tradi-tional power source of similar amperage. The new inverters also have a much smaller footprint than traditional welding power sources.

Inverters also feature advanced input volt-age protection – a must for high-performance use on job sites where power supplied to the welding power source isn’t always necessarily robust or reliable, and instead can be more erratic. Lincoln Electric worked with some large end user custom-ers to develop the latest inverter technology so that it is capable of surviving as much as 1000-volt in-put spikes on the job, and their welding equipment has survived and continued to operate.

Portable and lightweight, inverter-based welding power sources provide precise arc-start-ing capabilities and advanced output controls that allow welders to fine tune their welding output to desired parameters. The technology behind these units provides manufacturers with a power source

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that can perform high- and low-amperage flux-cored, stick, TIG and MIG welding, not to mention arc gouging and even CV submerged arc.

Today’s re-imagined inverter models de-liver multi-process welding capabilities, offering faster arc response, smoother arc action and a more consistent bead appearance. This yields quality welds the first time around, eliminating the need to re-weld and also lessening the incidence of scrap.

3) Closely track shop floor production & efficiency

Another way to track energy efficiency, overall production efficiency and quality is to begin using production monitoring tools in your welding operations. The latest welding pow-er sources provide data collection capabilities through special weld data acquisition tools, allow-ing monitoring of weld performance, equipment condition and efficiency.

These tools provide immediate, us-er-friendly access to a wide array of data monitor-ing information regarding the welding arc, helping fabricators deliver and verify procedure adherence, including current and voltage information, as well as True Energy™ and heat input verification,

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especially for those applications requiring heat input records. These units feature advanced digital controls to sample the welding arc parameters at extremely high speeds to deliver consistent and reliable statistics.

The latest monitoring tools now use the “cloud” and Software-as-a-Service (SaaS) technol-ogy. No computer hardware is required – saving on both capital expenditures and the energy to run such equipment – and the welder information can be viewed anywhere, anytime, and with any web device, without any special software.

With SaaS, the software application is not installed on a client computer or server like tra-ditional licensed software. Instead the software is hosted remotely and accessible to a client over the Web. With SaaS, up-front expenses are minimal because of the subscription-based pricing model; implementation is quick, and software upgrades are easily accomplished.

AlwaysOn™ alert systems in the newest monitoring programs can track and analyze weld-

er and facility faults, alerting you to issues even while you are away from the shop. This feature allows you to access your welder data anytime from anywhere – giving you 24/7 production and efficiency statistics that can be crucial to business decisions…and savings.

Energy savings: Easier than you think

While the idea of revamping welding oper-ations and equipment to reap much-needed energy savings might seem daunting at first, even a few simple changes can make a difference.

No two manufacturing facilities are alike. And, thus, no two facilities have the same level of energy usage in their welding shop. Careful as-sessment of your plant’s needs and power usage is the first step in generating savings. From that point forward, you can decide to upgrade, streamline and monitor your welding equipment in the way that best suits your shop’s needs and overall savings goals.

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The United States Bobsled & Skeleton Federation (USBSF) announced today that WIDIA, the world’s premiere manufacturer of metalcutting products, and their trusted partners Fastenal and Hi-Speed Corp. have joined the team as sponsors for the 2012-2013 and 2013-2014 World Cup seasons leading up to the 2014 Winter Olympic Games in Sochi, Russia. They join BMW, Under Armour, National Guard and KOA as full sled sponsors. Right out of the gate the dynamic four-man bobsled team of Nick Cunningham, Adam Clark, Andreas Drbal and Chris Fogt won a bronze medal while racing the WIDIA sled in the World Cup season opener in Lake Placid, NY. The tour continues through Europe, culminating with the World Champion-ships in St. Moritz, Switzerland (January 25 – February 3, 2013) and then an Olympic dress rehearsal in Sochi, Russia (February 15-17, 2013).

The WIDIA, Fastenal and Hi-Speed Corp. partnership goes beyond simple sponsorship, as this trio is also now USBSF’s official metalworking champions, ensuring that USA’s athletes are sliding down the track with the fastest machined bobsled runners possible. Bernie McConnell, Vice President of WID-IA, sees the partnership as an extension of his company’s extreme engineering.

WIDIA and partners Fastenal and Hi-Speed Corp. join the team

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“We're extremely excited about our USBSF sponsorship and their prospects for winning the World Cup," McConnell said. "This team personifies the strength and passion of the WIDIA

brand, as well as our partners, Fastenal and Hi-Speed Corpora-tion. Our company's brand is built on providing customers with the highest levels of productivity in the most extreme environ-

ments — just like this team.”

"In a sport that’s often won by a mere hundredth of a second, a quality runner program can eas-ily make the difference between a podium finish or placing outside the medals. It is an essential compo-nent for success and one of the reasons we are excited to have WIDIA behind us.” Darrin Steele, CEO of USBSF and bobsled Olympian, said.

The U.S. team are the reigning World Champions, winning four gold medals out of six events at the 2012 World Championships in Lake Placid; 86 medals during the 2011-2012 World Cup season; 24 Olympic Medals (nine gold, eight silver, seven bronze since 1928); and 56 World Cup Victories (19 gold, 16 silver, 21 bronze since 1985).

For media inquiries, please contact Amanda Bird, USBSF Marketing & Communications Manager, at [email protected], or at (518) 354-2250.

