Air Electricity

Energy from the Outlet
Air and Electricity Usage in Shape Moulding Machines
Kurtz GmbH
03.09.02.mz.sme
page 1

Contents
Demonstration of consumption
Saving potential
Kurtz GmbH
03.09.02.mz.sme
page 2

Energy- media costs in Germany

Media
Costs
Water
2,81
Electricity
0,1176 /kWh
Gas/oil/electricity
0,0332 /kWh
Steam
23-30
Air
0,0204 /Nm
/m
/t
Kurtz GmbH
03.09.02.mz.sme
page 3

Distribution of energy costs

11%
4%
7%
58%
20%
Steam
Water
Air
Electricity
Vacuum
Kurtz GmbH
03.09.02.mz.sme
page 4

Kurtz GmbH
03.09.02.mz.sme
page 5

Analysis of process steps
1.
2.
3.
4.
Air consumption during filling

Air consumption during drainage
Air consumption during demoulding
Air consumption of control
5. Consumption of the conveying system

(Presentation:
Energy for foam Energy consumption during

pre-expanding, transporting and storage)
Kurtz GmbH
03.09.02.mz.sme
page 6


Air throughput (m3/h)
Chamber pressure MI (bar)
Chamber pressure MII (bar)
Filling
Ejection
Kurtz GmbH
03.09.02.mz.sme
page 7


Filling
Drainage
Ejection
Kurtz GmbH
03.09.02.mz.sme
page 8

Kurtz GmbH
03.09.02.mz.sme
page 9

Filling methods
Conventional filling
Pressure filling with closed material tank
Pressure filling with back pressure in the
mould
Filling using a crack (crack filling)
Kurtz GmbH
03.09.02.mz.sme
page 10

Use of pressure filling

for large series production
with difficult moulding contours
when polyolefine materials are processed
increased air consumption !!!
Simple operation without any problems
Kurtz GmbH
03.09.02.mz.sme
page 11

Pressure filling steps

1. Pressure increase
the filling pressure is built up in the material pressure tank
2. Filling
Closing piston and material outlet are opened
Material beads are transported into the mould
3. Back-blowing
When the mould is filled, a back presssure is
created at the injector opening
filling air is diverted
material flows back into the tank
Closing piston and material outlet are closed
Kurtz GmbH
03.09.02.mz.sme
page 12

Pressure filling pressure increase
Mould
Material tank
with
compressed
air
Fill injector
Kurtz GmbH
03.09.02.mz.sme
page 13

Pressure filling steps

the filling pressure is built up in the material tank
2. Filling
3. Back-blowing
When the mould is filled, a back presssure is
filling air is diverted
material flows back into the tank
Kurtz GmbH
03.09.02.mz.sme

page 14

Pressure filling - filling
Mould
Materia ltank
with
compressed
air
Fill injector
Kurtz GmbH
03.09.02.mz.sme
page 15

Pressure filling, steps

the filling pressure is built up in the material tank
2. Filling
3. Back-blowing
When the mould is filled, a back pressure is
Filling air is diverted
Material flows back into the tank
Kurtz GmbH
03.09.02.mz.sme
page 16

Pressure filling back blowing
Mould
Venting valve at
the pressure fill
device is open
Fill injector
Kurtz GmbH
03.09.02.mz.sme
page 17

Luft
Consumers:
Injector
Pressure fill tank
Liruft
Air consumption during pressure filling
SAir = VInjector + VTank

Kurtz GmbH
03.09.02.mz.sme
page 18


Air consumption during filling depends on:
Pressure tank
Filling time
Design of fill injectors
Kurtz GmbH
03.09.02.mz.sme
page 19

Air quantities with increased tank pressure

0,25
Air quantity [Nm]
0,2
0,15
0,1
0,05
Air quantity
fillers [Nm]
0
0,5
Air quantity
tank [Nm]
0,8
1
Tank pressure [bar]
1,5
Kurtz GmbH
03.09.02.mz.sme
page 20

Total air consumption with increased tank pressure

0,3
0,29
Air quantity [Nm]
0,28
0,27
0,26
0,25
0,24
0,23
0,22
0,21
0,2
0,5
0,8
1,5
Tank pressure [bar]
With tank pressures over 1 bar increased air consumption!

