How To Increase Energy Efficiency in Extruder Machines? A Case Study of Removable Thermal Insulation Jackets (I-Cover)

 

In this case study, we are looking at the real-world application of removableinsulation jacket in a manufacturing industry and how it worked in improving the energy efficiency of extruder machines. Through a detailed examination of a client’s extrusion machine, we highlight the challenges faced by the client and how the implementation of removable thermal insulation jacketswas the best solution. 

 

Background

Our client is a leading manufacturer in the plastics industry and operates multiple extruder machines as a part of their manufacturing process. However, they had recently faced the challenges of rising costs and operational inefficiencies in their production which prompted them to look into energy saving solutions. Their main challenge was to minimize heat loss from the extruder machine to the surroundings and to reduce electricity consumption which can optimize energy savings. This case study will focus on the implementation of thermal insulation jacket on one unit of extruder machine.

 

Machine Details

• Machine Age: 7 years
• Operating Temperature: 300 °C
• Design Temperature: 400 °C

 

Challenges Faced

The client encountered several challenges with their extruder machines, including:

1. Heat Loss

As their extruder machines were bare and uninsulated, this resulted in significant heat loss to the surroundings during the extrusion process. The surface temperature of the extruder before the thermal insulation jackets were observed to be 200^oC. As such, this necessitated higher energy inputs to maintain the optimum process temperature.

2.                  High Energy Consumption

Elevated energy consumption levels of about 5,200 kWh per month led to an increase in electricity consumption which in turn led to inevitable increases in operational costs.

3.                  Operational Inconsistencies

Fluctuating temperatures and heat dispersion caused variations in the production output and in turn, production efficiency.

4.                  Personnel Protection

The surface touch temperature of the extruder machines before insulation was recorded to be about 200^oC. Due to the high temperature, there is a risk of burns and injuries to personnel performing maintenance tasks when they come into contact with the hot metal surface. 

 

KLAY EnerSol’s Solution

 

To address these challenges faced by the client, KlayEnerSol team proposed the implementation of a custom-designed removable thermal insulation jackets for the extrusion machines. These jackets were tailored to fit snugly around the various components of the extrusion machine including barrels, nozzles, heaters, blowers, air vents and protruding wires. Thus, this effectively contained the heat within the system and minimized energy loss.

 

KLAY EnerSol’s Implementation Process

 

The team of KlayEnerSol conducted a thorough assessment of the client’s extruder machine to determine the optimal insulation solution. During the site survey, dimensions of individual sections of the extruder were taken to produce design drawings of the jackets. 

Taking into consideration the process operating temperature and environmental conditions, the appropriate fabric and insulation material were selected. Custom fit jackets were then fabricated to ensure a perfect fit and maximum thermal efficiency. 

Their team of installers then successfully installed the jacket onto the extruder machine, considering factors such as accessibility and maintenance requirements.

 

Results of Removable Thermal Insulation Jacket (I-Cover) Implementation

Extruder Machine Before Installation of 

Removable Thermal Insulation Jacket (I-Cover)

Extruder Machine After Installation of 

Removable Thermal Insulation Jacket (I-Cover)

The implementation of the thermal insulation jackets yielded significant results for our client:

1.      Temperature Reduction

The client observed a significant decrease in temperature and heat loss, following the installation of the thermal insulation jackets. The surface temperature after installation of the jackets was recorded to be 50^oC. This led to more stable operating conditions and improved process control.

2.                  Energy Consumption Reduction

The enhanced thermal efficiency due to the insulation jackets resulted in a substantial drop in energy consumption. Energy consumption levels reduced to 950 kwh per week. This translated into significant cost savings within a short period of time.

3.                  Increased Production Efficiency

By preventing temperature fluctuations, the thermal insulation jackets contributed to minimizing production downtime. This supported an increase in production output by minimizing disruptions and optimizing operational continuity.

4.                  Improved Personnel Protection

The thermal insulation jackets act as a barrier between the heat source and personnel working nearby, thus minimizing the risk of burns and injuries to personnel who may come into contact with them during maintenance tasks or regular operation.

5.                  ROI Achievement

The return on investment for the thermal insulation jackets was able to be achieved within a year of installation, proving the cost effectiveness and tangible benefits.

 

Data Collection and Results

 

Temperature Profiling °C

Energy Consumption (unit of energy consumed) (kWh)

Conclusion

This case study highlights the transformative impact of thermal insulation jackets in enhancing the energy efficiency of extruder machines. KlayEnerSol offered removalinsulation jacket address heat loss and optimize thermal performance, hence offering a practical, cost-effective, and low maintenance solution for companies seeking to improve their operational efficiency and increase savings.

As companies continue to prioritize efficiency and sustainability, thermal insulation jackets emerge as a practical and impactful solution for significant cost savings and contribute to a more sustainable and competitive manufacturing process.