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MAPAL technology:
Our contribution to energy efficiency
You do not need to be a great prophet to predict that
energy costs and, in particular, electricity prices will
continue to rise. In Germany industry needs more than
40 % of the entire consumption of the electrical power
produced. Approximately 60 % of this usage is down to
the operation of production machines. In the case of
machine tools the energy necessary for machining is very
low in comparison to the total energy required by the
machine. On these machines there are a number of
possible ways of increasing the energy efficiency, for
example by using regulators and controllers to suit the
specific task, as well as by using energy-saving units.
However, these approaches often involve large investments
or even new machines. On the other hand, a
significant energy saving and therefore cost saving can
be achieved with intelligent process optimisation on
existing machines.
changes can be saved. On the other hand, higher feed rates
and the related shorter machine running time bring
significant energy savings.
The conversion to minimum quantity lubrication (MQL) or
dry machining offers even more potential. Energy savings
from 20 to 30 % can be achieved, as the units necessary to
supply the cooling lubricant are not required. MAPAL also
offers complete solutions for MQL technology from the
clamping tool to the cutting edge.
MAPAL specialists optimise the process management
Of particular importance for energy efficiency is reduced
machine running time, that is shorter machining time. On
the one hand this objective can be achieved with reduced
non-productive times. MAPAL’s complete machining tools
combine the machining of various bores, chamfers and
flat surfaces such that often four, five or more tool
Less non-productive time Higher speeds Modern Technology MAPAL +++
A medium-size machine tool consumes approx. 165,000 kWh* per year in three-shift
operation. This signifies carbon dioxide emissions of 95 t CO2* and corresponds to the
emissions from 66 small cars covering a mileage of 12,000 km each.
Due to high performance tools and optimised machining processes, 15 to 20 % of the
total energy required can be saved.
The energy required can be reduced by a further 20 to 30 %, for example by converting
to MQL or dry machining.
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* Sources: Zäh, M.; Niehues, K.: Wie viel Energie verbraucht eine
Werkzeugmaschine? “fertigung” journal 09/2009 date 28.09.2009, page 30ff.
Umweltbundesamt, FG I 2.5., date March 2010