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ecoPlus – Technology that pays off


ecoPlus saves resources and costs Energy, time, material and personnel – conserve these precious resources and save cash with ecoPlus technologies from the HOMAG Group, helping you to make your company more productive. ecoPlus is an integral part of nearly every machine made by the HOMAG Group. The innovative, environmentally friendly technologies are instantly recognisable by the ecoPlus sign.

Contents 04

Saving as standard – with ecoPlus

06

Saving energy on standby

08

Selective extraction technology

10

Reducing pressure – lowering consumption

12

SORB TECH – greater stability, maximum precision

14

Always at your disposal: higher productivity

16

Powerful drive systems, frugal consumption

18

BARGSTEDT: intelligent material flow

20

BRANDT: state-of-the-art technologies and innovative drive systems

22

BÜTFERING: fine finish efficiency

24

FRIZ: raising the profile of savings

26

HOLZMA: optimum material usage

28

HOLZMA: intelligent air cushion tables

30

HOLZMA: thin kerf saw blades

32

HOLZMA: good for the climate – and for your bottom line

34

HOLZMA: a competitive edge through continuous improvement

36

HOMAG: the laminating technology of the future

38

HOMAG: so that everything runs smoothly

40

HOMAG: edge banding with laserTec

42

HOMAG: efficiency for processing centres

44

HOMAG: always the right vacuum

46

HOMAG: resource savings made easy

48

LIGMATECH: intelligent technologies that save money and protect the environment

50

WEEKE: on course for higher cost-effectiveness

52

WEINMANN: more economy for the house

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Technology that benefits the environment


Saving as standard – with ecoPlus The 100-plus ecoPlus technologies from the HOMAG Group make production even more profitable for you. After all, we place a great deal of importance on progress and continuous improvement in our machine building. That’s what counts, and that is what we understand by genuine sustainability. In this brochure, you can discover how we make success measurable with the help of ecoPlus.

ecoPlus

Your benefit

The basis for calculations

Consumes up to 30 % less energy

In order to quantify potentials for savings, it is necessary to define uniform general conditions and costs. For this reason, the following values are used as the basis for calculations in all efficiency examples in this brochure, unless stated otherwise:

Any company that makes consistent use of HOMAG Group solutions – from the saw through to the edge banding machine, and from the processing centre through to the sanding machine – can benefit by energy consumption cuts of up to 30 %!

Electrical energy: 0.12 € per kWh (value varies with country ­and price scale) Compressed air costs: 0.04 € per Nm³ at 6-7 bar Extraction system:

rgy ss ene s. You 3 0 % le with ecoPlu o t p U o al at n mption cons u e a g r eat d e v can sa st! o ex tra c

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HOMAG Group

| The basis for calculations

Required electric power approx. 1.8 kW per 1 000 m3/h at 2 500 pascal negative pressure at the connection to the machine and 4 200 pascal negative pressure at the fan. Utilisation: We assume that the machine is operated for 50 weeks a year, for 80 hours per week using a two-shift operation (40 hours per week using a one-shift operation).

The ecoPlus effect – you can ­count on it! To show you in advance just how much you can save with ecoPlus, we have developed the ecoPlus calculator. Ask your HOMAG Group sales advisor for more details. He will be happy to use the ecoPlus calculator to show you your potential savings in a clear way and with no obligation. Tip: Look into any possible sources of governmental support for planned new investments. Your chances of qualifying are particularly good with the help of ecoPlus! HOMAG Group

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Saving energy on standby One of the central components of the ecoPlus concept is the standby function. This puts the machine into an energy-saving standby mode – either automatically after a certain period of time, or when the ecoPlus button is pressed. All the energy-consuming systems go into sleep mode. If you press the button again, the machine returns to its normal operating mode within a few seconds.

Resource: Energy| Standby

Your benefit

The technology

Efficiency example 1

Efficiency example 3

The ecoPlus button saves hard cash. This is an ideal solution for businesses where the machine does not need to work around the clock, but has to be available immediately if needed.

The ecoPlus button is clearly visible on the innovative user interface. In addition, many of the HOMAG Group machines automatically go into standby mode after a certain time interval has elapsed, even without a button. As soon as the standby mode is started:

HOMAG processing centre BMG 512 with a connection value of 26 kW:

Energy consumption at a glance

The standby function has already proved its value many times. That is why almost all the machines from the HOMAG Group are equipped with the ecoPlus button.

• The machine interrupts normal operation • Energy-consuming units are switched off • All servo drives are disconnected from the mains • A signal automatically deactivates the extraction system

• Standby operation alone can reduce energy consumption when the machine is idle by up to 8 160 kWh p.a. • Up to 5.7 t less CO₂ per year • Cost savings of up to 980 € p.a.

Efficiency example 2

button

Anyone looking to increase the energy efficiency of their production process, needs to know the current consumption of their machine. The HOLZMA energy monitor allows you to do exactly that, for example using panel saws from model series 3, 4 and 5. The CADmatic operating software displays how much energy the saw is consuming for processing steps at any given time. Savings potential can be accurately pinpointed.

KF 520 sizing and edge banding system (complete furniture line) for lengthwise and crosswise processing: • Connection value: 350 kW including transport • Yearly savings of up to 30 000 kWh • Up to 21 t less CO₂ per year • Cost savings of up to 3 700 € p.a.

HOLZMA energy monitor

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HOMAG Group

HOMAG Group

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Selective extraction technology The amount of energy required by extraction systems in woodworking applications has always been formidable – that is, until now. The new ecoPlus technologies from the HOMAG Group can reduce the energy consumed during extraction by up to 40 %.

