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COVER STORY SUPPLEMENT SUSTAINABILITY DOESN’T
HAVE TO COST THE EARTH Sustainability doesn’t have to come
at a cost, in fact many companies are finding that their initiatives are
saving them money. Turck Banner has identified areas where it can assist companies save costs and become more sustainable
T
urck Banner has identified areas in which it can help companies on the route to sustainability while saving costs. It has
broken these down into three broad categories: Energy management, product efficiency and supply chain management. So let’s look at the energy management category – heat management in mobile equipment; cabinet monitoring in electric vehicle charging; and air flow management at Lawton Yarns.
INTELLIGENT PRODUCT DESIGN The enormous increase in energy costs has focused everyone’s minds on their energy bills. At home, we often have to put up with just turning things off for periods of time, as the cost of replacing them with a more efficient item outweighs any savings. However, in the manufacturing industry, an intelligent redesign of the final product, focusing on heat and power consumption, is a viable proposition that can yield savings for both manufacturer and customer. For example, a large manufacturer of mobile equipment with worldwide customers faced the challenge of the equipment often operating in extreme temperatures. To protect internal components, the control cabinets required both heating and cooling. By providing control systems with an operating temperature range of -40 to +70˚C and a protection class of IP67, not only was the requirement for heating and cooling eliminated, but also the cabinet itself. This resulted in reducing the overall power
requirements of the vehicle, the weight and space required for the heating and cooling equipment, as well as the weight and space needed for the control cabinet. The reduction in weight and size also has an ongoing cost saving in fuel and wear and tear of the vehicle; while an added benefit of no control cabinet is that the control equipment is much more accessible, making repairs quicker and easier to perform whilst the vehicle is in the field.
MONITORING EV CHARGERS Electric Vehicle Charging points are rapidly
becoming a critical part of the country’s infrastructure. But, maintaining them in good working order is a particular challenge, as they are remote from the provider, and customers get very disgruntled when one is not functioning. Not only can the cabinets be subjected to both accidental damage and vandalism, but the internal components may also fail over time.
Yarns is one of the few remaining yarn and wool makers for the carpet industry. As many of its machines are quite old, modernising them is extremely difficult. When winding yarn onto spools, huge quantities of air are used to stop broken threads from jamming the machines. By detecting a thread break and only producing air when it is needed, the company was able to save £76K per year with an ROI of only nine months. The machines originally had no data capabilities, but Turck Banner was able to easily capture data from the sensors and inverter drives then pass this data to the cloud, where simple analysis identifies air leaks, bearing wear and other trends which allowed predictive maintenance to further reduce their costs. These are just three examples where careful
Monitoring EV charging points
By including a data logging cabinet monitor
which can detect conditions likely to result in a failure, an early warning can be sent to the provider. The conditions monitored are: whether the cabinet door is correctly closed; humidity from water ingress; light entering through a damaged casing; and temperature generated by the charging components. Data logging and internal trend processing result in the warning usually being sent before the charger fails, thus allowing maintenance to be planned for maximum efficiency and minimal cost. Repairing the charger before catastrophic failure is both less expensive and reduces scrap. Customers are also happier with greater charger availability.
DATA COLLECTION Monitoring the flow of liquid and gaseous media has many benefits, ranging from simply knowing how much is being used to identifying leaks and predictive maintenance. In your home, for instance, a single dripping tap or toilet overflow wastes about 5500 litres of water per year. Established over 120 years ago, Lawton
FEBRUARY 2023 DESIGN SOLUTIONS - SUPPLEMENT 35 Turck Banner
Lawton Yarns was able to save £76K per year
T: 01268 578888
https://www.turckbanner.co.uk/en/ sustainability-43697.php
investment in the right products can have a significant impact on both short and long term savings while, at the same time, making the product or process more sustainable.
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