infographic about energy savings

Reifenhauser Kiefel shows test results for energy savings in blown film extrusion

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  • Enclosure of barrels & heater-bands to be the most efficient measure
  • Reifenhäuser Kiefel Extrusion shows internal test results

Depending on the country, several thousand euros can be saved every year in blown film production through simple measures such as the enclosure of certain line components. The amount of savings depends on the component chosen. Tests conducted in the Technology Center of Reifenhauser Kiefel Extrusion with various raw materials and different production parameters have shown this result. The enclosure of barrels and heater-bands has proved to be the most efficient measure.

Insulating sleeves can lead to EUR 12,000 per year in energy savings

The engineers were able to save extruder heat energy between 20 and 50 percent alone by providing the barrels and heater-bands with insulating sleeves. In more specific terms, this means that energy savings of up to 100,000 kWh per year can be obtained when encased barrels instead of non-insulated ones are used in a 5-layer blown film line processing resin of 500 kgs/h. These savings correspond to about EUR 12,000, depending on the energy costs.

Insulation installed on extruders can save several thousand euros per year (Source: Reifenhauser Kiefel Extrusion)

Insulation installed on extruders can save several thousand euros per year (Source: Reifenhauser Kiefel Extrusion)

Insulation of blown film die much less effective

Much less effective is the insulation of the blown film die, which was also shown in tests carried out in the Technology Center. Here, the benefit lies only in the starting and heating-up phases of the extrusion line. Therefore, a medium-sized blown film line would generate cost savings of only some 1,000 € per year. The effects achievable for both insulation applications depend to a large extent on the material used, process parameters and output rate.

The company has summed up the most effective energy efficiency measures under the term of Blue Extrusion. The package encompasses the use of high-performance motors and drives in addition to insulation and customized design of complete lines. Many of the measures can be retrofitted without great time and cost expenditure in order to increase energy efficiency and production profitability.

Main Picture:Energy consumption and energy savings obtained with insulation, shown in percent for different extruded products (Source: Reifenhauser Kiefel Extrusion)

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