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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. 7 6 5 4 3 2 1 * 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
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