Energy Efficiency Archives - Page 4 of 7 - Unitherm Insulation Systems

April 17, 2012 by Kendal White

The New Heating System that will Radically Change the Way You Heat

Imagine a world where heat is always consistent, quick, efficient, and safe. Imagine a heating system that is 70% more efficient than the way you heat now and still safe enough to touch with bare hands. Is this some distant dream, or have we truly arrived at the future of heat technology?

At NPE 2012, UniTherm International introduced its latest product—RapidTherm, an innovative heat solution designed for plastics machinery. UniTherm has been manufacturing insulation jackets for over 20 years, but this new jacket is truly the first of its kind.

RapidTherm is unique in that it combines heating elements and insulation in one easy to use, easy to service unit. The 1-piece, removable insulation jacket includes a built-in thermal vein powerful enough to heat an entire machine. Not only is the thermal vein a more efficient heat source than traditional heater bands, but because it’s encased in high temperature insulation, it saves energy by eliminating excess heat loss.

In tests, the RapidTherm jacket heated barrels twice as fast (cutting start up time in half) and dramatically decreased energy usage. On production equipment, the new heating system

Decreased start-up time by 50%,
Cut energy usage by 70%
Kept the outer surface cool enough to comply with OSHA hot surface standards
Increased worker safety
Cut maintenance time and costs
Eliminated hot spots on the barrel heating profile
Eliminated the need for a barrel shroud

RapidTherm has proven itself as an efficient heating system and promises to liberate processors from the hassle of heater bands. “For years, we’ve known there has to be a better, more efficient way to heat machines,” explains UniTherm president Dan Sherrill. However, previous alternatives to heater bands have been plagued with problems. NPE 2012 was the perfect opportunity to unveil the new heating system, and RapidTherm sparked interest among processors looking to save time and money at their machines. It seems RapidTherm will be the solution that finally puts the heater band headache to rest.

It’s certainly an exciting time for new technology in engineering and manufacturing. Subscribe to our blog for more innovative ideas and industry updates.

March 20, 2012 by Kendal White

Less is More and Lean is Better: Managing Inventory in Manufacturing

The concept of lean manufacturing is simple. Much like a diet for your facility, the goal is to reduce your waste (like you would your waist) for healthier operations. It’s not about starving your business because, let’s face it, you can’t run a marathon or outlast competitors without proper sustenance. Lean strategies are about taking in only what you need and making the most of it—kind of like politely pushing away a plate of food when you’re full rather than stockpiling calories for a later date.

Now I know by March many of our weight loss resolutions have run their short-lived and often unfulfilled courses, but it’s always a good time of year to take on a new style of inventory management.

How manufacturers manage inventory
Many manufacturers produce products in large runs, even when the demand for that product is low. Products are stored or kept in inventory until they are eventually sold, which often leads the manufacturer to overspend on storage. When production runs are too large, manufacturers run the risk of filling inventory with products that might become outdated and remain unsold.

Why lean strategies are more efficient
A crucial component of lean manufacturing involves controlling inventory by reducing excess production. This means implementing a system for monitoring inventory and producing products in smaller runs rather than keeping excess inventory in storage.

Wait, it takes time and money to modify the way you manage inventory and thin out the production line. But just like dropping a few pounds, the payoff doesn’t occur overnight. Soon enough, the savings from storage costs and unnecessary waste will find their way to the bottom line. It’s well worth the change—just ask Toyota, Boeing, Caterpillar, and Xerox.

Not only will lean strategies lower your overhead costs, but they will also challenge your employees to think critically to improve existing procedures. No reason to keep things the way they are just because—hopefully your facility is always on the look out for more efficient ways to operate. Plus, you won’t have to feel that little pang of guilt as you throw away perfectly good products because of bad timing.

March 13, 2012 by Kendal White

See it to Believe it: The Benefits of Thermal Imaging

When thinking about energy output in a manufacturing plant, it’s natural to go to the lights and the HVAC. This makes sense since these are typically the top energy expenditures, but it’s a plant’s machines that devour more energy than all other utilities combined. That’s right, machines consume about 60% of total energy costs. How do we know this? Well, government agencies and other entities provide plenty of studies and statistics for us to read over, but why not see the energy output for yourself?

