Electro
Heat Engineer's Zone Heating System gives freedom
to heat only the desired zone of the rolls in
a Corrugating 2 Ply Machine. Provision of three
individual heaters in one roller gives the Corrugator
independence to heat the panel side, centre side
and motor side individually or in combinations
as desired. Such controls are facilitated by a
control panel.
Eg: In a 52" Corrugating Machine one may
have 17" hot part towards the panel side,
18" in the centre portion and 17" toward
the motor side. For 35" Corrugated sheet,
one may use just 2 zones Le., the panel side and
centre zone on one day; and alternatively the
motor side and the centre zone the next day. This
will give the Corrugator numerous advantages in
today's competitive scenario.
Advantages
of Zone Heating System |
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Savings
in Electricity Consumption |
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Normally the
electricity consumed by a Corrugating Machine
in 2 years is more than the cost of the machine
itself! Corrugators have a tendency to opt
for a bigger machine than their regular size
to accommodate bigger width of paper, if need
be. Often an average Corrugator runs 36"
or less width on a 52" Machine. By way
of putting a Zone Heating System on a Corrugation
Machine of 52" the following savings
may result.
We assume a Corrugator using a 52" Vertical
type Bearing mounted Corrugation machine for
240 hours in a month, produces 36" or
lesser width 2 ply 160 hours a month and sizes
above 36" 80 hours a month. The electricity
cost is Rs.5/= per unit.
Electricity Cost per month :
1.
With normal heaters (in all cases) |
27KW
x 240 hours x RS.5 |
= Rs.
32400 p.m. |
| 2. With Zone heating
system (using better heat disipating
materials) |
| (i) When producing 36" or more
2 ply |
23 KW x 80 hours x RS.5 |
= Rs. 9200 |
| (ii) When producing 36" or less
2 ply |
15 KW x 160 hours x RS.5 |
= Rs. 12000 |
| |
(i + ii) |
= Rs. 21200 p.m. |
| |
Electricity Savings (1-2) |
= Rs. 11200 p.m. |
| This value may vary depending
upon the electricity tariff paid by
your unit. The savings will increase
for a bigger width machine or a high
speed machine. |
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Extremely
good quality 2 ply output |
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For a higher gsm. paper,
the machine speed has to be normally reduced
as the heat requirement increases. If the
paper width is less than the machine size,
the temperature on the idle part of the flute
rolls and the pressure roll, where no conversion
is made, increases beyond desired. In that
area, the roll expands diametrically and hence
the edge of 2 ply, nearer to that area does
not get proper pressure, resulting in blister
formation. This problem is totally overcome
in Zone Heating System. |
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Elimination
of need for Multiple Machines |
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Very often,
Corrugators keep machines of various sizes
to improve quality and save electricity. Zone
Heating System can eliminate the need for
such multiple size machines thereby saving
investment and precious space. |
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Reduction
in Machine Wear and Tear |
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Conversion
of small paper width on a larger machine,
results in overheating of the part of rolls
where there is no conversion. This causes
various complications. The rolls on the idle
part expand more than the working part resulting
in the cutting of flutes from that part reducing
the life of the flute rolls considerably.
Large Variation in the temperature (on the
higher side) of flute. roll creates imbalances
in the running of the machine. This results
in negative impact on rotary parts of the
corrugation machine. Zone Heating System helps
reduce all such wear and tear, facilitating
longer life of the machine itself. |
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Reduction
of Overall Electricity Load |
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As explained
above in Advantage 1., the overall requirement
for electricity comes down drastically. This
automatically reduces the load on the generator
set, mains, electric wiring, fuses, MCB, and
transformers etc.; thereby increasing their
life and efficiency considerably. |
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Easy
Installation and Convenient Use |
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The Zone Heating
System can be installed on a Corrugation machine
within 4 hours, keeping minimum downtime.
Electrical heating for Corrugation machines
is a proven success in India. This system
is designed to make best use of electricity
by eliminating undesired heat. It is clean,
simple and convenient. |
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