GREEN PRODUCTION SUPPLEMENT CONTENTS/INTRODUCTION


Happened and happening


The forthcoming inclusion of machine tools within the EU’s Eco Design Directive has kicked off broader action within Europe’s machine tool industry to drive down energy usage. But such action, while more focused and concerted, is not new


t is probably to the irritation of a number of European, as well as non-European, machine tool manufacturers that their past efforts in the area of energy reduction are not picked up on in this supplement, because what they did in this area occurred a number years ago. Indeed, in its statement about sustainability, German machining centre maker Hermle draws attention to the fact that, specifically: “Energy recovery has been standard for over 20 years.” And back in 2008, GE Fanuc, as it then was, published a document, ‘The Environmental and Economic Advantages of Energy- Efficient Motors’ (still available, http://is.gd/uLCxUc). Concern for the environment, and action that is in harmony with it,


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is not new for machine tool makers or producers of ancillary equipment. But there’s nothing like legislation to focus the mind; that


CONTENTS


NEWS – environmentally-friendly news from manufacturing industry. From machine tool makers using renewable energy to power their factories, through energy-efficient machine tools to reduced energy consumption in air filtration, there are examples that demonstrate the breadth of activity. P4 POWER CUT – The improved energy-efficiency of machine tools is captured in a developing EU directive. We explain what Europe’s machine tool builders are thinking and doing in an effort to influence its content and drive down the energy usage of their products. P6


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Editor – Andrew Allcock MIET Art editor – Neil Young


ENERGY ANALYSIS – Where does the energy go in a machine tool and where can savings be made?


Heidenhain has undertaken some studies. While


some things are clear cut, others are much less so. P10 GREEN COMMITMENT – We run through a few Blue Competence initiative companies’ energy reduction efforts and claims.


Sales – Joe Opitz, Laura Cunningham, Stuart Tarrant Circulation manager – Chris Jones Production– Heather Upton Publisher – Peter Knutton


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It seems that much has already been achieved, although there is still promise held out for more. P12 WHEN LESS IS MORE – MQL (Minimum Quantity Lubrication) provides many benefits to manufacturers, explains David Pearson, Seco Tools’ business development manager (aerospace). P14 SYSTEMATIC APPROACH – Machinery highlights one particular example in the machine tool industry that, we suggest, is unusual in its systematic approach and communication of such. P17


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and customer demand. The former is coming, via the Eco Design Directive and, although its adoption and subsequent coming into force are still some years away, action is already prompted, as this supplement makes clear. The latter is evident within large public companies that boast


corporate social responsibility strategies (and who then often impose these down the supply chain), but not so much in the thousands of SMEs in Europe – although that varies, country to country, of course. But between the push of legislation and the pull of customer


demand, together with increasing energy costs, machine tool-using manufacturers that are not already concerned about their production equipment’s energy usage will, no doubt, become more so. ■


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GREEN PRODUCTION SUPPLEMENT


StarragHeckert and Finn-Power presented information on their efforts at the launch of CECIMO’s Blue Competence Machine Tools event last year (www.machinery.co.uk/41251). German-owned, Switzerland headquartered


cylindrical grinding machine specialist Fritz Studer is also a keen participant in the programme, even before CECIMO’s move (the Blue Competence initiative has its roots in 2008). According to Fred Gaegauf, Studer CEO,


only a few customers are asking for energy efficient improvements on capital investment goods. “Mainly larger organisations, with a sense for saving resources, are starting to make up their mind. However, we feel that as


Green commitment A


number of companies have given more than a few details about their energy- saving endeavours. Tornos,


the discussion has been started on a broader base, we definitely need to get ready to provide the right answers. I am sure the sensitivity is increasing,” he says. But the challenge will be to create


efficiency improvements without additional cost, he offers. “In the end, it is not just about saving energy; it is about saving money, too.”


SAVINGS STUDIED In a state-funded study, Studer, together with Inspire at ETH Zurich, identified all machine tool energy consumers in fine detail on different grinding machine types and prioritised them in order of importance. The grinding machine expends most energy in the grinding wheel drive, but this goes directly into the required grinding power, so there is little saving potential here, the company says.


For Studer’s grinding machines, there’s not


much to be done, in terms of wheelhead power consumption; the opportunities lie


elsewhere, says Fred Gaegauf, CEO


Andrew Allcock runs through a few Blue Competence initiative companies’ energy reduction efforts and claims. It seems that much has already been achieved, although there is still promise held out for more


However, there are gains to be made in the areas of air, coolant and lubrication supply, Mr Gaegauf adds. And the research project highlighted that an energy saving of 14% was possible. Overall, the company suggests that a 25% saving in energy consumption is achievable in the future. Right now, the company’s StuderTechnology


software, which supports the creation of grinding programs, claims to save up to 50% energy, on average, versus a cycle generated without StuderTechnology. “StuderTechnology is not finished yet. The system is being further developed,” says the company. Elsewhere, motors controlled by frequency


converters and the use of regenerative technology are already applied. And at a recent press briefing in Switzerland, Mr Gaegauf said that Studer would soon be in a position to offer real benefits in the energy efficiency area, citing the area of coolant circulation and supply as one of these. But already last year, Studer’s CEO drew


attention to other areas of energy saving. With its latest machine, the S41, the company boasts a reduced warm-up cycle. In a test set- up, a regulated active cooling system is now able to bring an S41 to a stable thermal level within 25 minutes, it said. Mr Gaegauf also highlights the energy-


saving credentials of its machines, prior to use in production. “Studer, for instance, is using machine beds made from a mineral casting. The total energy consumption for producing a Granitan machine bed is only one fifth of the energy required for the same bed in cast iron.” And even further up the process chain, the


company also announced this year that it would now only use electricity from renewable sources in its operations, this having commenced at the beginning of this year. Summing up, Studer’s CEO says: “No


legislation is as strong as customer demand. I assume that, quite soon, the race will start. No one wants to be in the ‘offside position’. We are talking about more efficiency and


12 May 2013 www.machinery.co.uk


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