Thermography is more than fancy spy gear for secret agents to expose hidden enemies—it has a wide range of commercial and industrial applications for those of us in the real world as well. For manufacturers, thermal imaging allows you to visually track the amount and consistency of heat emitted by your equipment. With a thermal camera, you can compare the output of the different heat sources (even those not-so-easy-to-access heat sources) in your facility from a comfortable distance. This way you can find defects in shafts and pipes and locate deteriorating components before they fail.

Equipped with a thermal picture (a thermogram, in case you want to sound technical), you can easily spot the energy hogs highlighted in yellow, orange, and red—so you know exactly what areas to target as you take steps to reduce your energy costs.

Thermal Imaging

Immediately you’ll see your machines light up hot—as they should, that’s how they work. But most likely they don’t need to be operating that hot or emitting as much heat as they do.

The good news? Machines represent your greatest opportunity to conserve energy. Instead of idling, consider powering down equipment during non-peak hours, make sure motors are working as efficiently as possible, and insulate, insulate, insulate. The ROI is remarkable—insulation saves an average of $164 per machine per month. See what thermal imaging reveals so you can start saving.

February 28, 2012 by Kendal White

Why Induction Heat is Super Efficient

Faster than a speeding bullet! More powerful than a locomotive! It’s not up in the sky, it’s…unbelievably efficient induction heat technology!

Ok, maybe I sound a little fanatical, but if you’ve never seen induction heaters in action, I seriously recommended you watch some induction heating demos. These videos will blow your mind. You’ll see metal wires melt, aluminum cans explode, and ice cubes set ablaze—before they even have a chance to melt!

What is induction heat?
Induction is a heating method, but unlike conduction or convection heating methods, it doesn’t require a transfer medium. The inductor itself can be a simple-looking strip of coiled metal (precisely designed to optimize the magnetic field and alternating currents), and the magic is, the inductor never touches what it’s heating, and it never gets too hot to handle with bare hands. I won’t get into the physics of it all, but if you’re interested in how induction heating works, see inductionatmostpheres.com. Basically, induction heat uses radio frequencies, and that’s how it can work sans transfer medium—heat is “induced” by the circulating electrical currents.

The shift toward lean manufacturing and the emphasis on better quality control have led to the rebirth of induction technology and the development of precisely controlled, solid-state induction power supplies.

How can induction heat benefit manufacturers?
For most industrial applications, induction heating offers significant advantages over traditional heating methods—the fast, accurate, and consistent heat transfer reduces energy consumption and creates a safer working environment.

Companies like Ford, John Deere, GM, Cat, Volkswagen, and BMW have already implemented induction heat into their manufacturing processes. Most manufacturers that switch over to induction technology report a decrease in their utility bills. Why is this? Because induction is a highly efficient means of heating that requires less energy to do the same job as, say, a heater band, which is constantly losing energy and reheating.

In fact, uninsulated heater bands are only 30-70% efficient and have a limited lifespan because they must stay hot to operate. Induction heaters, on the other hand, are typically 95% efficient and don’t emit excess energy. Even better, insulated induction heaters can reduce ambient energy loss by 98%.

How can you use induction heat to make your manufacturing process more efficient? If you haven’t already, start thinking about this innovative heating method, and stay tuned for the latest in energy efficient technology.

February 21, 2012 by Kendal White

The Best Ways for Manufacturers to Save Energy: Surveying the Site

Who doesn’t want to save energy? Now more than ever, we are all looking for ways to cut back—we turn down the lights and turn off the thermostat, we run the dishwasher less and take shorter showers—hoping to save some money on the monthly energy bill.

But when you run a large manufacturing plant, the task of saving energy may be a bit more daunting. Before you can start conserving energy, you have to know where the most energy is being consumed and what the best opportunities are for reducing high-energy output.

Knowledge is power, so we’ve put together a simple site survey checklist to help managers get well acquainted with their plant’s energy output. According to the Energy in Plastics Good Practice Guide, you should carry out an initial survey immediately because “if energy is being wasted, it is costing money.” A 20% cut in energy costs can equal the same bottom line benefit as a 5% increase in sales.

