Implementation of a variable speed system on dust or fumes extractor fans
The project consists in setting up a speed regulation system on the extractor fan, activated by the machines in operation which actually require the extraction of sawdust or fumes. It involves the addition of valves and a speed variator on the extractor fan. The valves open only when the machine is operating and the fan flow rate adjusts according to the pressure.
Installing this technology, which has been available on the market for more than 5 years, the company can save significantly, up to 50%, on its electricity bills (depending on the baseline production regime) and reduce its carbon footprint. This measure is quite simple to implement, can show a rapid return on investment, and does not require a production shutdown during installation.
Use of high-performance, combination tools to reduce cycle time
The measure involves replacing simple machining tools, changing the production mode and avoiding shutdowns for unplanned maintenance and cleaning.
Use of high-performance machining tools to increase machining speeds.
Use of combination machining tools to reduce the operating time of machine tools.
Optimisation of production changes using the SMED method (Single Minute Exchange of Die – rapid tool change in less than 10 minutes).
By installing these technologies, which have been available on the market for over 5 years, companies can save up to 30% on electricity costs and reduce their carbon footprint. This measure is not simple to implement and would entail a medium-to-long term return on investment. This measure can be implemented with only a partial production shutdown during installation.
The use of articulated arms to extract dust and fumes is a system that optimises dust collection.
Dedicated profiled nozzles must be placed as close as possible to the points generating dust or fumes.
It is necessary to set up a heat recovery system on the extracted air flows with air reinjection to balance the pressures.
By installing these technologies, which have been available on the market for over 5 years, companies can save up to 20% on electricity costs and reduce their carbon footprint. This measure is quite simple to implement and would entail a medium-to-long term return on investment. However, this measure requires a production shutdown during installation.
Some older machines do not have standby mode or energy-saving mode. Companies need to purchase new machines equipped with automatic shutdown functions to save money during periods when their equipment is not in use. Here are some examples of equipment requiring ECO mode: lubrication pumps, cooling fans, hydraulic pumps, servo motors and display standby (screens).
Installing this new technology can save businesses up to 5% on electricity consumption and reduce their carbon footprint. This measure is not easy to implement and cannot be justified by the cost of energy alone. This measure requires a temporary shutdown of production during installation.
Unclogging of dust filters using a differential pressure sensor rather than a timer
Most filter unclogging installations are equipped with a timer which injects compressed air against the flow to remove the sawdust. However, this practice is energy-intensive and does not work if the filters are clogged. Instead of ordering filter unclogging, it would be better to install pressure sensors upstream and downstream of the filters. The operation entails controlling filter unclogging by differential pressure sensor (pressure difference upstream and downstream of each filter), i.e. only when the filter bags are saturated with sawdust and when unclogging is really necessary.
The use of this technology, which has been on the market for over 5 years, can save businesses up to 5% in electricity costs and reduce their carbon footprint. This measure is quite simple to implement, can show a rapid return on investment, and does not require a production shutdown during installation.