Kurtz GmbH
03.09.02.mz.sme
page 21


Tank pressure
Filling time
Kurtz GmbH
03.09.02.mz.sme
page 22

Influence of increased tank pressure on filling time

0,3
0,29
6,5
0,28
6
Filling time [s]
0,27
5,5
0,26
0,25
4,5
0,24
0,23
4
0,22
3,5
3
0,50
0,21
0,60
0,70
0,80
0,90
1,00
1,10
1,20
1,30
1,40
Filling [s]
Fllzeit
time [s]
Total air
Luftmenge
quantity
gesamt
[Nm]
0,2
1,50
Tank pressure [bar]
The higher the tank pressure, the faster the filling!

Kurtz GmbH
03.09.02.mz.sme
page 23


Tank pressure
Filling time
Kurtz GmbH
03.09.02.mz.sme
page 24

Selection of fill injectors

Comparison of air throughput
1000
900
800
700
600
Air throughput
[l/min]
500
400
300
200
100
0
Nymphius
Kurtz Standard
Sarga
Kurtz
Schaltdrossel
Filler types
Kurtz GmbH
03.09.02.mz.sme
page 25


Comparison of loading:
Materialdurchsatz 100 Liter -Material

Beladung =
[ Liter -Flluft = %]
Luftdurchs atzFller
The transport capacity of filler is considered
Kurtz GmbH
03.09.02.mz.sme
page 26


Comparison of loading
12,00
10,00
8,00
Loading
[%]
6,00
4,00
2,00
0,00
Kurtz Standard
Kurtz Schaltdrossel
Nymphius
Sarga
Filler types
Kurtz GmbH
03.09.02.mz.sme
page 27

Influence of fill injectors

Comparison of filling costs
Filling costs = air costs + machine costs
The factor time is considered!

Kurtz GmbH
03.09.02.mz.sme
page 28


Comparison of filling costs
12
10
8
Filling costs
[cent/Zykl]
6
4
2
0
Kurtz Schaltdrossel
Kurtz Standard
Nymphius
Sarga
Filler types
Kurtz GmbH
03.09.02.mz.sme
page 29

Influence of fill injectors

Influence of fill injector on costs
Injektor
Kurtz Schaltdrossel
Nymphius
Filling
Additional
costs p.a. costs
[]
48.700
0
198.300
149.600
Production facility with 15m moulding area, two-shift operation

Kurtz GmbH
03.09.02.mz.sme
page 30

Filling costs
The most economic filling process:
Short filling time
High loading
Achievement of required parts quality
Kurtz GmbH
03.09.02.mz.sme
page 31

Pressure filling, data

Volume of pressure fill tank
Machine
Quantity Volume VDF
Tot.Vol. VDF,ges
K44-K57
40 l
40 l
K66-K710
60 l
60 l
K810-K813
90 l
90 l
K1013-K1314
90 l
180 l
K1317-K1121
90 l
270 l
Usual standard configuration of pressure fill devices

(configuration may vary accord. to special application and
customer request)
Kurtz GmbH
03.09.02.mz.sme
page 32

Pressure filling - equipment
better
2 small pressure tanks can be better adapted to variable filling

conditions
Kurtz GmbH
03.09.02.mz.sme
page 33

Kurtz GmbH
03.09.02.mz.sme
page 34

Use of drainage
With heavy moulds

With high cooling requirement (large quantity of cooling
water)
For mouldings with low content of residual moisture
Kurtz GmbH
03.09.02.mz.sme
page 35


Filling
Drainage
Ejection
Kurtz GmbH
03.09.02.mz.sme
page 36

Use of Drainage
With heavy moulds

With high cooling requirement (large quantity of cooling
water)
For mouldings with low content of residual moisture
Kurtz GmbH
03.09.02.mz.sme
page 37

