FEATURE Springs & Fasteners
B
ath-based strap, clip and cla mp manufacturer, HCL Fasteners, continues to demonstrate its unwavering commitment to the sustainability agenda with its latest technology investments. A long-term Demag advocate, this year the manufacturer of high strength hose clamps, non-corrosive offshore strapping, and renewable energy farm bandings, upgraded its production line installing two 75 ton and one 50 ton IntElect machines from Sumitomo (SHI) Demag. Another 75 ton machine was delivered in February. Saying farewell to three Systec 50 ton hydraulic legacy systems was a bittersweet moment. Having produced tens of millions of Herbie Clips and other patented components since the company’s inception, Managing Director David Coles cites the reliability of the 25 year old machines as the key rationale for the micro-enterprise transitioning to Sumitomo (SHI) Demag’s all-electric series. Says Mr Coles: “Serving such a diverse international client base, we need to balance resilience and agility alongside constantly innovating ways in which we can lessen our environmental impact. We are always seeking more ways to address the climate crisis and accelerate our decarbonisation efforts.”
PRODUCING MORE, USING LESS With energy consumption responsible for approximately two-thirds of greenhouse gas emissions, the precision and energy effi cient IntElect’s are predominately powered by a 130kW solar-panel system located on HCL Fastener’s roof top. Any additional energy generated is fed back into the grid. Comparative tests performed by Sumitomo (SHI) Demag on the new 75 ton IntElect’s has resulted in a minimum 42 per cent energy saving. Even with a bigger machine and robotics. In addition to improving HCL’s energy
HCL Fasteners strengthens
environmental stewardship at source
consumption metrics, the three machines have collectively boosted productivity by up to 30 per cent. For an SME and ‘climate positive’ business like HCL, this helps to tackle the misnomer that all-electric effi ciency is purely linked to reducing your emissions.
Mr Coles explains: “Processing predominantly
exotic, non-corrosive and high tensile polymers used in marine, oil and gas, renewable energy and automotive applications, cycle time, machine uptime and reliability almost supersede the energy saving stakes. Equipped with robotic sprue separators, our new IntElect’s have proven that it is possible to signifi cantly optimise our resources and increase commercial productivity without having a detrimental environmental impact.” Precision moulding is equally critical for safety,
with HCL manufacturing tensioning tools to install high strength cable clamps and sea straps in extreme conditions, including submerged marine environments, offshore oil and gas rigs, windfarms and underground mines. “Guaranteed fi t and fast tension fi tting are paramount,” Mr Coles went on. “We have developed a number of systems manufactured in-house to minimise the time that engineering specialists, for example divers, would need to spend exposing themselves to the ocean depths.” Maintaining a consistent melt cushion and stable process has noticeably improved moulding accuracy, he reports, aided by the in-built hot runner and non-return activeLock valve. The addition of cartesian robots on all three IntElect machines supports HCL’s self-sustaining manufacturing approach and eliminates parts getting stuck at source. “Production consistency for a lights out operation like ours is critical to operational effi ciency. I’m now confi dent that I won’t come into the factory the next day to encounter 12 hours of lost production time,” he states. As well as being markedly more hygienic and easier to maintain, the automatic resetting of clamp forces and intuitive control panel made the transition to the IntElect machines seamless. Mr Coles adds: “Switching from the NC4 to the NC5+ control panel could not have been easier. From everyone’s perspective, our new IntElect’s are even easier to use.”
HCL Fasteners uses the machines to manufacture tensioning tools to assist with the installation of high strength clamps, non-corrosive tidal ties and bands in high-risk environments.
28 March 2022 Irish Manufacturing
Sumitomo (SHI) Demag
http://uk.sumitomo-shi-demag.eu
www.irish-manufacturing.com
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