Sustainable Manufacturing Processes Address Numerous Industrial Challenges
Eco-friendly machinery and raw materials from industry leaders empower companies to achieve their sustainability targets. The post Sustainable Manufacturing Processes Address Numerous Industrial Challenges appeared first on Fabricating & Metalworking.
New Eco-conscious Bending and Blanking Solutions
AMADA AMERICA, INC.’s (Buena Park, CA) latest generation of servo-controlled press brakes, the EGB 6020 ATCe, is equipped with a high-performance electric drive system combined with an Automatic Tool Changer (ATC) and voice command control. These production-enhancing features ensure high-speed bending and repeatable accuracy even if an operator lacks experience. In addition, a compact, newly-redesigned ATC can precisely load complex tool layouts within minutes — making it the ideal solution for variable lot sizes and the seamless introduction of rush jobs.
An integrated HMI control tablet is positioned above the tooling bed to provide convenient access to bending data, thereby maximizing efficiency and productivity. A backgauge camera connects to the HMI tablet and AMNC 4ie control to ensure the correct bend position. The control provides operator face recognition and allows voice commands to request, change, and verify bend information while the operator is on the move — all as an automatic foot pedal slides to the next bending position to ensure continuous operation.
To further boost productivity, Bi-S II Bend Indicator Sensors automatically measure and correct bend angles up to 85% faster than Bi-S technology. And a new electric Auto-Crowning system maintains longitudinal accuracy throughout production. Additional EGB e models available include: 6020 standalone, 8025 standalone, 1303 standalone and 1303 ATC.
In adherence to the primary section of AMADA’s Basic Policy on Sustainability, the company is
committed to treating people and the global environment with respect. We achieve this goal by reducing CO2 emissions, promoting the reduction and reuse of waste, and protecting the global environment, including biodiversity in all processes. We also provide environmentally friendly products and services through our business activities.
Tooling Company Exceeds Sustainability Strategy Goals
The CERATIZIT Group has made significant progress in implementing its ambitious global sustainability strategy. CERATIZIT USA Inc. (Schaumburg, IL) is part of CERATIZIT Group. In a sustainability report released from the Plansee Group, of which CERATIZIT is a part, some of the defined targets have been exceeded.
CERATIZIT’s global sustainability strategy focuses on four key areas: sustainable product and technology innovation; material and resource efficiency in production; attractive working conditions; and the combination of ecological and social aspects in the supply chain.
A key performance indicator in the first phase is CERATIZIT’s corporate carbon footprint (CCF). The company demonstrated significant progress toward its 35% target CCF reduction by fiscal year 2025. Using 2020 data as a baseline and Europe-based markets for new operations roll-out, CERATIZIT was able to reduce its CCF by 22% in fiscal year 2023. The company went from 201,449 tons of carbon dioxide equivalent (CO2e) emissions to 156,988 tons of CO2e.
Another key performance indicator is the recycling rate for the primary raw material tungsten. CERATIZIT was able to exceed the target of 90% in 2023, with a recycling rate of 95% in European markets. In conjunction with achievements in the recycling rate, CERATIZIT featured the ProACT-Mill at IMTS 2024. The new line of milling cutters not only offers up to 30% longer tool life but was also developed from the more sustainable upGRADE carbide CT-GS20Y. This carbide grade is characterized by 99% reclaimed carbide powder and therefore conserves valuable raw material resources.
“CERATIZIT’s ownership of the supply chain continues to be a key differentiator for us,” said Dan Cope, president of the Americas for CERATIZIT. “Our metallurgists have been forming, sintering and finishing quality carbide for decades and now that includes recycled tungsten carbide.”
The high-impact achievements towards CERATIZIT’s global sustainability goals have been executed in Europe but have a direct benefit for manufacturers in the Americas. “In addition to providing a proven blueprint to implement sustainable logistics and recycling practices in our market, we are prepared for companies throughout the Americas that currently require OEMs and tier partners to meet sustainability benchmarks,” Cope added.
www.cuttingtools.ceratizit.com
Fully Electric Plate Roll Machine Offers Precision and Energy Efficiency
e-POWER electric plate rolls from Davi are at the forefront of innovation.