Resource: Energy

| Extraction

Your benefit

The technology

Efficiency example 1

Efficiency example 3

The amount of energy required for chip removal is reduced by up to 40 %, thanks to process-dependent, needs-based extraction concepts such as:

Process-dependent extraction controlled on the basis of individual flaps and with two separate negative pressure areas:

HOMAG KFL 326 with ecoPlus:

BÜTFERING Series 300 with ecoPlus:

Every extraction unit that is not permanently in use has its own gate at the connection to the tool. This opens and closes automatically, depending on its operating status.

• Negative pressures: 2 500 Pa for finish processing, 1 800 Pa for sizing • Savings: up to 33 000 kWh p.a. • Payback period for the additional investment: 2-3 years • With control of the individual flaps

• Annual energy savings in the range of 18 000 kWh, achieved by lowering the extraction volume

Furthermore, there are two separate areas with controlled fans and different negative pressures. This allows the extraction of the individual units to operate as needed.

Efficiency example 2

Efficiency example 4

Profile trimming unit with i-tools on a HOMAG edge banding machine:

HOLZMA has reduced the required extraction volume by up to 15 %:

• Extraction requirement cut by up to ­3.8 million m³ a year • Energy consumption reduced by up to 4 200 kWh p.a., or 47 % • CO2 emissions cut by up to 3 t a year • Cost savings: up to 500 € p.a.

• Optimisation of all components relevant to the extraction system • New geometry of the saw carriage and the chip channel • Cost savings of approx. 170 € p.a.

• Individual flap control and two separate negative pressure areas • i tools • Multi-section extraction hoods • Tools with chip guidance and fitted extraction hoods

In order to coordinate when the extraction system is switched on and off precisely with the operation of the saw, HOLZMA has been equipping the panel saws of its ­3 series with intelligently controlled switching contacts since 2009. As a result, the units are only activated when they are actually needed, which significantly reduces energy consumption.

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HOMAG Group”

HOMAG Group

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Reducing pressure – lowering consumption Compressed air is a major issue for many machines when it comes to energy efficiency. Several consumption reduction measures can yield annual savings that run into four figures.

Resource: Energy

| Reduction in compressed air consumption

Your benefit

The technology

Efficiency example 1

Efficiency example 2

The amount of energy used to supply your machines with compressed air can be reduced by up to 40 %. This is achieved by optimising or eliminating consuming units.

2-line compressed air supply reduces compressed air consumption

HOLZMA HPL 400:

HOMAG KF 500:

• Implementing all measures, including the options available for the compressed air, can achieve savings of up to 28 % • Cost savings of up to 403 € p.a. • Energy consumption cut by up to 1 209 kWh p.a. • Up to 0.85 t less CO2 per year

• Depending on equipment, potential savings of up to 25 % for compressed air • Cost savings of up to 7 700 € p.a. • Energy consumption cut by up to 23 100 kWh p.a. • Up to 16 t less CO2 per year

The technology HOLZMA panel saws: • Shortening the length of the hose between valves and cylinders • One cylinder instead of two for the lift drive of the main saw • Scoring saw lifted by means of motor instead of pneumatic drive (optional) • Clamp cylinders dimensioned according to blade projection, thus avoiding unnecessarily filling unused cylinder capacity • Reduction of cylinder diameter and capacity for pressure beam cylinders

HOMAG decided to divide the compressed air supply system into two parts: an actuating air network and a blowing air network. As a result, only those consumers that require high pressure are operated using high pressure (in the same way, consumers that only require low pressure are only supplied with low pressure). • Reduced operating pressure in the blowing air network • Reduced total compressed air consumption by approx. 25 % HOMAG processing centres:

The basis for calculation 1 • A cost of 0.04 €/Nm³ for compressed air • One-shift operation • Triple Mix cutting patterns • Eight hours per shift • 250 working days

The basis for calculation 2 • A cost of 0.04 €/Nm³ for compressed air • Two-shift operation • Eight hours per shift • 250 working days

• Automatic central lubrication with semifluid grease • Use of optimised blowing nozzles, for example for better results when blowing away chips HOMAG throughfeed machines: • Use of Laval nozzles • Use of sensor system without cleaning air • Improved use of cleaning air

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HOMAG Group

HOMAG Group

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SORB TECH – greater stability, maximum precision The HOMAG Group produces its machine frames – the “supporting platforms” for the processing units and the workpiece supports – from the mineral material SORB TECH. SORB TECH stands for a low-vibration, stable machine design promising improved work results and maximum precision. Complete with savings potential.

New material

| SORB TECH

Your benefit

The technology

Efficiency example

The basis for calculations

The primary energy input for producing SORB TECH is three times lower than the input required for steel.

SORB TECH absorbs vibrations very effectively, and its high weight allows it to absorb almost 100 % of all machine jolts. The result is faster acceleration coupled with improved precision and smoother operation.

HOMAG processing centre BMG 511 with SORB TECH machine bed:

In terms of resources, SORB TECH provides a substantial increase in efficiency as early as the manufacturing phase. The amount of primary energy required to produce a tonne of steel is substantially higher than that needed to produce a tonne of SORB TECH.

The advantages in day-to-day operation: • Longer tool lives • Higher feed speeds and faster acceleration • Saves time • Saves money

The fibre-reinforced mineral mix also makes far more efficient use of energy and resources than steel does and offers significant cost advantages in comparison with a welded steel design.