Consists of:
Tansfer air
Demoulding air
Kurtz GmbH
03.09.02.mz.sme
page 38

Demoulding
Less air requirement with use of

mechanical ejectors
When an automatic handling system

is used the requirement of
demoulding air is reduced
Increased air requirement with AZA

(2x transfer air)
Kurtz GmbH
03.09.02.mz.sme
page 39

Air requirement for control
The same for all machines (approx. 0.15m/cycle) with min 6 bar
Air for valves (control air)
Air for valves (drives)
This amount of consumption can be neglected. The more so because there is no

saving potential.
Kurtz GmbH
03.09.02.mz.sme
page 40

Effect of spacer frames

Steam chamber volume K68:
150 l
Extension of volume by 100 mm spacer frame:
48 l
Volume increase in percent:
32%
M1 + M2
Aufbau
Volume increase increased consumption of transfer air, during drainage and for
ejection air
Minimal steam chamber volume omptimum consumption
Kurtz GmbH
03.09.02.mz.sme
page 41

Check list for planning
Energy Agenda
Air consumption planning stage
RE:
No.
Action required
Proper design of infrastructure
Separate air connections for high and low pressure
Include possible extension steps of plant
Better two small pressure fill tanks than one big one
Done
5
6
Kurtz GmbH
03.09.02.mz.sme
page 42

Check list produktion
Energy Agenda
Re:
No.
Air consumption - production

Action required
Filling as short as possible, as long as necessary
Use of economic fill injectors
Economic use of transfer air, ejection air and AZA
Automatic handling reduces air requirment during

ejection
Volume of steam chambers as much reduced as

possible (spacer frames, steam chamber reductions)
Done
Kurtz GmbH
03.09.02.mz.sme
page 43

Check list maintenance
Energy Agenda
Re:
Air consumption - maintenance
No.
Action required
Minimize leakages
Done
2
3
Kurtz GmbH
03.09.02.mz.sme
page 44

Kurtz GmbH
03.09.02.mz.sme
page 45

Analysis of electricity consumers
1. Hydraulic plant
2. Vacuum pumps
3. Side channel fans
4. Control
5. Demoulding device
Kurtz GmbH
03.09.02.mz.sme
page 46

[k
W]
5,0
Electric power consumption
2,5
Demoulding
Condensation
Autoclave
Cros steam
03.09.02.mz.sme
Purging
Filling
Mould
closing
Kurtz GmbH
Stabilization with vacuum
Time
page 47

Total power consumption

0,5
p[bar]
P[kWh]
with saver circuit

without saver circuit
0,4
0,3
0,2
0,1
0
0
-0,1
50
100
150
200
250
t[s]
0
300
-1
Kurtz GmbH
03.09.02.mz.sme
page 48

Power consumption of hydraulic pumps
use of hydraulic drive only with drive movement

without drive movement only basic load
actual consumption approx. 70% of nominal capacity of motor
Kurtz GmbH
03.09.02.mz.sme
page 49

Design and operation conditions for hydraulic pumps

Hydraulic pump design
Capacity of hydraulic pump depending on number and size of closing cylinders.

(3,0 - 7,5 kw)
Conveying quantity designed, to achieve mould movement speeds of 330mm/s.
Operation pressure selected, to achieve the necessary closing forces at the

mould.
Capacity requirement of the hydraulic pump only depending on physical conditions.
Kurtz GmbH
03.09.02.mz.sme
page 50

Design and operation conditions for hydraulic pumps
Energy saving potential
Switch off hydraulic pump after locking and switch on

shortly before the step stabilization is finished.
Adaption of hydraulic pressure to required closing forces.
Kurtz GmbH
03.09.02.mz.sme
page 51

Power consumption of vacuum pumps
Almost constant current consumption over the entire area of use

Kurtz GmbH
03.09.02.mz.sme
page 52

Design and operation conditions for water ring vacuum pumps
Design vacuum pump
Suction capacity depending on volume of steam chamber
Required suction capacity achieved by number of used standard vacuum pumps

