Thermoforming - Gas Technology Institutegta.gastechnology.org/reflibrary/thermformcase.pdf · Using...
Transcript of Thermoforming - Gas Technology Institutegta.gastechnology.org/reflibrary/thermformcase.pdf · Using...
Technologyin Actiona leading ice chest manufacturer - Texas
benefitsBenefits RealizedIncreased SafetyIncreased Production by 20%Increased Energy SavingsReduced Reject RatesLower Maintenance Costs
locationTechnology on LocationA leading manufacturer of deep-drawer ice chest liners converted to catalyticheating after a succession of fires occurred at their plant. Dropped plastic sheetssparked fires that evacuated the thermoforming department.
(This is) one ofthe fastestreturns on
investment thatwe have ever
made.
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d”MaintenanceManager
whatWhat was InstalledManufacturer: Vulcan
Catalytic SystemsType: Catalytic System
RetrofitsGas Company: Texas Gas
Industrial Center Inc.www.industrialcenter.org
The Gas Research Institutewww.gri.org
Plastics Suitewww.plasticssuite.com
ThermoformingOvens/Burners
The Plastics Suite® is a collection of tools and resourcesto help increase awareness ofnatural gas technologies in theplastics industry. Currently plastics processing consumes approximately 280 trillion BTU’sof energy throughout NorthAmerica. Electricity accounts for95% of this energy consumption.Natural gas is an under-utilizedoption which can in mostinstances produce the sameproduct at a reduced cost. ThePlastics Suite® consists ofequipment manufacturer guidesand software for calculating equipment feasibility and projecting cost estimates. For more information on thePlastics Suite®, visit the webpage at www.plasticssuite.com.
Other Plastics Suite®Technology in Action
Profiles Available
Air Compressors
Central Thermal Fluid Systems
Chillers
Desiccant Air Dryers
Resin DryersactionTechnology in ActionIncreased SafetyNatural Gas catalytic heating is safe because it is flameless. This low intensity, non-glowing technology eliminates NOx emissions and is 99.9% efficient.
Increased ProductionThe plant received a 20 percent increase in production from each thermoformer. Infact, the operators who handle the post-thermoforming work have become overbur-dened by the increased production. The company intends to ease this burden by automating some of their secondary trimming and tasks which will allow them toturn the heaters up higher to create even faster cycle times.
Energy SavingsUsing natural gas to heat thermoplastic sheet products during thermoforming oper-ations provides 25-70% energy cost savings over electric heating. Even better, thereare no demand charges for gas. The increased efficiency of natural gas catalyticheaters often results in pay-off times of less than one year. The company’s mainte-nance manager calls this retrofit project “one of the fastest returns on investmentthat we have ever made.”
Reduced Reject RatesThe heaters deliver uniform wall thickness in the parts, which has resulted inreduced reject rates for the company.
Lower Maintenance CostsThe company has experienced lower maintenance costs since the purchase of thenew thermoforming units.
Overall SatisfactionThe two initial installations became the thermoformers choice for the operators ofthe difficult-to-mold ice chest liners. Convinced of the benefits from catalyticheaters, the ice chest manufacturer ordered two more.
For more information please contact your local Gas Supplier or visit our website: www.plasticssuite.com
The information contained herein is provided for general information purposes only and is not intended orto be construed as a warranty, an offer, or any representation of contractual or other legal responsibility.
ThermoformingOvens/Burners