• Energy input reduced by up to 4.48 MWh/t* • Energy input for machine bed reduced by up to 12.15 MWh/t* • Primary energy savings of up to 63 %*

SORB TECH is used in manufacturing:

The bottom line: the production of a tonne of steel requires 3.6 times more energy.**

• BÜTFERING wide-belt sanding machines SWT 500 and SWT 900 • HOLZMA panel saws of the 5 series • WEEKE CNC processing centre BMG 400 • HOMAG CNC processing centre BMG 500/600

* When manufacturing a machine bed

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HOMAG Group

• Primary energy required to produce a tonne of steel: 6.236 MWh/t • Primary energy required to produce a tonne of SORB TECH: 1.752 MWh/t

** Sources: • Stahl-online: Energy management – CO₂ monitoring of the steel industry • Agreement between the government of the Federal Republic of Germany and German industry on climate targets

HOMAG Group

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Always at your disposal: higher productivity There is also another way to achieve energy efficiency: by producing more without increasing energy consumption. Over recent years, productivity in HOMAG Group machines has risen on average by up to 30 %. The machines produce more in the same time period – and use no more energy than before. This can be done, for instance, by implementing intelligent production processes, as the example of HOLZMA shows.

ecoPlus availability

Your benefit

The technology

Efficiency example 1

Efficiency example 3

Increasing output, more intelligent processes and more productive hours of operation – while consumption of energy and resources remains unchanged or even falls. That is what the new ecoPlus technologies promise, thanks to:

Optimised processes at HOLZMA:

HOMAG edge gluing machines with the new QA 65 application unit for low glue levels:

HOLZMA Power Concept:

• A guaranteed steady production flow • Prevention against exceeding the capacity of individual components, thereby eliminating the risk of bottle-necks • Lower workloads for machine operators, allowing them to take on other tasks More output for the same or less input, for example by reducing set-up periods by means of: • woodLine • woodScout • The HSK push button • The new QA 65 application unit

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HOMAG Group

Intelligent processes start with the feeding system and continue right through to destacking. • Perfect saw/storage interface • Cut Rite from HOLZMA is the best-selling optimisation software worldwide, delivering real cash savings • Power Concept • Pressure beam height control and prepositioning • Cutting length limitation • Simultaneous label printing • Central side aligner • AB-BA system for angular saws • …and much, much more

• Production time increased by up to 30 minutes per shift and up to 125 hours per year • Cost savings: up to 17 500 € p.a.

| Productivity

The additional clamp, which can move independently of the program fence, prevents performance peaks and increases performance by up to 40 %.

Efficiency example 2

The basis for calculations

BRANDT edge banding machine KDF 1680 profiLine with workpiece gap optimisation:

• Two-shift operation, heating up only once • Machine-hour rates of 100-140 €

Calculation of the ideal gap between workpieces in relation to the feed speed and workpiece thickness guarantees up to 20 % higher output for the same input.

HOMAG Group

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Powerful drive systems, frugal consumption Efficiency begins with the drive system. This is why the HOMAG Group has replaced all the three-phase asynchronous motors by new highly efficient motors with IE2 energy efficiency rating. In addition to this, HOLZMA, for example, employs frequency-controlled main saw motors, which allow the rotation speed to be individually matched to the material. Thanks to an integrated bypass circuit, the machine can still achieve short bursts of maximum power exceeding the rated kW.

Resource: Energy

Your benefit

The technology

Efficiency example

You save from the word go thanks to energy-efficient IE2 motors. HOMAG already complies with the provisions regarding IE2 drive units set forth in the relevant EU Directive, even though it does not come into force until 1 January 2017. Beyond that, the HOLZMA frequency converter allows you to...

IE2 motors:

HOLZMA HPL 300 with IE2 motor:

Regulation (EC) No. 640/2009 is applicable within the European Union; there are other directives in place in other parts of the world. The key features:

• With energy-efficient 18-kW main saw motor (optional) • You can save up to 190 € a year

• Process many different materials • Process plastic sheets • Set a high value on precision • Cut large books • Subject the saw to high loads for short periods – time and again

• Higher degree of efficiency • Therefore lower energy costs • Lower thermal loads achieved by greater engineering precision • Lower CO2 emissions*

| Drive systems

HOLZMA bypass circuit: With a frequency-controlled 21-kW main saw motor and 50 % use of the bypass circuit, you can save up to 36 € a year.

HOLZMA bypass circuit: The frequency converter improves the cut quality and prevents short-term overload operation of the motor. The integrated bypass circuit allows you to work in a particularly flexible way: You can use it to deactivate the frequency converter and switch to mains power at the push of a button. The ideal solution for short periods of high throughput or when processing very hard materials. * Applies to three-phase motors that are designed for 50 Hz or 50/60 Hz operation (for a more precise definition and exceptions please refer to Regulation (EC) No. 640/2009).

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HOMAG Group

HOMAG Group

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Intelligent material flow For an effective material flow, you need efficient machines. The ecoPlus measures are another step in BARGSTEDT’s on-going commitment to solutions that offer low total operating costs. BARGSTEDT machines are known for their long service life, low wear and low maintenance – equipped with ecoPlus features, they also save energy and considerably reduce costs.

Intelligent logistics for efficient material flow

BARGSTEDT

| Efficiency included

Your benefit

The technology

Efficiency example

The basis for calculations

Increased process stability:

The more efficiently a company deals with resources, the higher the added value achieved by its products.

TLF 210 horizontal storage system with ecoPlus:

• Total output of the three axes: 7 kW • Based on one shift a day • Approx. 30 panels to be processed and approx. 200 movements per shift • Up to 480 panels per shift at approx. 60 seconds per movement

• Easy, reliable panel handling even when a large number of types is involved • No disruption of production caused by lack of material Optimisation of the production process: • The material flow is optimised – only amounts that are going to be used in the near future are stored Closed resource cycles: • Shorter delivery periods allow just-in-time purchasing • Optimum use of left-over material cuts material costs Loss-free infrastructure operation: • Savings in human resources – the jobs of cutting and preparing material are dealt with separately • Automated transport ensures high utilisation of the processing machines • All material is managed

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HOMAG Group

BARGSTEDT provides its customers with logistic solutions that optimise the entire material flow from the receiving of the goods to the processing machine, and also make efficient use of available resources. • Reduction of the moving masses • Intelligent stand-by operation • Optimised compressed air consumption for parts handling • Ultrasonic sensors for low compressed air consumption • Integration of storage system, saw, offcuts store and cutting pattern optimisation • High degree of process reliability in separating parts • Fewer storage movements

• Savings of up to 58 % achieved by intelligent standby operation • Savings of up to 50 % achieved by use of ultrasonic sensors • Savings of up to 14 000 € achieved by reliable parts handling (i.e. books of thin panels, weight measurement); the operator does not need to intervene

woodStore analyser — simply better woodStore analyser is a unique software module offered by BARGSTEDT for optimising warehousing systems. The program examines and analyses the main functions of a customer’s warehouse over an individually specified period of time in order to determine if the customer is using the warehouse system optimally. If the analysis reports a need for improvement, the integrated expert system uses the findings as the basis for suggestions for increasing warehouse efficiency.