Davi Inc.’s (Addison, TX) e-POWER steel plate roll machine embodies the highest levels of precision, productivity, ease of maintenance and energy efficiency all within a quiet, compact machine that ensures hassle-free installation.
Because it is electric, the machine achieves a positioning accuracy of five hundredths. This is compared to the typical one-tenth precision normally offered. With such precise control and positioning, the machine ensures repeatable and reliable results for a variety of applications, delivering exceptional quality and accuracy in the end product.
For increased productivity, e-POWER’s smooth and simultaneous movement across multiple axes allows the machine to execute multiple tasks concurrently, saving valuable time and effort. Maintenance tasks are cleaner and more straightforward, thanks to the system’s single actuator component. The absence of hydraulic control units significantly contributes to e-POWER’s small footprint and makes it more space-efficient to conserve valuable production floor space.
As an intelligent system, e-POWER utilizes energy only when necessary. This approach to energy management proves to be advantageous in plate rolling processes where there are frequent idle times during the operation. The machines significantly reduce carbon emissions and contribute to a greener future.
Green Hydrogen Cutting Tech for Hydrocarbon-free Automated Cutting
To improve performance while decarbonizing automated cutting of steel, ESAB (North Bethesda, MD) offers its new SmartJet Green oxy-hydrogen cutting. When hydrogen burns in combination with oxygen, the main byproduct is water, eliminating the carbon dioxide produced by burning acetylene, natural gas or propane. At FABTECH 2024, the SmartJet Green technology was part of live demonstrations using a Combirex PRO, ESAB’s most popular high-precision automated system for oxyfuel and plasma cutting and beveling.
SmartJet Green’s hydrogen cutting technology offers faster pre-heat speeds, excellent cut quality, slightly faster cutting speeds and reduced dust generation compared to oxy-acetylene, noted Steve Zlotnicki, global product manager, cutting systems at ESAB. “Preliminary cost efficiency calculations indicate that hydrogen costs about 20% less than acetylene and 30% less than propane. Because it combines cost, quality, and performance benefits, we believe hydrogen cutting will become a preferred process in steel service centers, shipyards, wind tower and other heavy fabrication applications.”
Hydrogen cutting has a distinct advantage for cut starts and piercing regardless of plate thickness. Zlotnicki said a good table operator can preheat a plate in 20-to-30 seconds with oxy-acetylene. Using SmartJet Green technology reduces preheat time to 5-to-10 seconds because the focused hydrogen flame heats a specific point (which also the mitigates the risk of excessive overheating). The SmartJet Green torch can pierce steel up 150 mm (6”) and edge start on steel up to 300 mm (12”).
In terms of average flame temperature, acetylene is 3,200° C, hydrogen is 2,976° C and propane is 2,850° C. However, because of hydrogen’s focused flame, cutting speeds are equal to, or slightly faster than acetylene. As an example, tests at ESAB’s cutting automation center in Karbon, Germany, showed that the SmartJet Green torch cut 30 mm plate at speeds of 480 mm/min or better; in comparison, an oxy-propane flame cuts steel at 400 mm/min.
Manufacturing Wellness Habits Boost the Bottom Line
Sandvik Coromant (Mebane, N.C.), a manufacturer of premium metal-cutting tools, continues to build on its Manufacturing Wellness initiative, which is a mindset that values balance in the manufacturing industry, helping companies thrive and forge lasting change. Sandvik Coromant believes successful manufacturing companies deliberately do certain things. These can be consolidated into a series of habits that lead to a state of Manufacturing Wellness. There are eight habits the company follows to achieve Manufacturing Wellness, which includes choosing sustainable paths, which are not only good for the planet but also boosts a manufacturer’s bottom line; and eliminating waste by uncovering waste along the value chain to find new ways to improve processes.
One of Sandvik Coromant’s newest sustainability products is Sustainability Analyzer, a new feature to its Productivity Analyzer software tool. It assists users in measuring energy consumption and carbon footprints. Users can track energy consumption per component in kilowatt hours (kWh), the energy consumption per year, and the amount of CO2 emissions generated per year.
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