It’s also a good idea to take an unannounced walk around the site at about mid-shift to see how things are running during normal working hours.

What to look for during an initial walk through
Keep a close eye on the machines. Machines consume about 60% of energy costs. Yikes. But think of it this way—here lies your greatest opportunity for energy savings.

As you survey the site, keep these questions in mind:

Which areas have the largest energy load? Look for the largest machines; they will have the largest motors and consume the most energy.
Which motors are running? Would smaller motors be more efficient? Could they be turned off during non-peak hours?
Are machines well insulated? Is the insulation in good condition?
Are hot and cold pipes insulated? Is the insulation in good condition?
Which cooling water pumps and vacuum pumps are running?
Does compressed air pressure need to be so high, or the vacuum so low? Can you hear steam and compressed air leaks?
Are lights and machine heaters left on? What is running during lunch breaks and and after working hours?

With a better understanding of where unnecessary energy output occurs, you can now take productive steps to decrease it. Don’t wait—conduct your site survey today to start saving energy and increase that bottom line!

*Statistics from European Best Practice Guide.

February 14, 2012 by Kendal White

More Energy Rebates for More States

We recently wrote about energy rebates and incentive programs offered in Michigan to manufacturers who take action to save energy. Well, we have more good news. Duke Energy’s Smart $aver Incentive Program now offers businesses in Kentucky, Ohio, and North and South Carolina energy rebates for installing equipment such as high-efficiency lighting and HVAC pumps.

Energy rebates in Kentucky, Ohio, North and South Carolina
Duke Energy’s Super $aver program is designed to help businesses offset up-front costs, shorten payback periods, and improve their bottom line by reducing energy output. Companies can qualify for different Super $aver incentives based on their type of equipment—Duke Energy offers incentives for lighting, thermal storage, premium motors, process equipment, and many more.

In addition to providing a list of prescriptive incentives, Duke Energy also offers a Smart $aver Custom Incentive Program to its commercial and industrial energy customers.

Ask your account manager about how to enroll in a Smart $aver Program. And remember, UniTherm offers insulation jackets to keep your equipment insulated and efficient. Be sure to explore all avenues of energy efficiency.

Live in one of the other 46 states?
EnergySavvy.com is a great resource that lets you search for energy rebates and incentive programs in your area.

Check back soon for more energy incentive updates.

February 8, 2012 by Kendal White

NPE 2012—The Event of the Year, Are You Attending?

We find ourselves asking this question what seems like a hundred times every day. With less than 2 months until NPE, the buzz is really building about how this year’s show in Orlando will go and who will be attending.

There’s no doubt that for anyone in the plastics industry this is the show to attend. We’re promised more machines, more innovation, and greater access to our counterparts around the world.

It is an important show, without a doubt. And the new location certainly makes travel and accommodations more affordable than ever before. But we’re still hearing quite a bit of uncertainty from our customers and partners about making the investment to attend.

Simply put, you need to attend this show to learn about new technologies, network with your peers in the industry, find new resources, and maintain a cutting-edge on your company’s competition. We want to see you make it to the show, and so we’ve written a form letter to help you get the conversation started with your decision makers about sending you to NPE 2012. This letter includes the costs for transportation, meals, hotel, and the show itself. Just download the letter and fill in the projects and initiatives you’ll focus on benefiting through NPE. We’ll also get you into the EXPO for free—register here and save $80 with your free EXPO pass. The show begins April 2nd, so you’ll want to make your NPE plans asap.

I hope to see you at the show. Come by and see the new innovative technologies we’re working on in booth #3883!

November 22, 2011 by Kendal White

Energy Rebates Exponentially Increase ROI

To encourage customers to conserve electricity, energy providers across the country are offering their customers some very generous special offers, such as rebates on qualified insulation products. This is one green-friendly program that can save a company significant green-backs for years to come.

UniTherm Insulation Systems is here to help you “green your machines” by providing insulation products for the plastics industry. Our insulation blankets are high return, low investment insulation solutions that can lower your energy bill, protect your employees and lower the ambient air temperature in your facility. With off-the-shelf blankets and the ability to custom design to meet any company’s insulation needs, (altered with slits, cutouts, and/or other augmentations) we make it easy for you to make significant strides toward greening your organization and lowering your monthly electric bill.