HOMAG Group

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State-of-the-art technologies and innovative drive systems BRANDT uses a number of ecoPlus technologies to benefit your bottom line. Innovative drives optimise the performance/consumption ratio. State-of-theart sheet-type heating elements shorten the heat-up period in the gluing unit. On top of that, intelligent management of the control voltage lowers energy consumption during interruptions to work or breaks. BRANDT snipping unit with workpiece gap optimisation

BRANDT

| Resource efficiency

Your benefit

The technology

Efficiency example 1

Efficiency example 2

• Reliable processes thanks to the use of servomotors: reducing set-up periods and downtime • Intelligent standby operation saves on compressed air, extraction and energy costs • More efficient production in the same processing time: optimisation achieved by adapting workpiece gaps to the feed • Optimised gluing system: development and implementation of innovative heating technology • Minimising set-up times shortens the time machines are running and thus yields significant energy savings

• Standby operation is automatically activated after machine has been idle for 15 minutes • Flat heating elements in the QA 45 gluing system for shorter heat-up period • Online help minimises downtime • IE2 motors for efficient energy yields • Optimisation of workpiece gaps for higher output in the same processing time • Use of energy-saving lamps • Automatic central lubrication of the feed chain reduces frictional resistance • Minimum edge overhangs achieved by adaptive control technology • Line-controlled blow-off device reduces air consumption • DFC post-processing tools ensure better extraction performance and better chip capturing

BRANDT edge banding machine Highflex 1880:

BRANDT edge banding machine Highflex 1440:

• More performance for the same energy expense thanks to reduced gaps generates energy savings of 1 280 €/year • Up to a 20 % increase in manufacturing capacity in the same period of time

• Use of synchronous motors • Minimum set-up periods and downtime due to automatic edge infeed

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HOMAG Group

The basis for calculation 1 The calculated savings indicated here are based on the following assumptions: • 8 hours a day • 2 800 edge metres per day • 250 working days • A cost of 0.12 €/kWh for electricity • A cost of 0.04 €/Nm³ for compressed air • Feed rate of 20 m/min

HOMAG Group

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Fine finish efficiency Innovative solutions for every type of sanding task — that’s what you expect from the BÜTFERING brand. What’s more, innovation also covers resource efficiency. Whether a wide-belt sanding machine or alternative solutions for sanding panel-shaped workpieces: BÜTFERING and ecoPlus save you money at every step.

Air jet cleaning of sanding belt

BÜTFERING

| Resource efficiency

Your benefit

The technology

Efficiency example 1

Efficiency example 2

• Electricity consumption reduced while maintaining the same output • Reduced extraction requirement and improved dust extraction • Reduction in the air output of the extraction suction device • Lower heating costs • Reduced compressed air consumption

• Integrated sanding belt blasting device • Five-stage control of the sanding belt blasting device • 3-section extraction hoods with individually controlled blast gates • Automatic activation of standby mode when machine is idle • IE2 motors • Area-related control of vacuum • Reduction of the no-load current in variable frequency drive operation

Series 300 with ecoPlus:

BÜTFERING 5-belt sanding machine SWT 955:

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HOMAG Group

• Annual energy savings in the range of 18 000 kWh achieved by lowering the extraction volume • Electricity consumption reduced by approx. 12 000 kWh p.a. • Energy requirements cut by approx. 8 000 kWh by controlled vacuum output and reduced air output • Total savings: 38 000 kWh a year

Equipped with variable frequency drives and vacuum, powerful 140 kW machine with SORB TECH machine frame: • Potential savings of up to 35 % • Energy consumption cut by up to 2 900 kWh • Up to 2 t less CO₂ • Cost savings of up to 4 700 € achieved by application-dependent air-jet belt cleaning device

HOMAG Group

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Raising the profile of savings FRIZ Kaschiertechnik specialises in profile wrapping technology. The company has been supplying special-purpose machines to the furniture and structural elements industry since 1906. Across all its activities, FRIZ strives towards a single goal: to wrap your products in a quicker, more efficient and more flexible way. The energy-saving technologies of the ecoPlus package are exactly the right approach.

The parabolic heater provides precision heating with no loss due to dissipation

FRIZ

| Resource efficiency

Your benefit

The technology

Efficiency example

The basis for calculations

• Energy savings of up to 60 % achieved by using new generation heaters • Precision heating with no loss due to dissipation • Bonding of the surface already covered remains intact • Additional energy savings with standby feature

• Intelligent standby operation with the ecoPlus button • New generation parabolic heater with parallel outgoing rays. When wrapping the profile edges, only the area required is heated, i.e. there is no dissipation loss • Precision heating, with no detrimental effects on the bonding of the surface that has already been wrapped

Profi PUM 310 with ecoPlus:

Standby operation approx. 800 h/year

• Potential savings of up to 80 % or 4 000 kWh with standby feature • Potential savings of up to 60 % or 16 000 kWh per year thanks to parabolic heater • Up to 16 t less CO₂ per year • Total savings of up to 2 900 € p.a.

Precision heating of the area required with a parabolic heater

Conventional heater with wide heat dissipation

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HOMAG Group

HOMAG Group

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Optimum material usage Every reject and every cutting scrap is wasted capital. HOLZMA software solutions help you prevent any scrap from being produced – with HOLZMA, you can process material in a careful and individual manner.

