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Energy Saving TCS Heater Band SystemRitchWaterfieldProduct Manager, Injection End ServicesMilacron
TCS Heater Band Systems Thermal Control Solution for Heating & Cooling Barrels on Plastic Machinery… Any Make, Any Model… Injection Molding         Blow Molding         Extrusion 2
Energy SavingTCS Heater Band Systems Overview ServTek& Rex Materials Group Partnership What’s Unique about the TCS system Benefitsof the TCS system for all brands and models How the TCS System will save you money throughenergy and maintenance savings Comparison of the TCS system with competition 3
Partnering to Serve Customers ServTek and RMG (Rex Materials Group) Partner to bring this Energy Savings Technology to our Customers Over the past few years ServTek has worked with RMG to testand prove the viability of this product. In 2007 ServTek / Milacron preformed intensive testing at ourmanufacturing facility in Afton, Ohio Based upon this testing, in June of 2008, we entered into anagreement with RMG to be an exclusive supplier of this product 4
About RMG Rex Materials Group has been manufacturing heaters for OEM’s since 1973 in the following markets: Industrial Laboratory Commercial Hobby Specialty Heat Processing Achieve chamber temperatures to 2100 F – plastic processes max out around 750 F 5
Example Kendro Lab Furnace Lining 6
Example Lindberg Furnace Heating Panel 7
What’s Unique about theTCS Heater Band System 8
Two Designs… This product is offered in two designs The two designs are necessary toaccommodate a larger range of barrel diameters The two designs are “Segmented”and “Clamshell” The “Clamshell” designaccommodates barrel diameters from2” - 9.9” The “Segmented” designaccommodates diameters from10” - 17” 9
The Segment Design 10
The Clamshell Design… 11
TCS Heater Band System… Manufactured from a vacuumedformed ceramic fiber Completed segment design iscomposed of multiple segments, theclamshell two halves With the segmented design thenumber of segments is determined bythe barrel diameter Both designs are wired in series, thesegmented design is assembled withVelcro, the clamshell with metalclamps Both consist of embedded radiantheating elements 12
TCS Heater Band System… 13 Elements are imbedded into a channel
The Cooling Option The bands are designed to accommodate cooling if required The heating elements channels are also used for cooling Optional blower can be added Air is pulled through the channels directly across the surface of the barrel 14
The Cooling Option 15 High Radiant Energy release from exposed element permits much faster heat up and response time than conductive type band heaters. Does not depend on maintaining good barrel contact to conduct heat to the barrel. Faster & more effective air cooling directly on the barrel. Do not have to cool the band heaters or aluminum clamshells first. Does not depend on maintaining good barrel contact to conduct heat away from barrel.
During Heating & Cooling This system totally encapsulates your barrel Heating elements do not require direct contact with the barrel Cooling is more efficient, air has direct contact with the barrel 16
Benefits of the TCS System Reduced Energy Consumption of conventional bands by 30% To 50% Faster Heat Up Time 30% To 50% Faster  Tighter Temperature Control +/- 1degree F Improved Worker Safety Safe to the touch under operating conditions Reduction In Air Conditioning Costs Lower Maintenance Costs 17
How Saving & Benefits are Achieved Wattage of the TCS system is reduced by 30% Bands cycle less due to superior insulating Additional savings with reduced heat-up time Conductive heat into your facility is almost eliminated reducing air conditioning requirements 18
Maintenance Savings Lower wattage equals longer band life replacement costs are reduced The single segment or clamshell designallows for ease of replacement maintenance time and cost is reduced with single replacements Lead wires and terminations run much cooler Replacement inventory is reduced reducing inventory costs 19
Energy Savings Estimate 20
Energy Savings Estimate 21
Actual Energy Study 22
TCS Verses the Competition 23 Typically 50-80% lower in cost than induction heating Equivalent or better energy savings - Reduced ROI Barrel cooling can be easily incorporated TCS bands wire into existing relays, thermocouples, and temperature controllers No converters, transformers, or additional power supply necessary No safety or electronic equipment concerns due to signal noise Minimal downtime for conversion Superior reliability and replacement parts at a small fraction of the cost
Sample Installations 24
Sample Installations 25
Sample Installations 26
Success Stories… 27 Injection Molders Automotive Molder – Converted 39 machines to TCS including 20Milacron 725 ton machines. Average energy reduction was 36%. Medical Molding Application – 35% energy reduction on a 225 Ton Milacron. Payback less than 18 months. We are in the process of converting multiple machines at this location Packaging Application – 43% energy reduction on a Husky XL500PET. Payback less than 20 months.
Extrusion 28 Wire & Cable – Have purchased eight TCS systems with savings ranging from 32% to 70% less energy. Have reduced scrap and dimensional variability. Sheet Extrusion – 33% less energy. Eliminated the need to water cool the barrel. Payback less than 24 months. Blown Film – 52% less energy. Eliminated the need to oil cool the barrel. Payback less than 14 months.
