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Preliminary Evaluation on Industrial Mould & Equipment

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Preliminary Evaluation on Industrial Mould & Equipment Evolve in real life A case study Matrix seminar – March 2011 Liviu BÂRSAN 1 Who am I? Liviu BARSAN Who am I Who we are Diploma in Mechanichal Engineering, Politechnical University, Bucharest What we do Roto shop Master in Biotechnical Engineering Beginnings In Valrom since 2005 Evaluation Trial R&D department – part design & engineering Industrial run Conclusions How to 2 L. Barsan (Marh 2011) - © Valrom Industrie Who are we? VALROM Industrie srl Who am I Who we are Romanian company headquarted in Bucharest What we do Shareholders: Valsir Spa (Italy) & Romstal Roto shop Group (Romania) Beginnings Established: 1996 Evaluation Trial 330 employees in 2010 (630 in 2008) Industrial run Sales of 45 mil. € in 2010 (75 mil. € in 2008 ) Conclusions How to Market leader in plastic pipes & fittings 3 L. Barsan (Marh 2011) - © Valrom Industrie Who are we? • Branches in Bulgaria, Moldavia & Ukraine Who am I (production site) Who weare arewe What we do Roto shop Beginnings Evaluation Ukraine • logistics • production site Trial Moldovia • sales Industrial run Conclusions How to Bulgaria • sales 4 L. Barsan (Marh 2011) - © Valrom Industrie Our business Heating & sanitary systems; water, gas and Who am I sewage networks; waste-water treatment plants Who we are Production: plastic pipes & fittings – PE, xPE, What we do PP (homo & random) etc Roto shop Beginnings Production facilities: Romania (2 sites) & Ukraine Evaluation Trial Extrusion (12 lines); injection molding Industrial run (8 machines) Conclusions Roto: 4 machines (Caccia & Polivinil) How to 5 L. Barsan (Marh 2011) - © Valrom Industrie Roto shop Established in 2003 Who am I Machines: 2 Caccia RT 3503F, 1 Polivinil 3500 3C, 1 Who we are Polivinil 4500 3C What we do Tools shop – reworking, new moulds, maintenance Roto shop Grinding process in house – Powder King PK DD Beginnings 220 Evaluation Consumption – 60 MT/month Trial Industrial run Raw materials: PE – compact & foaming, PP (limited) Conclusions How to In house design & engineering 6 L. Barsan (Marh 2011) - © Valrom Industrie Roto shop Who am I Who we are What we do Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to 7 L. Barsan (Marh 2011) - © Valrom Industrie Roto shop Products range: water tanks, sewage manholes, Who am I water-meter chambers, small waste-water Who we are treatment plants etc What we do Technology: single, multi-layer, foaming, lining Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to 8 L. Barsan (Marh 2011) - © Valrom Industrie Evolve - beginnings Who am I Involved in this project since beginning (2009) Who we are The material still under development What we do Valrom agreed to test it on industrial scale Roto shop Beginnings Our goal – cost cutting by either decrease of oven temperature or cooking time Evaluation Trial Steps: Industrial run 1. preliminary evaluation on industrial mould & equipment Conclusions 2. limited production test (subject to material availability) 3. full production test (at least 24 hours) How to 4. economical evaluation 9 L. Barsan (Marh 2011) - © Valrom Industrie Evolve – preliminary evaluation Preliminary evaluation on industrial equipment: Who am I mould & equipment Who we are Scope: evaluate how much we can decrease the What we do oven temp and/or cooking time Roto shop Equipment: Caccia & Polivinil Beginnings 0 Evaluation Standard condition: 50 kg for 30 min @ 270 C 0 Trial • PIAT 155 C Industrial run Thickness: standard 6 mm Conclusions Material: Evolve M748F, powder, black How to Part evaluation: Matrix lab 10 L. Barsan (Marh 2011) - © Valrom Industrie Evolve – preliminary evaluation Who am I Who we are What we do Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to 11 L. Barsan (Marh 2011) - © Valrom Industrie Evolve – preliminary evaluation Who am I Who we are What we do Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to 12 L. Barsan (Marh 2011) - © Valrom Industrie Evolve – preliminary evaluation Who am I Who we are What we do Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to 13 L. Barsan (Marh 2011) - © Valrom Industrie Evolve – preliminary evaluation Who am I Who we are No. Cooking Density Impact Aspect conditions (g/cm3) strength (J) What we do 1 25 @ 260 0C 0.942 60.9 