With HOLZMA saws and software, you can process even particularly demanding materials in an efficient and careful manner HOLZMA | Material

Your benefit

The technology

Efficiency example

The basis for calculations

Software

You can use material optimally with:

• Cutting patterns optimised to minimise scrap and costs • Optimisations on the fly possible • No issues with ERP/PPS connections • You always have an overview • You are able to work in a targeted manner • You can harmonise the saw parameters with the material

• Cut Rite – the worldwide leading software for cutting pattern optimisation • CADplan, for optimisation at the saw

The use of an optimisation program can save you over 14 000 € a year.

• 20 half-format panels per day • 240 working days per year • Price of the panels: 5 €/m², equates to 580 € per day • Wages and ancillary labour costs: 30 € ­an hour

Technology

This special technology can be used for: • Scratch-sensitive surfaces • Pressure-sensitive material • Plastics • Individual adjustment of the saw • And much more

• Material savings: 5 %, equates to 6 960 € a year • Time saved: 240 hours a year • Savings on wages and ancillary labour costs thanks to automatic cutting pattern creation: 7 200 € a year

• Gentle processing of pressure-sensitive or scratch-sensitive material • Labelling avoids errors and specifies the next step

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HOMAG Group

HOMAG Group

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Intelligent air cushion tables HOLZMA air cushion tables blow enough air out of their nozzles to move even the heaviest books of panels. This process prevents damage to the material and facilitates handling. The optional “load-dependent air cushion table control system” builds up only the amount of air pressure required, thereby saving energy.

Intelligent air table with load-dependent control

HOLZMA

Your benefit

The technology

Efficiency example

The load-dependent air cushion table control system...

The load-dependent air table control system works in conjunction with pressure sensors. If there is material on the air table, the speed of the fan motor increases until the ideal operating pressure is achieved.

Depending on mode of operation and air table size you can save up to 144 € a year.

• Protects the material • Saves energy thanks to on-demand power • Reduces noise • Is ergonomic • Minimises draughts The principle: sealing balls that are springloaded, therefore closing automatically when not under a load.

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HOMAG Group

| Air cushion tables

If there is no material on the table, the fan power is reduced to an individually adjustable idle pressure.

HOMAG Group

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Thin-kerf saw blades The thinner the saw blade, the lower the energy consumption of the main saw motor.

Thin kerf saw blades reduce energy consumption and lower the amount of scrap produced

HOLZMA

| Thin-kerf saw blades

Your benefit

The technology

Efficiency example

The basis for calculations

• Lower energy consumption • Less scrap • Blade changing is quick, trouble-free and tailored to your needs thanks to the HOLZMA Power Loc system – even with differing steel plate thicknesses

HOLZMA studies show that if a saw blade with a standard 4.8 mm thickness is replaced by a saw blade that is only 3.8 mm thick, the power required for a two-metre-long cut through a book of 5 x 16-mm-thick chipboards is reduced by up to 20 %.

HOLZMA HPL 300:

• One-shift operation • Triple Mix cutting patterns • 8 hours per shift • 250 working days • A cost of 0.12 €/kWh for electricity • Efficiency example: Triple Mix operation, 80-mm high book of panels, saw carriage speed of 50 m/min

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HOMAG Group

Using a saw blade with a 3.8 mm kerf over a 4.8-mm-thick saw blade, you can save up to 230 €.

HOMAG Group

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Good for the climate – and for your bottom line New for LIGNA 2013: Effective immediately, HOLZMA will be equipping the switch cabinets of all machines with energy-efficient air-conditioning units. These units reduce energy costs in production, protect the environment, ensure fault-free electronics with ideal temperatures and thus increase the service life of your HOLZMA machine.

HOLZMA

Your benefit

The technology

Efficiency example

The new, energy-efficient airconditioning units ensure

Thanks to innovative technologies, the new air-conditioning units are not just extremely energy efficient. Mounted directly on the switch cabinet, these units also ensure enclosed air circulation, similar to that achieved by pressing the air-circulation button in a car: The cool interior air is completely separated from the exterior air, keeping out dust and moisture.

The consumption of energy per year is reduced by roughly 350 kWh in comparison to previous switch cabinet cooling. This global average value can prove to be considerably higher in certain regions, as seasonal and reasonable climate differences are taken into account in the calculation.

• A significant reduction in energy consumption and therefore costs • The optimal operating temperature – even at very high external temperatures • A completely dust-free and moisture-free switch cabinet climate • Fault-free control and drive technology • Higher machine availability and service life

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HOMAG Group

| Air-conditioning units

HOMAG Group

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A competitive edge through continuous improvement Reduce costs and increase performance – this is the motto for HOLZMA’s continuous optimisation of all cutting processes. The results: efficient material usage, smooth-running production, maximum output and reduced personnel costs.

HOLZMA

Your benefit

The technology

Efficiency example

With HOLZMA, you can optimise your production at critical points and profit in the long thanks to:

HOLZMA ensures progress and continuous improvement with numerous technologies that are perfectly matched to one another, setting standards throughout the industry. Examples:

• Optimum working conditions motivate your employees, reduce illness-related absences and thus lower personnel costs • More efficient utilisation of resources saves hard cash • High machine availability lowers your maintenance costs and raises productivity • Flowing processes prevent errors, reduce unproductive waiting times and unnecessary movements, and speed up the entire production process

• Reduced personnel costs, as HOLZMA continuously improves ergonomics, thus promoting employee health • Optimum usage of materials, as HOLZMA technologies guarantee careful material handling, thus reducing waste and scrap • High machine availability, as HOLZMA saws have an impressively long service life, low maintenance expense and minimum downtime • Flowing production processes, as HOLZMA intelligently links together all the work steps and technologies that relate to cutting