(at present max. 4)
Low saving potential, as continuous operation is required:
Bias of condenser with vacuum
Drainage over vacuum pump
Kurtz GmbH
03.09.02.mz.sme
page 53

Single vacuum and central vacuum system

Saving potential
Central vacuum system
For production facilities with more than 5-7 machines, depending on size
Single vacuum
Central vacuum
system
One or more pumps at a

machine
Pumps are running

continuously
Central vacuum station with

4 6 pumps
Some pumps are running

continuously
Remaining pumps only if
required
Kurtz GmbH
03.09.02.mz.sme
page 54

Power consumption of side channel fans
Capacity requirement of side channel fan only during filling of the

material tank.
Nominal capacities of motors 0.75 KW 5.5 KW
Kurtz GmbH
03.09.02.mz.sme
page 55

Power consumption of control
Capacity requirement of control relatively constant.

Per machine with power consumption < 500 W
Kurtz GmbH
03.09.02.mz.sme
page 56

Power consumption of demoulding device

Capacity requirement of motors only during drive movements.
Vertical stroke
0,75-1.75 KW
Horizontal stroke 0.5 KW

Stacking table
0.5 KW
Kurtz GmbH
03.09.02.mz.sme
page 57

Check list for planning
Energy Agenda
Electricity usage planning stage
RE:
No.
Action required
Proper design of infrastruture
Include possible extension steps of plant
Use central vacuum system where possible
Done
4
5
6
Kurtz GmbH
03.09.02.mz.sme
page 58

Check list production
Energy Agenda
RE:
No.
Electricity usage - production

Action required
Use saver circuit for hydraulic aggregate
Adapt hydraulic pressure to requirements
Shortest possible and most economic use of vacuum
Done
4
5
Kurtz GmbH
03.09.02.mz.sme
page 59

Check list maintenance
EnergyAgenda
Electricity usage - maintenance
RE:
No.
Action required
Facilitate smooth running of demoulding device with

proper lubrication
Done
2
3
Kurtz GmbH
03.09.02.mz.sme
page 60

Thank you for your attention !
Kurtz GmbH
03.09.02.mz.sme
page 61

Pressure filling, data

Amortization
Erlenbach
Nymphius
Sarga
125
250
50
0,00908
0,01760
0,03253
0,55
1,06
1,95
8,72
16,90
31,23
43,60
84,48
156,14
174,40
337,94
624,56
Amortizations time
Behl
Bentzen
Erlenbach
Nymphius
Sarga
Saving purchase
price number hours number days number weeks number months
165
2027,1
126,7
25,3
6,3
190
3808,9
238,1
47,6
11,9
165
1164,6
72,8
14,6
3,6
40
61,3
3,8
0,8
0,2
240
155,0
9,7
1,9
0,5
Kurtz GmbH
03.09.02.mz.sme
page 62

Air and ElectricityExample
Usage in Shape
air throughput
Moulding Machines
Make
Kurtz
Erlenbach
Heitz
Type
EPS short stroke
MF5 (at one air connect.)
with 42mm dia.
Adjustment
fix
fix
fix
KBM
KBM
Nymphius
Vario short stroke, steps 1-8 step 1-8

long stroke (LS), 200/28/26/16 fix
J18 LS 28 mmdia.
fix
Volume stream
179
380
220
60 - 180
135
130
Kurtz GmbH
03.09.02.mz.sme
page 63

Air and ElectricityExample
Usage in Shape
drainage
Moulding Machines
Consumption per cycle
V& E
VE = V& E * pmax * t
l
VE = 60 sbar
* 1,5bar * 3s
pmax
VE = 270l
Air throughput approx. 60-90 l/(s *bar)

(60 with K68, 90 with K1014)
Pressure in the air supply
Drainage time 3s
z
Kosten Jahr *sekunde = 0,09 mzs 0,0204 m 288000 Jahr
= 600 Jahr s
Unnecessary drainage costs 600 per year!!!
Kurtz GmbH
03.09.02.mz.sme
page 64

