July 2002 - New Maguire Low Pressure Dryer Lights the way for Automotive Lighting

New Maguire Low Pressure Dryer Lights the way for Automotive Lighting

Vacuum Drying versus Dehumidifying Drying. 

Summit Systems Ltd the plastics automation specialist from Tamworth has completed extensive on-site tests with leading 1^st Tier automotive lighting manufacturer Automotive Lighting UK Ltd of Cannock.

Over a six-month period tests have shown dramatic savings with an incredible capital payback of less than 2 months.

Molding Engineer Michael Griffiths for Automotive Lighting stated, "We knew there would be significant power savings benefits from this technology and this is confirmed with us saving £517 a month but more exciting is the vast reduction in rejects. Clear Polycarbonate lenses are notoriously difficult to mould free of contaminates & splash marks, with this technology we have reduced scrap rates by 50%" Mr Griffiths quoted other benefits being the reduced start up time, reduced heat exposure to the material & constant process conditions all of which contribute to improved moulding conditions.

The 28-minute start-up time add to zero material changeover times equates to a 30% increase in production capacity for the machine.

Mike Jordan, managing director of Summit Systems Ltd is delighted that the hard work has paid off. "Bob Ryles, our sales engineer, has handled the project with Michael Griffiths of Automotive which has been challenging considering we were introducing new technology to a demanding production environment".

Summit is investigating the claim procedure for subsidies from the government in relation to the climate change levy, with this power saving it is likely that the capital cost can be written off within the first year.

Automotive Lighting UK Ltd
Walkmill Lane
Cannock, Staffordhsire
UK WS113LP

Test results are detailed below:

Taking a critical application:

Products manufacturing automotive headlamp lenses:

Output approx. 70kg/hr

Material: Clear Polycarbonate

 ·       Power Consumption Savings

Maguire LPD-100 - rated at 2.2kW/hour

Dehumidifier dryer - rated at 18.0kW/hour

Assuming the dryers are running at their maximum kW/hour rating for 75% of the time, the power consumption saving is as follows: -

(18 x 75%) -  (2.2 x 75%)  = 11.85 kW per hour saving

This equals an 87.7% Reduction in the running costs.

Based on the average industrial power cost of 6.5p per kW/hour, the saving per month is as shown below: -

6.5p/kWh x 11.85kW/h x 24h x 7 days x 4 weeks =  £517.60 saving per month.

·  Space Saving

The Maguire LPD-100 takes up to 50% of the floor space of a dehumidifier dryer with a 600 L dryer hopper.

·  Start Up Time Saving

The start up time for the Maguire LPD-100 dryer is 15 to 30 minutes, this compares with 4 to 5 hours using a conventional dehumidifier dryer, saving up to 4½ hours or a 90% reduction in mould start up times.

To give an idea of possible cost savings we can insert these facts in to a model example:

Based on production of, say,100 mouldings per hour @ 73 second cycle, 2 impression mould & a product cost of £1.00 each. The savings due to a  5% scrap rate reduction over one months production would be as set out below:

100 parts/hour X 24hr X 7days X 4wk X 5% scrap reduction X £1.6 Molding price each =

£5,376.00 saving per month

Clearly the part cost has a direct influence on the saving but these figures demonstrate a significant reduction.

Maguire Products, Inc., headquartered in Aston, Pennsylvania, U.S.A., is the world's largest supplier of gravimetric blenders and liquid color pumps and also manufactures loading systems, granulators, dryers, auger feeders, and related equipment. Its customers include injection, blow, and rotational molders, extrusion processors, and compounders. Founded in 1977, Maguire operates five manufacturing facilities in Aston and Smithfield, Rhode Island, U.S.A. The company maintains a network of distributors in the Americas and overseas. Maguire Europe, a sales and service subsidiary, operates a distribution center in Tamworth, Staffordshire, United Kingdom, that supports customers throughout Europe. Maguire Asia, based in Singapore, serves customers throughout South Asia and the Pacific Rim. Visit the Maguire Products web site: www.maguire.com