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HOMAG Group

• Protection of employees, for example through low dust generation and increased machine safety • Optimum material and resource utilisation thanks to Cut Rite – the world’s leading software for optimising cutting patterns – and special solutions for scratch-sensitive and/or pressure-sensitive materials • High machine availability thanks to wellthought-out design and the use of highquality components for uncompromising quality • Flowing processes thanks to intelligently interlinked technologies such as the HOLZMA Domino System or the new intelligent HOLZMA destacking concept with operator guidance

| Processes

HOMAG Group

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The laminating technology of the future With reacTec furniture laminating, HOMAG throughfeed machines are redefining quality and economy in the manufacturing of construction elements and furniture. Developed in cooperation with Henkel and Nordson, reacTecscores high in nearly all important criteria. This innovative technology combines the advantages of the hot melt process with the benefits of other methods. reacTec impresses not only with low manufacturing costs but also with a high degree of environmental compatibility. The heart of the reacTec furniture laminating process: calender rolls

HOMAG throughfeed technology

Your benefit

The technology

Efficiency example

• The amount of glue applied can be reduced by up to 20 g/m² • Lower production costs • Significantly improved surface quality • High process stability due to “simple” technology • Performance characteristics on par with urea • As user-friendly as hot melt • No formaldehyde emission

• New hot-sealing adhesive with high temperature and moisture resistance • Innovative hot melt application system: new generation wide slit nozzle technology • New machine design

reacTec reduces your energy consumption by up to 50% – or more than one million kWh a year. In the same period of time, you can cut CO2 emissions by up to 700 t and save up to 120 000 € on energy costs.

| reacTec

In addition to these savings, you also benefit from higher productivity with fewer rejects. The process as a whole can deliver yearly savings of up to 400 000 €.*

* * Using the in-line method, in comparison with urea

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HOMAG Group

HOMAG Group

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So that everything runs smoothly HOMAG throughfeed machines are team players: they integrate seamlessly into your production lines and boost productivity. ecoPlus demonstrates that these benefits work in perfect harmony with resource efficiency. The machines reduce consumption and ensure a high degree of energy efficiency with a number of standby options.

doubleEdge effect on edge banding machine

HOMAG throughfeed technology

| Resource efficiency

Your benefit

As standard

As an option

Efficiency example

• Savings in time, material and energy – and consequently higher productivity and greater flexibility in your budget • Enhanced process stability achieved by minimising set-up times, non-productive time and downtime • More efficient production processes due to the development and deployment of innovative manufacturing technologies

• Temperature of heaters automatically lowered to reduce electricity consumption • Shorter heat-up periods with QA 65 for increased productivity • Energy-efficient machine lighting • Sensor system without cleaning air for reduced compressed air consumption • Servo edge feed for lower edge banding consumption • Use of modern, decentralised control technology (passive cooling, minimised leakage currents and less use of copper) achieves savings • IE2 drive units as defined by EU Directive; HOMAG already meets these requirements, which will not come into force until 1 January 2017 • i-tools in most of the refinishing units for lower extraction output and improved chip capture • Noise reduction during throughfeed: ­10 dB(A) less for snipping saw processing, 1.5–2.5 dB(A) less for joint trimming. The “whistling sound” when snipping has also been significantly reduced

• Optimisation of the compressed air supply by using a dual-circuit pressure system • Measuring and display of compressed air consumption • Measuring and display of electrical energy consumption • HSK 63 push button • Quality inspection systems • woodLine • woodScout • Timer • Process-dependent control of individual flaps • Synchronous motors for dynamic refinishing units • Tool-adjusted dust hoods • MMR – machine monitoring and reporting: for the systematic acquisition and analysis of all machine data

HOMAG sizing and edge gluing machine OKFL 326/C:

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HOMAG Group

• Potential savings of up to 25 % • Cost savings of up to 14 600 € p.a. • Consumption cut by up to 77 000 kWh p.a. • Up to 54 t less CO₂ per year

The basis for calculations The calculated savings indicated here are based on the following assumptions: • Two-shift operation • 8 hours per shift • 250 working days • A cost of 0.12 €/kWh for electricity • A cost of 0.04 €/Nm³ for compressed air

HOMAG Group

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Edge banding with laserTec HOMAG laserTec is a completely new manufacturing technique for edge banding – revolutionary in its quality, efficiency and economy. The innovation: laserTec entirely eliminates the need to use conventional adhesives. Instead, a laser simply melts a special adhesive coating on the edging, which can then bond to the counterpart for a joint-free, long-lasting result – absolutely precise and very easy to operate.

Joint-free workpieces

HOMAG

| laserTec

Your benefit

The technology

Efficiency example 1

Efficiency example 2

• Percentage of rejects reduced • Simple operating processes • Lower additional costs • Highest level of availability • No logistical cost for glues • No complicated manual entries • No auxiliary materials such as separating and cleaning agents • No waiting periods and set-up work for colour changes • No energy consumption without productive results • Unlike when using hot-melt glue application units, there are no contamination or cleaning problems

In comparison with conventional, gluing methods, HOMAG laserTec is a clear winner: With this method, a special adhesive coating on the edging strip is melted by a laser beam – and then pressed directly onto the workpiece. An oscillating mirror automatically deflects the laser beam to the required height, depending on the thickness of the edging. This simplifies processing enormously.

In comparison with conventional hot melt glue technology on throughfeed machines:

In comparison with conventional hot melt glue technology on CNC processing centres:

• laserTec saves up to 36 911 kWh p.a. • Energy savings: more than 40 % • Reduction in CO₂ emissions: up to 26 t a year • Cost savings: up to 4 430 € p.a.

• laserTec saves up to 2 250 kWh p.a. • Energy savings: more than 20% • Reduction in CO2 emissions: up to 1.6 t a year • Cost savings: up to 270 € p.a.

HOMAG continues to increase the efficiency by on-going optimisation of the laser system.

