A Modification Case - on Extruder
Advantage and disadvantage of current heating status of traditional extruder:
(1) Advantage: No radiation pollution.
(2) Disadvantages: (a) Too much power wasting. (b) High Malfunction Rate (c) High-temperature working condition
Advantage of the modified heating (extruder) by KFE:
(1) Power Conservation: Electromagnetic induction heating efficiency reaches to 90%, which benefits to raise the entire power supply of substation.
(2) Working Condition Improvement
(3) Upgrade Product Quality: Because electromagnetic induction heating process is stable, therefore PET granule won’t get stuck in the tube and can be completely melted before forming.
(4) No risk of radiation pollution
I. Overall evaluation of traditional heating & KFE modified heating on Extruder
II. Equipment surface temperature measured:
According to our modification experience, on condition that extruders operate normally, and circumstance 30 degrees, the following table shows the result that different heating systems influence on extruder surface temperature:
III. Preventing Radiation Pollution Risk---EMC
To avoid electromagnetic interfering with equipment operation, we take EMC into our extruders and devote ourselves to a reliable design to develop multi-protective components and modules apply to various industrial conditions, such as: anti-interference part and metal electromagnetic shield to ensure workers a safe working environment.
IV. Overall Energy Conservation Analysis (10000kWh x 3.0 is 1 ton standard coal)
Electromagnetic heating equipment helps to reduce power consumption of injection molding machine drastically, and saves 30% to 60% of power according to our experience. The following table shows estimated budget after launching KFE modified extruder:
Remark1. Traditional Extruder:
Assuming traditional extruder heating power is P = 62.4KW；
actual heating power is P × 40%；
Yearly operating hour is T = 8000 hours
Hourly power consumption would be 62.4KW × 40% = 24.96KW/H
Yearly power consumption would be 24.96KW/H × T = 199,680KW
Remark 2. KFE modified heating (extruder)
Assuming KFE modified heating (extruder) power saves 40% of energy (how much energy saving depends on circumstance temperature, equipment heating temperature, plastic raw materials …etc, generally it saves 30%~50% of power, so we assume 40% power conservation here.)
Hourly power consumption would be 24.96KW/H × (1-40%) = 14.98KW/H
Yearly power consumption would be 14.98KW/H × T = 119,840KW
To sum up, electromagnetic induction heating can save up to 40% of energy, which contributes to cost down and be more competitive, moreover, it also reduces power supply of the whole business substation.
Before Modification After KFE Modification
No rediation pollution- Equipment Major Controlling Cupboard & Electromagnetic Induction Coil Radiation Measuring.
For more information: kfe@kfe.tw
Contact: Mark Lee
Advantage and disadvantage of current heating status of traditional extruder:
(1) Advantage: No radiation pollution.
(2) Disadvantages: (a) Too much power wasting. (b) High Malfunction Rate (c) High-temperature working condition
Advantage of the modified heating (extruder) by KFE:
(1) Power Conservation: Electromagnetic induction heating efficiency reaches to 90%, which benefits to raise the entire power supply of substation.
(2) Working Condition Improvement
(3) Upgrade Product Quality: Because electromagnetic induction heating process is stable, therefore PET granule won’t get stuck in the tube and can be completely melted before forming.
(4) No risk of radiation pollution
I. Overall evaluation of traditional heating & KFE modified heating on Extruder
| Items | Heating Principle | Advantage | Disadvantage |
| Traditional Extruder | Resistance Heating Principle | No Radiation Pollution |
|
| KFE Modified Extruder | Electromagnetic Induction Heating Principle |
|
None |
II. Equipment surface temperature measured:
According to our modification experience, on condition that extruders operate normally, and circumstance 30 degrees, the following table shows the result that different heating systems influence on extruder surface temperature:
| Item | Equipment Content | Equipment Surface Temperature Measured |
| Traditional Extruder | Resistance Wire Heating Block | ≥180℃ |
| KFE Extruder | Electromagnetic Induction Coil | ≤60℃ |
III. Preventing Radiation Pollution Risk---EMC
To avoid electromagnetic interfering with equipment operation, we take EMC into our extruders and devote ourselves to a reliable design to develop multi-protective components and modules apply to various industrial conditions, such as: anti-interference part and metal electromagnetic shield to ensure workers a safe working environment.
IV. Overall Energy Conservation Analysis (10000kWh x 3.0 is 1 ton standard coal)
Electromagnetic heating equipment helps to reduce power consumption of injection molding machine drastically, and saves 30% to 60% of power according to our experience. The following table shows estimated budget after launching KFE modified extruder:
| Items | Yearly Power Consumption | Yearly Power Consumption convert to Standard Coal |
| Traditional Extruder | 199,680KW (Ref. to Remark 1) | 59.90TONS |
| KFE Extruder | 119,840KW (Ref. to Remark 2) | 35.95TONS |
| Total Yearly Power Conversation | 79,840KW | 23.95TONS |
Remark1. Traditional Extruder:
Assuming traditional extruder heating power is P = 62.4KW；
actual heating power is P × 40%；
Yearly operating hour is T = 8000 hours
Hourly power consumption would be 62.4KW × 40% = 24.96KW/H
Yearly power consumption would be 24.96KW/H × T = 199,680KW
Remark 2. KFE modified heating (extruder)
Assuming KFE modified heating (extruder) power saves 40% of energy (how much energy saving depends on circumstance temperature, equipment heating temperature, plastic raw materials …etc, generally it saves 30%~50% of power, so we assume 40% power conservation here.)
Hourly power consumption would be 24.96KW/H × (1-40%) = 14.98KW/H
Yearly power consumption would be 14.98KW/H × T = 119,840KW
To sum up, electromagnetic induction heating can save up to 40% of energy, which contributes to cost down and be more competitive, moreover, it also reduces power supply of the whole business substation.
Before Modification After KFE Modification
No rediation pollution- Equipment Major Controlling Cupboard & Electromagnetic Induction Coil Radiation Measuring.
For more information: kfe@kfe.tw
Contact: Mark Lee