energy savings & molding costs retrofit motor speed control 1 Energy Savings & Molding Costs Fred Pratt Business Development CCS SyncroSpeed what can retrofit motor speed control achieve?

energy savings & molding costs retrofit motor speed control 2 what to expect from this session how much savings to expect the cost of retrofit installations what makes a good system perform well how to avoid poor results & failed investment

energy savings & molding costs retrofit motor speed control 3 molding costs relative and rising costs of –material –labour –energy –maintenance, depreciation, overheads energy is not the greatest spend, but costs can be managed and reduced

energy savings & molding costs retrofit motor speed control 4 savings in perspective

energy savings & molding costs retrofit motor speed control 5 energy savings in perspective energy for the molding machines is most of the utility bill source

energy savings & molding costs retrofit motor speed control 6 energy savings in perspective power consumption operating hours savings potential cost of realisation risk

energy savings & molding costs retrofit motor speed control 7 savings index motors and heaters offer the greatest potential but not the least risk

energy savings & molding costs retrofit motor speed control 8 hydraulic IMMs what’s not to like?

energy savings & molding costs retrofit motor speed control 9 moulding machine hydraulic losses Q p actual pump discharge actual discharge pressure true flow demand USEFUL POWER WASTED POWER true working pressure requirement prime cause of losses is mismatch of power supplied to true demand

energy savings & molding costs retrofit motor speed control 10 how the savings are made matching supply to demand –speed of movement –volume of oil from the pumps –regulation of required oil volumes reducing pressure losses attack the over supply of oil volumes and pressures

energy savings & molding costs retrofit motor speed control 11 performance … what to expect reduction in motor energy consumption –25% to 55% reduced load on oil cooling system –additional 5% to 15% of above machines to operate as normal still working 10 years on a developing technology that delivers measurable results

energy savings & molding costs retrofit motor speed control 12 examples of savings

energy savings & molding costs retrofit motor speed control 13 plasticising injection hold cooling 47 kW 21 kW injection estimate power reduction is 55% Sandretto 1100t machine study

energy savings & molding costs retrofit motor speed control 14 actual power reduction is 30% Husky EW1150ES ps 28s

energy savings & molding costs retrofit motor speed control 15 manufacturertonnagetotal motor power kW saving motor loading Engel kW41.1% LG550104kW33.3% Demag50055kW36.5% Meiki850110kW35.4% Van Dorn kW38.2% Krauss Maffei kW44.7% Oima40045kW51.7% Negri Bossi33030kW66.4% Mitsubishi65090kW34.0% MIR20030kW60.1% Stork44090kW52.4%

energy savings & molding costs retrofit motor speed control 16 annual savings by tonnage annual operating hours6000 energy costEuro 0.10 / kWh oil coolingtower ♦ annual savings

energy savings & molding costs retrofit motor speed control 17 annual savings by motor size annual operating hours6000 energy costEuro 0.10 / kWh oil coolingtower ♦ annual savings

energy savings & molding costs retrofit motor speed control 18 cost vs annual benefit annual operating hours6000 energy costEuro 0.10 / kWh oil coolingtower ♦ annual savings ♦ system cost

energy savings & molding costs retrofit motor speed control 19 typical system inverter to drive the motor controller to regulate the inverter signal interface with host machine user interface for information techniques & experience –installation design & specification –maximise energy savings –deal with host machine faults

energy savings & molding costs retrofit motor speed control 20 typical installation

energy savings & molding costs retrofit motor speed control 21 main screen The main screen displays essential operational information; drive (inverter) status motor speed motor power averaged energy savings

energy savings & molding costs retrofit motor speed control 22 calculate power savings The ‘re-calculate’ button forces the motor to run at full speed for three cycles, then revert to speed control. The Full Power data is retained and the SyncroSpeed data refreshed every three cycles. Users can establish benchmarks of energy performance for every job. Setters have the vital information to refine the job setup to further optimise energy saving performance.

energy savings & molding costs retrofit motor speed control 23 power consumption This screen provides useful information for the user concerning power consumption and energy costs. The ‘energy cost per kWh’ is set by the user. The consumption and cost variables are automatically updated and displayed every 3 cycles of the machine.

energy savings & molding costs retrofit motor speed control 24 candidate machine factors to consider when selecting machines

energy savings & molding costs retrofit motor speed control 25 candidate machine all variablemixedall fixed pumps /7 hours single 55kW motor size cycle 40s static time 50% screw speed = 100% screw speed < 100% job setup Euro 0.06Euro 0.10 energy, kWh nonesoft loans$$ per kW or kWh incentives thin wall ppabs, pathick sections, pvc, pc material & form

energy savings & molding costs retrofit motor speed control 26 candidate retrofit system limited configurabilityconfigured for dynamic performance inadequate overload capacitysized for massive overloads unknown performanceinternational reputation immunity to ‘nuisance trips’ vsd specification it’s ok, it’ll take just a few weeks to put in a bigger one guessworkengineered solutions focus on time & material costsfocus on codes & good practice installation standards oops, no-one told me to ground just one end of the braid

energy savings & molding costs retrofit motor speed control 27 candidate retrofit system commissioning knowledge I don’t know why it’s started to do that... does it matter? apathyproject champion interest, understanding, authority lack of control or proceduresmethods commitment how long have these energy savers been switched off? patchy process knowledgeunderstands IMMs in depth missed linksoperation, control, malfunctions

energy savings & molding costs retrofit motor speed control 28 candidate retrofit system software just like the iPhone 4S – it’s all about the software manually set for each job‘transparent’ to the user fixed speedsfull speed-range response no visual informationstatus & performance screens

energy savings & molding costs retrofit motor speed control 29 in summary vsd retrofits can deliver great savings management understanding and commitment is needed at the start supplier knowledge and experience is the route to the desired result lost savings today are lost forever

energy savings & molding costs retrofit motor speed control 30 checklist for success

energy savings & molding costs retrofit motor speed control 31 success with retrofit MSC … planning select good candidate machines management commitment reliable assessment of energy savings accurate overall project cost

energy savings & molding costs retrofit motor speed control 32 success with retrofit MSC … project installation installation work to correct standards optimal delivery of savings

energy savings & molding costs retrofit motor speed control 33 success with retrofit MSC … delivery IMM productivity OK verify the results

energy savings & molding costs retrofit motor speed control 34 centrally based in the UK retrofit MSC installations around the world CCS SyncroSpeed

energy savings & molding costs retrofit motor speed control 35 energy savings & molding costs Fred Pratt CCS SyncroSpeed, England Robert Knaster CCS SyncroSpeed, New York (914) CPT CCS SyncroSpeed, Cincinnati