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Kent R.,Tangram Technology Ltd.
Plastics Technology | Year: 2012

Robin Kent from Tangram Technology Ltd., shared his views on the role of cooling-water management in energy savings. The first stage in such a program involves minimizing the demand, and the first step is to reduce heat gains. The reduction of heat gains will minimize the cooling load and can have a large impact on the running costs of any installation. It is possible to make major improvements to energy efficiency by identifying the heat loads and reducing them. The important thing is the water temperature at the operating process in place of the temperature as it leaves the chiller. There are two main areas for improvement, such as minimizing parasitic loads by insulating pipes, tanks and other components and minimizing unwanted heat gains by providing chilled water only to areas where it is actually needed. Source


Kent R.,Tangram Technology Ltd.
Plastics Technology | Year: 2012

The article discusses the importance of optimizing the distribution of compressed air to save energy. Compressed air must be treated to remove oil and water vapors and other contaminants, and the quality of the air can have a significant effect on the reliability and maintenance cost of the system. Treatment is an expensive operation, but even companies who are good at managing compressed air can fail in this area. Treatment costs depend on the air quality specified, but most companies have no idea of the specification to which they are producing compressed air. Filters cause pressure drops and to save energy it is recommended that only the minimum filtration requirement be met. Filters should be adequately sized for the duty and should be regularly checked for cleanliness. Distribution costs are hidden, and improving the distribution system can produce large reductions in the cost of supplying compressed air. Source


Kent R.,Tangram Technology Ltd.
Plastics Technology | Year: 2011

Industry experts suggest that plastic processors need to use less energy to generate compressed air in their plants. The best solution to minimize unproductive off-load energy consumption is to use a piston or screw compressor fitted with a variable-speed drive (VSD). These use a variable-speed AC motor to continuously adjust the amount of compressed air generated and will significantly reduce energy use when the compressor is lightly loaded. It is possible to provide the base load with a fixed-speed compressor and use an additional VSD compressor to provide the variable demand and trim overall energy usage where the demand for compressed air is high. Plastic processors also need to monitor their compressor operations and consider purchasing a VSD compressor to reduce costs when the compressor is operating with a long off-load cycle. Source


Kent R.,Tangram Technology Ltd.
Plastics Technology | Year: 2012

Robin Kent from Tangram Technology Ltd., states that a reliable and consistent source of cooling is essential in plastics processing. Regular analysis of performance data is recommended to enable any loss of efficiency to be detected before complete loss of service. This is particularly important, as cooling consumes 11% to 16% of the energy used in a plastics processing plant and simple actions can significantly reduce this energy use. It is essential to differentiate between cooling water at 60 to 95 F and chilled water, as they can be generated by very different methods and are used for different applications. Cooling water can be provided by simple cooling towers and is used for general non-critical machine cooling. Chilled water needs chillers or similar equipment and is used for more critical mold cooling and temperature control. Source


Kent R.,Tangram Technology Ltd.
Plastics Technology | Year: 2012

Process cooling is a major energy user in injection molding, and many processors use a split system. Split systems enable processors to use the chilled and cooled water systems to their best advantage. Where multiple chillers are used, it is common to find that they have different setpoints. In this case, the first remedial action is to get the chilled-water temperatures consistent across the plant. As a first step, operators must choose the highest reliable temperature setting and synchronize all other settings with this. They must check for any problems with machines or processes and solve the problems. They must be careful of using uncalibrated thermometers when setting chilled- water temperatures. In most cases, the production staff will campaign for lower chilled- water temperatures, in the belief that they can provide shorter cycle times and faster production. If temperature controls are not used, the system may deliver water at a variable temperature and this can affect process control and process stability. Source

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