Example transfer
V = VDK * l * p e
Streaming factor 3 ... 5
VDK
Volume
1
* 0,3bar
V = 150l * 3 bar
V = 135l
of steam
chamber from which
transfer is made
e.g. 150 l at MI side with
K810
Transfer air
pe
Over pressure
approx. 0,3 bar
Kosten Zyklus = 0,135m * 0,0204 m Norm

= 0,003
/ Zyklus
Every cycle costs 0,3 Cent, that is 900/year*

Unnecessary transfer and demoulding air costs 400/year**
Kurtz GmbH
03.09.02.mz.sme
page 65

Example demoulding
VEntformen = A S * VS,Entformen
VS, Entformen Specific air requirement

during demoulding
approx. 0,5m/m z
= 0,48m * 0,5 mm
AS
= 0,24m
Kosten Zyklus = 0,24m * 0,0204

= 0,5
moulding area
Cent / Zyklus
Every cycle costs 0,5 Cent, that is 1440/year*

Unnecessary transfer and demoulding air costs 400/year
Kurtz GmbH
03.09.02.mz.sme
page 66

Example demoulding demoulding ejector
Kurtz GmbH
03.09.02.mz.sme
page 67

Example Kurtz helps you save money

1.
Example:
Efficient filling Comparison of fill injectors of different manufacturers/ Venturi
nozzle design
Comparative calculation to save costs
2.
Example:
Low pressure circuit for ejector air, with comparative calculation
Kurtz GmbH
03.09.02.mz.sme
page 68

Conversion in normal litres
Conversion of throughput under pressure in throughput in normal litres
V& N = V& 1 pe
V& N
V& 1
Volume steaom in normal litres

Volume stream with pabs
Absolute pressure
= atmospherical pressure +
over pressure
pe
Relative pressure = over

pressure
= absolute pressure
atmospherical pressure
Kurtz GmbH
03.09.02.mz.sme
page 69

Calculation data / values

Estimate value:
1 m/h compressed air with 7,5 bar over pressure 0,106
kWh
1 l/s compressed air with pe=7,5 bar 0,029 kWh 3,463
10-3
1kWh 0,1176
1Nm air = 0,0204
Kurtz GmbH
03.09.02.mz.sme
1Nm= standard cubicmeter

page 70
Values for Germany

Leakage costs
Hole diameter
Leakage with 7,3

bar [l/s]
Energy costs
[/a]
131
10
1320
27
3560
10
105
14066
Kurtz GmbH
03.09.02.mz.sme
page 71

Adjustment values without drainage

Formteil:
Materialtype
Drcke
Gegendruck Fllen I
Behlterdruck Fllen II
Fluidisieren I
Flluftdruck geregelt I
Gegendruck Fllen II
Fluidisieren II
Flluftdruck geregelt II
Behlterdruck bei
Rckblasen
Druckhaltung Fllbehlter
Querdampf Festseite
Querdampf Fahrseite
Autoklav Festseite
Autoklav Fahrseite
Lego
EPS-Mix
[bar]
1,00
6,00
-
Zeiten
Vorblasen/ Druckaufbau
Druckfllen I
Druckfllen II
Fller freiblasen
Fller schlieen
Rckblasen
Dampfverzgerung
[s]
2,00
1,00
0,70
Wege
Eilgang schlieen
Spalt
auf bei AZA
zu bei AZA
Kriechgang ffnen
Auslaventil ffnen
bergabeluft aus
0,80
0,80
1,20
1,20
Splen
Querdampf Festseite
Querdampf Fahrseite
Autoklav
Kondensieren
Khlen dosiert, Festseite
Khlen dosiert, Fahrseite
Entwssern
Stabilisieren mit Vakuum
Kondensator Khlen
bergabeluft vor ffnen
2,00 Auswerfen ein (Entn. Einf.)

