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Problems and Causes
The owner of plastic Extrusion Machines, most of which have a diameter of 30 cm and length of approximately 1.00 m, operating 24 hours per day for 26 days per month, was assigned to implement an energy conservation project in the production area to reduce unnecessary costs. They had the idea that if the temperature difference between the extruder surface and room temperature could be reduced, it would help decrease the electricity costs of the extruder. The improvement method must not impact the extruder and production process, and the system installer must provide after-sales service and product warranty.
Improvement Method
Based on the requirements specified by the extruder users, NTI recommended installing removable thermal insulation, a model that is water-resistant and can withstand chemicals or molten plastic flow, brand ZAVE® which is fire-retardant and asbestos-free. Since it needs to be removed and installed multiple times each month, they chose insulation with a density of 170 kg/m³ (high density) as it would be more durable and have a longer lifespan than general thermal insulation. This comes with a warranty for post-installation heat prevention efficiency, guaranteeing that the insulation surface temperature will not exceed 50 degrees Celsius.
Improvement Results
| Comparison | Average Extruder Surface Temperature (Celsius) |
Heat Loss/Year (Heat Loss: kW) |
Electricity Cost Loss/Year (Electricity: Baht) |
| Before ZAVE® insulation | 250.0 | 17,472 | 63,773.00 |
| After ZAVE® insulation | 45.0 | 3,744 | 13,665.00 |
| Reduction | 205.0 | 13,728 | 50,108.00 |
