Skyrocketing energy costs in recent years have put a lot of companies in a squeeze, especially the most energy-intensive ones. Among them, window profile producers and others using extrusion processes.
Cross-Box is a new vacuum supply system for PVC profile extrusion lines which has been developed by the Austrian company Politsch Kunststofftechnik GmbH. It provides energy savings of up to 85 % compared to a traditional calibration system. This means each production line could earn from €10.000 up to € 20.000 in energy savings.
‘’You don’t need to invest in new tooling,’’ says Mr Meinhard Schwaiger of Politsch Kunststofftechnik. ‘’’Only an investment in Cross-Box as a renewing kit for existing extrusion lines is necessary.’’
What’s new about Cross-Box:
Here’s why the old way soaks up so much energy. A traditional calibrator system consists of one or more dry calibrators and one or more vacuum tanks. For each dry calibrator and vacuum tank, a different vacuum level is needed. To adjust different levels, fresh air is pumped in using air valves located on each vacuum cone. This means that most of the energy needed to produce the vacuum capacity is lost.
Now try the new way. The Cross-Box system contains only one central vacuum pump. For each vacuum level inside the dry calibrator and vacuum tank, a vacuum sensor controls the levels individually, thanks to servo controlled valves.
The system is designed to run the vacuum pump for the lowest possible energy consumption. Once the profile touches the inner surface of the dry calibrator, a lower air volume is necessary to suck the profile surface against the calibrator surface. The vacuum pump runs at a lower speed (25Hz or lower).
At that time, the vacuum valves are controlled automatically according to the preset levels. The energy consumption of the vacuum pump is reduced automatically up to 85% by reducing the amount of air flowing in.
Save energy, reduce warm-up time, boost production stability and keep degraded material to a minimum. How much more win-win can you get?