3,00 Auswerfluft ein
0,00 Auswerfer Fller ein
4,00 Auswerfluft aus
0,50 ffnungshub Stop
1,50 Entnahme Warteposition
1,50 Entnahme Einfahrposition
- Entnahme Abholposition
20,00
15,00
1,00
Summe (soll)
Summe (ist)
52,20
53,00
[mm]
0,00
-
Kurtz GmbH
03.09.02.mz.sme
page 72

Adjustment values with drainage

Formteil:
Materialtype
Drcke
Gegendruck Fllen I
Behlterdruck Fllen II
Fluidisieren I
Flluftdruck geregelt I
Gegendruck Fllen II
Fluidisieren II
Flluftdruck geregelt II
Behlterdruck bei
Rckblasen
Druckhaltung Fllbehlter
Querdampf Festseite
Querdampf Fahrseite
Autoklav Festseite
Autoklav Fahrseite
Lego
EPS-Mix
[bar]
1,00
6,00
-
Zeiten
Vorblasen/ Druckaufbau
Druckfllen I
Druckfllen II
Fller freiblasen
Fller schlieen
Rckblasen
Dampfverzgerung
[s]
2,00
1,00
0,70
Wege
Eilgang schlieen
Spalt
auf bei AZA
zu bei AZA
Kriechgang ffnen
Auslaventil ffnen
bergabeluft aus
0,80
0,80
1,20
1,20
Splen
Querdampf Festseite
Querdampf Fahrseite
Autoklav
Kondensieren
Khlen dosiert, Festseite
Khlen dosiert, Fahrseite
Entwssern
Stabilisieren mit Vakuum
Kondensator Khlen
bergabeluft vor ffnen
2,00 Auswerfen ein (Entn. Einf.)

3,00 Auswerfluft ein
0,00 Auswerfer Fller ein
4,00 Auswerfluft aus
0,50 ffnungshub Stop
1,50 Entnahme Warteposition
1,50 Entnahme Einfahrposition
2,00 Entnahme Abholposition
20,00
15,00
1,00
Summe (soll)
Summe (ist)
54,20
55,00
[mm]
0,00
-
Kurtz GmbH
03.09.02.mz.sme
page 73

Design diagram hydraulic pump
Kurtz GmbH
03.09.02.mz.sme
page 74

Air Electricity

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Air Electricity

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Energy from the Outlet

Air and Electricity Usage in Shape Moulding Machines

Energy from the Outlet

Energy from the Outlet

Energy- media costs in Germany

Energy from the Outlet

Distribution of energy costs

Energy from the Outlet

Energy from the Outlet

Analysis of process steps

Air consumption during filling

5. Consumption of the conveying system

Energy for foam Energy consumption during

Energy from the Outlet

Analysis of process steps

Energy from the Outlet

Analysis of process steps

Energy from the Outlet

Energy from the Outlet

Energy from the Outlet

Use of pressure filling

Simple operation without any problems

Energy from the Outlet

Pressure filling steps

Energy from the Outlet

Pressure filling pressure increase

Energy from the Outlet

Pressure filling steps

Closing piston and material outlet are closed

Energy from the Outlet

Pressure filling - filling

Energy from the Outlet

Pressure filling, steps

Energy from the Outlet

Pressure filling back blowing

Energy from the Outlet

Air consumption during pressure filling

SAir = VInjector + VTank

Energy from the Outlet

Air consumption during pressure filling

Energy from the Outlet

Air quantities with increased tank pressure

Air quantity [Nm]

Tank pressure [bar]

Energy from the Outlet

Total air consumption with increased tank pressure

Air quantity [Nm]

Tank pressure [bar]

With tank pressures over 1 bar increased air consumption!

Energy from the Outlet

Air consumption during pressure filling

Energy from the Outlet

Influence of increased tank pressure on filling time

Tank pressure [bar]

The higher the tank pressure, the faster the filling!

Energy from the Outlet

Air consumption during pressure filling

Energy from the Outlet

Selection of fill injectors

Energy from the Outlet

Selection of fill injectors

Materialdurchsatz 100 Liter -Material

Energy from the Outlet

Selection of fill injectors