Under patent law in Germany, only for use with Rehau edges!

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HOMAG Group

HOMAG Group

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Efficiency for processing centres HOMAG CNC processing centres are powerful one-man armies: They saw, drill and trim – and deliver top performance. These processing centres are a separate item in the balance sheet: Your productivity and consumption figures cannot be “pushed” onto a production line – they stand alone. What a good thing that ecoPlus scores high with plenty of efficiency here too.

HOMAG CNC processing centre ­BMG 512

HOMAG stationary technology

| Resource efficiency

Your benefit

The technology

The technology

Efficiency example

Low consumption: Optimised machine components reduce the consumption of compressed air, extraction and electrical energy.

HOMAG software gets you quickly, easily and safely to the finished component:

collisionControl: Permanently monitors for potential collisions between machine components and spindle directly on the machine.

HOMAG CNC processing centres with ecoPlus semi-fluid grease lubrication.

Efficient workpiece programming: No need for test runs when producing with HOMAG software modules. Saves time, saves material for test parts and avoids rejects.

woodMotion: Simulates processing programs using original machine data. Positioning periods are not required.

Fast set-up: Time savings of up to 70 % when setting up, and checks can be performed at a glance with the help of LED indicators. Reduced unproductive downtime: Software modules prevent collisions. Malfunctions are quickly detected, located and remedied.

woodNest: Makes optimum use of the unfinished panel by nesting the parts.

woodWOP Wizard with technology database: Creates programs for edge banding automatically, including any adjustments to the parameters for edging material and contour that may be necessary.

The machine as powerhouse The electrical energy generated by braking the spindles and drives in HOMAG CNC processing centres can be fed back into the grid. That lowers consumption, without requiring any preparations on the power supply.

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HOMAG Group

woodScout: Helps errors to be recognised, located and remedied quickly. Spindle sensor: detects critical vibrations in good time and thus prevents chatter marks or parts being released due to insufficient clamping Intelligent set-up aids: Patented LED displays on consoles and machine frames for easy and fast positioning of the vacuum clamps and consoles.

The CNC machines work with an automatic central lubrication system on a hydraulic principle, which needs no additional compressed air. Optimised air jets and processes additionally lower the consumption of compressed air. The result: • Up to 67 200 Nm³ less compressed air per year • 100 % savings in compressed air consumption in comparison with oil-air lubrication • Up to 5.64 t less CO₂ per year

The basis for calculations • Semi-fluid grease lubrication: savings in compressed air of, on average, 350 NI/min compared with oil-air central lubrication • Oil-air central lubrication with a switch-on time of approx. 80 % HOMAG Group

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Always the right vacuum The pumps of the HOMAG CNC processing centres, which work with highvolume vacuum generation, are equipped with variable speed control. Sensors measure the current negative pressure and control the air flow of the pumps as needed. The machine only uses as much energy as is necessary, even during interruptions and set-up periods, or when only a low volume is needed.

Panel material is held in position by suction for efficient vacuum production

HOMAG stationary technology

| Vacuum control

Your benefit

The technology

Efficiency example

The basis for calculations

Needs-based control of vacuum generation matches the output to the current situation.

Speed-controlled vacuum pumps with frequency converters in conjunction with an intelligent closed-loop control adjust the volume output to match the current need.

HOMAG CNC processing centres with speed-controlled vacuum pumps:

• Two-shift operation • 8 hours per shift • 250 working days • A cost of 0.12 €/kWh for electricity • A cost of 0.04 €/Nm³ for compressed air

This way you never use more than is necessary, even if demand varies. A particular advantage for: • Nesting processing • Use of reinforced pumps • Use of a certain amount of porous materials • Greatly varying part dimensions

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HOMAG Group

Multi-pump systems with intelligent activation and deactivation of individual pumps on a needs basis.

• Energy savings: up to 6 320 kWh p.a. • Up to 4.4 t less CO₂ per year • Cost savings: up to 750 € p.a.

HOMAG Group

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Resource savings made easy Less is more – this is the basic principle that led lightweight construction to become a successful trend. After all, anyone who can offer at least the equivalent product features using less material and resource input can save hard cash and protect the environment. However, challenging technical requirements must be fulfilled during production if these goals are to be achieved. The HOMAG Group identified this trend at an early stage and now offers complete solutions for creating and processing lightweight panels that are setting standards throughout the industry.

doubleEdge process in patented lightweight design

HOMAG throughfeed technology

Your benefit

The technology

Efficiency example

Thanks to machines and systems from the HOMAG Group, customers have control over all processing steps for lightweight construction and profit from:

The HOMAG Group offers technologies to cover all process steps for producing and processing lightweight panels – whether for producing kitchens or furniture, or for shop fittings, automotive engineering or interior furnishings including doors.

The innovative doubleEdge process

• New design possibilities thanks to a variety of processing options for lightweight panels in almost any thickness or format • A significantly extended material mix • Lower panel weight and therefore more cost-effective logistics • A broadly diversified range of applications and materials

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HOMAG Group

The spectrum of machines and systems covers the entire added-value chain: from lightweight panel production with or without rails, through panel sizing, coating and edging in throughfeed or CNC processing, all the way to applying fittings and installation.

| Lightweight design

• doubleEdge stands for the ultimate in convenience, cost efficiency and simple processing • The support edge and the decor edge are glued together in a gluing station and then glued onto the narrow surface of the panel in the same work step • This process allows time savings of 80 % in processing centres!

HOMAG Group

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Intelligent technologies save money and protect the environment Assembly, packaging, automation – these are LIGMATECH’s areas of expertise in the wood-processing industry. In all these areas, the subsidiary of the HOMAG Group delivers production solutions designed for the future. Cost-effectiveness and efficiency are at the top of the list – for customers and companies alike. The new ecoPlus technologies allow LIGMATECH to integrate efficiency and savings possibilities from the start. Higher machine IQ with intelliCut

LIGMATECH

| Resource efficiency

Your benefit

The technology

Your benefit

Your benefit

Environment-friendly packaging with LIGMATECH

Packaging with corrugated board:

Energy savings thanks to intelligent control

By using the VKV 020 automated carton ­ closure machine and the VKV 710 carton closure machine, you are able to significantly reduce material consumption.