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SETCO EXPANDS GLOBAL SPINDLE

Setco is proud to announce the purchase of a majority interest in NEO Precision Tech. Co., Ltd., Taichung Taiwan, Taiwan’s premier builder of machine tool spindles and machining heads. After 100 years of serving North America, Setco extended its expertise to the India spindle market in June of 2012 acquiring majority interest in Ultra Precision Spindles Pvt., Ltd. (UPSPL), the largest independent rebuilder of precision machine tool spindles in India. This move further strengthens Setco’s commitment to serving its global customer base.

Jeff Clark, President of Setco, says “NEO is another perfect fit for Setco’s overall strategy of growing sales globally. Setco exhibited NEO Preci-sion Tech’s spindles at IMTS and saw great interest from North American customers and customers across the globe. NEO Precision Tech. custom motorized spindle technology greatly enhances Setco’s product offerings as well as support ca-pabilities in Asia. The merging of these two great companies provides customers the best of both companies product offerings while bettering worldwide support.”

Setco - Setco is owned by Holden Indus-tries, Inc., a 100% Employee-Owned Company headquartered in Deerfield, Illinois, USA. Holden Industries operates four wholly-owned subsidiar-ies which comprise four core business areas. For 100 years — since 1912 — Setco has designed, built, and serviced precision spindles and slides and is recognized worldwide as a technical leader in design and manufacturer of precision spindles

and spindle/slide combinations. Setco is a major spindle manufacturer with over 250,000 spindles in the field — new and rebuilt — which include belt-driven, geared, motorized, high speed and high frequency models. In addition, Setco offers a complete line of precision linear slides which in-clude dovetail, hardened way and linear rail slides in 21 standard sizes and hundreds of standard cat-alog models. Setco products are used worldwide in a variety of industries; including automotive, aerospace, construction, die/mold, cabling and winding, plastics, woodworking, stone cutting and general metalworking industries.

NEO Precision Tech. - With manufacturing and the corporate office located in Taichung, Tai-wan, NEO is recognized as a leader in the design, manufacture and service of high performance pre-cision motorized spindles and machining heads. NEO is only 7 years new but 75 employees strong and growing due to increasing market recognition from machine tool builders around the world for NEO’s engineering application depth in building world class motorized precision spindles and machining heads. It’s this foundation that Setco plans to build upon and make Setco the world’s most recognized name for precision spindles and machining heads.

Cincinnati, Ohio-based manufacturer and servicer of precision machine tool spindles and slides expandsglobally acquiring Taiwan’s leading spindle builder.

SERVICE NETWORK INTO ASIA

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Lincoln Electric Welding Technology Takes Center Stage at

Siemens Mobility Division’s

Green Manufacturing FacilityEnergy efficient Flextec™ 450 welder’s proven energy savings makes impact

at railcar manufacturer’s U.S. headquarters When Siemens Mobility Division incorporated solar ener-gy into its U.S headquarters and railway manufacturing facility in Sacramento, Calif., the leading pro-vider of transportation and logistics solutions demanded that sustain-ability be built into all areas of the plant.

This focus on sustainability includes welding, a major compo-nent of the assembly line for the facility’s light rail production oper-ations. So major, in fact, that 140 of the headquarters’ 700 workers are on the welding team for the plant’s car shell and bogie operations.

Spanning 54 acres, the headquarters’ col-lective 385,000 square feet of facilities includes warehouse, subassembly, carshell welding, car body painting, cladding, final assembly, bogie assembly and testing areas.

Products include traction electrification, propulsion systems, rail automation, rolling stock and integrated services for light rail, heavy rail, commuter rail and locomotives. Siemens supplies one out of every three light rail vehicles in North America and is the market leader.

Siemens welding operators use MIG, TIG and stick processes on the carshells and bogies (trucks) for light rail vehicles. Each car shell starts

with 3,000 pieces of steel per vehicle, primarily assembled through welding operations – one of the plant’s major energy consumers.

Since 2008, Siemens Mobility has com-pleted two construction phases for a solar energy system that generates 2 megawatts of clean, green and renewable electrical power for delivery direct-ly to the manufacturing facility. The system is designed to produce more electrical energy than the facility requires, espe-cially on weekends and holidays. Excess electricity is sent to the Sacramento Municipal Utility Dis-trict’s (SMUD) grid system and is used to power area homes and businesses. The excess electricity is “net metered,” and Siemens accrues credits for what the solar system exports to the grid.

Siemens turned to Lincoln Electric to pro-

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vide an energy-efficient solution for its 40-booth welding area; namely, a welding power source that could withstand years of high-volume steel weld-ing, while significantly reducing energy consump-tion with a substantial return on investment.

The answer? Energy-efficient Flextec™ 450 multi-process welding power sources. The new Flextec™ machines deliver up to 500 amps of welding power, using the latest inverter and transformer technology for faster arc response and considerable energy savings thanks to lower power consumption.

The Flextec™ 450’s energy efficiency and welding process versatility was a perfect fit for Siemens welding operators, who handle carbon steel, low-alloy steel, high-tensile steel and stain-less steel on a daily basis.

“Energy efficiency was the driving factor for the pur-chase of this machine. We want-ed the latest inverter technol-ogy that offers energy savings and lower power consumption,” notes Mayk Lehmann, head of carshell production for Sie-mens Mobility. “The Flextec™

is a real energy saver. And, an investment return calculation revealed that the payback time

for us is only six months.”