Summary 29 TCS System Energy savings of 30 - 50 % over conventional bands Reducedair conditioning costs Lowermaintenance and inventory costs Fasterheat up time Uniformdistribution of heat - tighter temp control Optional efficient cooling package if required Improve worker safety and comfort Any makeany modelmachine
Energy Saving TCS Heater Band SystemRitchWaterfieldProduct Manager, Injection End ServicesMilacron

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Mz133 milacron ppt_tcs

  • 1. Energy Saving TCS Heater Band SystemRitchWaterfieldProduct Manager, Injection End ServicesMilacron
  • 2. TCS Heater Band Systems Thermal Control Solution for Heating & Cooling Barrels on Plastic Machinery… Any Make, Any Model… Injection Molding Blow Molding Extrusion 2
  • 3. Energy SavingTCS Heater Band Systems Overview ServTek& Rex Materials Group Partnership What’s Unique about the TCS system Benefitsof the TCS system for all brands and models How the TCS System will save you money throughenergy and maintenance savings Comparison of the TCS system with competition 3
  • 4. Partnering to Serve Customers ServTek and RMG (Rex Materials Group) Partner to bring this Energy Savings Technology to our Customers Over the past few years ServTek has worked with RMG to testand prove the viability of this product. In 2007 ServTek / Milacron preformed intensive testing at ourmanufacturing facility in Afton, Ohio Based upon this testing, in June of 2008, we entered into anagreement with RMG to be an exclusive supplier of this product 4
  • 5. About RMG Rex Materials Group has been manufacturing heaters for OEM’s since 1973 in the following markets: Industrial Laboratory Commercial Hobby Specialty Heat Processing Achieve chamber temperatures to 2100 F – plastic processes max out around 750 F 5
  • 6. Example Kendro Lab Furnace Lining 6
  • 7. Example Lindberg Furnace Heating Panel 7
  • 8. What’s Unique about theTCS Heater Band System 8
  • 9. Two Designs… This product is offered in two designs The two designs are necessary toaccommodate a larger range of barrel diameters The two designs are “Segmented”and “Clamshell” The “Clamshell” designaccommodates barrel diameters from2” - 9.9” The “Segmented” designaccommodates diameters from10” - 17” 9
  • 12. TCS Heater Band System… Manufactured from a vacuumedformed ceramic fiber Completed segment design iscomposed of multiple segments, theclamshell two halves With the segmented design thenumber of segments is determined bythe barrel diameter Both designs are wired in series, thesegmented design is assembled withVelcro, the clamshell with metalclamps Both consist of embedded radiantheating elements 12
  • 13. TCS Heater Band System… 13 Elements are imbedded into a channel
  • 14. The Cooling Option The bands are designed to accommodate cooling if required The heating elements channels are also used for cooling Optional blower can be added Air is pulled through the channels directly across the surface of the barrel 14
  • 15. The Cooling Option 15 High Radiant Energy release from exposed element permits much faster heat up and response time than conductive type band heaters. Does not depend on maintaining good barrel contact to conduct heat to the barrel. Faster & more effective air cooling directly on the barrel. Do not have to cool the band heaters or aluminum clamshells first. Does not depend on maintaining good barrel contact to conduct heat away from barrel.
  • 16. During Heating & Cooling This system totally encapsulates your barrel Heating elements do not require direct contact with the barrel Cooling is more efficient, air has direct contact with the barrel 16
  • 17. Benefits of the TCS System Reduced Energy Consumption of conventional bands by 30% To 50% Faster Heat Up Time 30% To 50% Faster Tighter Temperature Control +/- 1degree F Improved Worker Safety Safe to the touch under operating conditions Reduction In Air Conditioning Costs Lower Maintenance Costs 17
  • 18. How Saving & Benefits are Achieved Wattage of the TCS system is reduced by 30% Bands cycle less due to superior insulating Additional savings with reduced heat-up time Conductive heat into your facility is almost eliminated reducing air conditioning requirements 18
  • 19. Maintenance Savings Lower wattage equals longer band life replacement costs are reduced The single segment or clamshell designallows for ease of replacement maintenance time and cost is reduced with single replacements Lead wires and terminations run much cooler Replacement inventory is reduced reducing inventory costs 19
  • 23. TCS Verses the Competition 23 Typically 50-80% lower in cost than induction heating Equivalent or better energy savings - Reduced ROI Barrel cooling can be easily incorporated TCS bands wire into existing relays, thermocouples, and temperature controllers No converters, transformers, or additional power supply necessary No safety or electronic equipment concerns due to signal noise Minimal downtime for conversion Superior reliability and replacement parts at a small fraction of the cost
  • 27. Success Stories… 27 Injection Molders Automotive Molder – Converted 39 machines to TCS including 20Milacron 725 ton machines. Average energy reduction was 36%. Medical Molding Application – 35% energy reduction on a 225 Ton Milacron. Payback less than 18 months. We are in the process of converting multiple machines at this location Packaging Application – 43% energy reduction on a Husky XL500PET. Payback less than 20 months.
  • 28. Extrusion 28 Wire & Cable – Have purchased eight TCS systems with savings ranging from 32% to 70% less energy. Have reduced scrap and dimensional variability. Sheet Extrusion – 33% less energy. Eliminated the need to water cool the barrel. Payback less than 24 months. Blown Film – 52% less energy. Eliminated the need to oil cool the barrel. Payback less than 14 months.
  • 29. Summary 29 TCS System Energy savings of 30 - 50 % over conventional bands Reducedair conditioning costs Lowermaintenance and inventory costs Fasterheat up time Uniformdistribution of heat - tighter temp control Optional efficient cooling package if required Improve worker safety and comfort Any makeany modelmachine
  • 30. Energy Saving TCS Heater Band SystemRitchWaterfieldProduct Manager, Injection End ServicesMilacron