Improved cost-effectiveness and energy savings
“The energy savings achieved with the EcoStar system are the result of reduced waste gas loss and the use of energy-optimized switched-mode power supplies in the microwave channel,” explains Harald Hepke, Head of Rubber Technology at Hannover-based KraussMaffei Berstorff. “Closed circulation of the process air provides maximum cost savings because the air is heated centrally and 90 percent of the energy-intensive hot air remains in the system,” Hepke says. Another new feature is the improved thermal insulation of the process chambers. Hepke is convinced that “as energy prices continue to rise these technical improvements will be key criteria for a positive investment decision in favor of KraussMaffei Berstorff systems.” Moreover, KraussMaffei Berstorff is the only manufacturer worldwide who has managed to reduce the opening and closing times of microwave and hot air treatment channel doors to a few seconds. “Many profile manufacturers handle three to four recipe changes per day and need to open the treatment chambers for this purpose, so EcoStar will give them a significant increase in productivity,” Hepke explains.
Where frequent material changes are necessary, the pneumatic doors reduce set-up and cleaning times substantially. When the treatment channel is opened, the hot inside panel of the doors automatically moves downward towards the frame, giving operators easy and ergonomic access to the profiles and enhancing operator safety.
Time-tested technology for maximum reliability
Each of the three microwave channel modules is equipped with four 1.5 kW generators. This means that each module supplies 6 kW magnetron power, which adds up to a total installed magnetron power of 18 kW for the entire channel. A circulator integrated into the energy supply transfers the energy not absorbed by the product to the connected water load, thus improving the magnetron service life. The microwave generators are arranged above and below the conveyor belt. The specific design of the microwave coupling system ensures an extremely homogeneous field distribution. Both the microwave power and the conveyor belt speed can be continuously adjusted. The microwave channel has an effective cross-section of 150 mm width and 75 mm height.
The central control panel ensures that system settings can be selected with maximum ease of use. And the innovative process-oriented user interface helps to reduce set-up times during material changes.
Focus on environmental protection
Environmental aspects such as energy efficiency and a long machine lifecycle have played a vital role in the development of the new system. Thanks to its sophisticated intelligent technology, the EcoStar rubber profile production line is an eco-friendly solution even at high production speeds.