No pinholes; inside surface looks nice & smooth Roto shop 2 23 @ 260 0C 0.939 60.9 No pinholes; inside surface looks nice & smooth Beginnings 3 20 @ 280 0C 0.937 60.9 No pinholes; inside surface Evaluation looks bumpy – slightly undercooked Trial 4 20 @ 285 0C 0.943 60.9 No pinholes; inside surface looks nice & smooth Industrial run Conclusions How to 14 L. Barsan (Marh 2011) - © Valrom Industrie Evolve – preliminary evaluation Who am I Who we are What we do Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to 15 L. Barsan (Marh 2011) - © Valrom Industrie Evolve – preliminary evaluation Who am I Conclusions for evaluation: Who we are The new material performs well What we do There is no decrease in product performance Roto shop Beginnings It allows decrease of oven temperature and/or cooking time Evaluation Trial Further tests to follow on either time or temperature Industrial run decrease Conclusions How to 16 L. Barsan (Marh 2011) - © Valrom Industrie Small scale trial Who am I Scope: • confirm preliminary evaluation of product capabilities – Who we are lower gas consumption; on larger scale What we do • test effect of dry blending Roto shop Equipment: Polivinil machine running exclusively Beginnings Evolve for one shift Evaluation Material: Evolve powder, natural, dry blend pigment Trial (grey) in our facility Industrial run Lab evaluation: Matrix Conclusions How to 17 L. Barsan (Marh 2011) - © Valrom Industrie Small scale trial Evolve cooks faster Who am I Natural better than grey dry blend Who we are N-307 N-307 EVOLVE N-307 GREY EVOLVE What we do 0.945 Roto shop 0.940 Beginnings Evaluation 0.935 Trial 0.930 Industrial run Part Density (g/cm^3) Conclusions 0.925 How to 0.920 5 7 9 11 13 15 17 19 21 23 25 Cook time (min) 18 L. Barsan (Marh 2011) - © Valrom Industrie Small scale trial Who am I Conclusions Who we are Standard part thickness 6 mm What we do Standard cycle: 30 min @ 270 0C Roto shop 0 Beginnings Oven temperature reduction: 30 min @ 252 C Evaluation Cycle time reduction: 22 min @ 270 0C Trial Part evaluation: Matrix lab Industrial run Conclusions How to 19 L. Barsan (Marh 2011) - © Valrom Industrie Full industrial run Who am I Scope • record of primary data Who we are • perform economical calculation What we do Two days run on all machines Roto shop Beginnings Product range: shafts, water tanks Evaluation Evolve used exclusively Trial Industrial run Gas consumption measured accurately Conclusions • before trial • during trial How to 20 L. Barsan (Marh 2011) - © Valrom Industrie Full industrial run Who am I Results Who we are 2010 average: What we do • 617.390 kg processed • 285.062 m3 consumption Roto shop Beginnings 24 h before: Evaluation • 2.561 kg PE processed • 1.230 m3 consumption Trial Industrial run Evolve, in 2 days: Conclusions • 5.338 kg PE • 2.181 m3 consumption How to 21 L. Barsan (Marh 2011) - © Valrom Industrie Full industrial run Who am I GAS Consumption 0.5 Who we are 0.4802 0.460 What we do 0.4 0.4085 Roto shop Beginnings 0.3 Evaluation 0.2 Trial Industrial run 0.1 Conclusions How to 0 2010 (average) 24h before EVOLVE 22 L. Barsan (Marh 2011) - © Valrom Industrie Conclusions Who am I Gas consumption can be decreased by 15% (14,93%) Who we are What we do Cooking time can be reduced by 25% Roto shop The values depends on local conditions: Beginnings • machine efficiency Evaluation • type of material • processing conditions Trial Industrial run Savings: it depends on your conditions Conclusions How to 23 L. Barsan (Marh 2011) - © Valrom Industrie How to ... in 8 steps 1. Who am I Get a gas meter Who we are 2. Make it works What we do 3. Register your average consumption Roto shop • 1 month minimum Beginnings 4. Get enough material for 24 h production Evaluation Trial 5. Register your consumption before trial Industrial run Conclusions How to 24 L. Barsan (Marh 2011) - © Valrom Industrie How to ... in 8 steps 6. Who am I Run full day production • decrease your oven temperature with 18 0C or Who we are • decrease your cooking time with 26% What we do 7. Register gas consumption during trial Roto shop 8. Beginnings Check quality of the final product • Matrix might run some lab test for you Evaluation Trial Industrial run Calculate the savings and take the right decision! Conclusions How to 25 L. Barsan (Marh 2011) - © Valrom Industrie Thank you ! Questions and comments... 26.
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