SMR saved $17,297

Many have already cashed in on their energy provider’s current discounts and rebates, like Samvarhana Motherson Reflectec, a member of Samvardhana Motherson Group, who recently saved 55% on the purchase of insulation blankets for their largest injection molding plant that houses 45 machines ranging from 250 to 1,000 tons.  Their total savings: $21,250.

96% of Purchase Reimbursed

Another Michigan-based company was faced with the too common concern of spiraling energy costs and needed a way to reduce its environmental footprint for the five 2,000 ton injection molding machines the company uses, but didn’t want to break the bank in the process. After learning of the special rebate from their energy provider the injection molding company decided to purchase qualify insulation products, a decision that will continue to save them money for years to come. Their rebate totaled $15,075, saving 96% on the total purchase.

Mold Masters Company Received $21,725 in Rebates

Heat loss costs organizations hundreds of thousands of dollars annually, but can be prevented with the proper insulation system. With the increased concern for more energy conservation, many companies, like Mold Masters Company in Lapeer, Michigan, will want to take advantage of one of these generous offers provided by energy utility companies all over the country. As a leading manufacturer of thermoplastic parts for the auto industry, Mold Masters Company needed to insulate their entire facility of 40 machines. Ranging in size from 85 tons to 2,450 tons, their rebate totaled $21,725. Mold Masters Company only paid $11,794 out-of-pocket for their $33,519 worth of insulation blankets.

So do these insulation blankets actually work? The answer is yes. Just ask Prism Plastics, who needed their 220 ton Sumitomo machine insulated. According to St. Criox Electric, their energy savings totaled 39.24%. Samvardhana Motherson Reflectec (SMR) is now saving 13.6% on their energy bills for their entire facility – and they expect to save even more in the summer months.

UniTherm insulation blankets have a typical pay-back in as little as 12 months. Add a big-bucks savings rebate from your energy provider and that time frame is significantly decreased to 3 – 4 months or less. You’ll continue to save year over year for the life of the blankets – making the ROI higher and faster than any other energy savings programs you can implement in your facility.

Typical incentive programs differ from state to state and company to company, but on average the offer is $1 per ton on blankets for injection molding, extrusion, blown film, and blow molding and $10 to $30 per linear foot on insulation for pellet dryer ducts (making your out of pocket costs about 50% less on machines and 90 – 120% less on dryer hose insulation).

To find out if your provider is offering a rebate program just give them a call. Be sure to check the details for specific machines and purchasable products.

Companies who have already cashed in on this incentive are doing their part to reduce energy consumption and are moving the savings straight to their bottom line.

Our sales representatives are here to help you start saving.

October 11, 2011 by Kendal White

Compressed Air Safety

Thanks to Kirk Edwards, Application Engineer Manager at EXAIR Corporation for his contribution to the UniTherm blog. EXAIR Corporation manufactures compressed air products for industry with a focus on efficiency, safety and process improvement.

My first experiences with compressed air were many years ago and involved welding gas tanks. My friend’s dad was a welding supply salesman in Grand Rapids, MI and we had full access to his welding rigs in the garage. This generally included large tanks of oxygen, acetylene, helium and regular compressed air. We had a few favorite activities with all this gas. One, for when the parents were away, involving helium to lift a plastic bag of acetylene, a long string (wick), and a lighter – enough said? The other was blowing air at each other or using a needle nozzle to blow the air on our skin and watch the cool indent it made. We always knew raising flammable bags of acetylene in the air was a bad idea, but couldn’t resist feeding our youthful pyromania. And we never gave a second thought to blowing air at each other or onto our skin. Come to find out that’s a really bad idea too… [Read more…]

October 7, 2011 by Kendal White

Plastics Manufacturing Insulation Jackets – Site Visit, Manufacturing, Install, and Support

At UniTherm International it is our goal to provide outstanding experiences and solutions for our customers. If you are in the plastics industry this post can serve as a guide to the process of outfitting your facility with UniTherm products. [Read more…]

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