Corrugated board is sustainable by nature and combines both environmental and financial advantages. With the cutting technology of LIGMATECH VKS 200 and 250 cardboard cutting machines, customers can profit from producing tailor-made packaging themselves, at the right time and in the quantity required. The benefits stem from: • Less packaging material • Less filler material • Lower storage and transport volumes • Fewer complaints thanks to optimum product protection What’s more, cardboard scrap can be further reduced by up to 30 % thanks to intelliCut cutting optimisation.

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HOMAG Group

• Conserves resources • Is environmentally friendly due to CO² binding • Is completely and cost-effectively reusable • Is a single substance and therefore easily recyclable

Machines driven by compressed air consume an enormous amount of energy. LIGMATECH therefore relies on new electronic drive technology and more refined control systems for maximum energy efficiency.

intelliCut – higher machine IQ • Multiline processing • Automatic selection of track widths and rotation of the package design

The technology

The technology

• New MDE 120 electric continuous operation press: The previous pneumatic counterbalance has been replaced by an electronic dead-weight counterbalance. Reducing the pneumatics resulted in up to 50 % lower energy costs.

• Hot melt technology yields savings of up to 85 % compared to adhesive tape technology.

• BOOMERANG® ZHR 5xx gantry return: The new electronically controlled Z-axis allows energy savings of up to 30 %.

• Depending on the geometry of the material to be packaged, using carton designs that are closed on the side can save up to 40 % of the cardboard.

HOMAG Group

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On course for higher cost-effectiveness Wherever wood has to be drilled, grooved or routed, WEEKE is the specialist you need. In addition to precision drilling, WEEKE also offers a raft of ecoPlus measures designed to save important resources. Whether energy, material, time or space – WEEKE opens up enormous savings potential with its up-todate technologies.

BHX 050/055

WEEKE

| Resource efficiency

Your benefit

The technology

The technology

Efficiency example

• Environmentally aware machine design ‐‐Potential for marketing communication regarding environmentally responsible partnerships ‐‐Potential for applying for subsidies • Savings in time, material, energy and space ensure greater flexibility in your budget • Products with SORB TECH boast an 80 % faster vibration absorption rate • Longer tool service lives and higher processing quality as a result

• Standby mode: with ecoPlus button, or automatic: ‐‐switch-off of motors for drilling and routing ‐‐switch-off of conveyor belts ‐‐closing of extraction system ‐‐switch-off of conveyor belt for chips • Program-controlled, multi-position extraction – only activates where needed, thus saving energy • Intelligent, energy-efficient vacuum system adapts to the power required • Clamp system instead of vacuum system for clamping workpieces in the entire BHX series • Frequency-controlled drives

• Use of servomotors with high-efficiency: ‐‐Compact construction ‐‐High rotational speeds ‐‐Low power consumption ‐‐Low weight • Only uses solvent-free paints • Our software guarantees time savings thanks to: ‐‐Optimised travel paths ‐‐Optimised tool changes ‐‐Optimised processing sequences

WEEKE BHX 055 vertical processing centre with ecoPlus:

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HOMAG Group

• Low energy consumption (less than 10 kW) thanks to efficient drive technology • Vacuum-free workpiece clamping and low compressed air consumption • Efficient extraction – total extraction power max. 2 170 m3/h Savings in time, material, energy and space ensure: • Potential for applying for subsidies • Potential for alternative investments • Potential for increasing your profitability • Potential for marketing communication regarding environmentally responsible partnerships

HOMAG Group

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More economy for the house The use of wood as a building material for housing means a large amount of material and particularly high demands. All the more reason for particular attention to be paid to the economical use of resources. WEINMANN excels here and has integrated a whole range of ecoPlus technologies in its products. For wood processing on a large scale – with relatively low energy costs. High tech for timber construction: the new, innovative Combi Wall System WEK 100 from WEINMANN

WEINMANN

| Resource efficiency

Your benefit

The technology

Efficiency example

The basis for calculations

• Less cleaning time required for the machine • Increased tool service life • Less dust exposure • Cost savings • Improved operational safety • High time savings

• Energy savings due to needs-based extraction • The extraction systems delivers a negative pressure of 1 800 pascal to the machine; the difference in pressure up to 2 500 pascal for finishing is generated, for example, by supporting fans • Reduction of the extraction output and the cleaning required for the machine and workpieces, coupled with improved chip capture due to tools with chip guidance and fitted extraction hoods • Installation of energy-efficient, three-phase motors for a savings of around 7.3 % • Savings in saw cuts, trimming and drilling thanks to stack processing

WEK 100 combi wall system

• Two-shift operation • 8 hours per shift • 250 working days • A cost of 0.12 €/kWh for electricity • A cost of 0.04 €/Nm³ for compressed air

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HOMAG Group

• Extraction costs reduced by 90 % • Savings potential of 8 380 kWh due to intelligent control of the extraction system. • Savings equate to 1 005 € p.a. and potential CO₂ savings of 5.9 t

sts tion co E x trac d by 9 0 %! reduce

HOMAG Group

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Technology that benefits the environment ecoPlus demonstrates very impressively: output and economy can well be combined. The technologies use energy intelligently – that is what spurs us on, that is why we set the standard across the entire industry for more efficiency and increasing potential for savings. In this way, eco Plus benefits the environment and your budget. Excellent prospects for today, tomorrow and the future.

ecoPlus | Outlook

“Sustainable growth is only possible with cutting edge technologies that pay off and protect the environment. This applies particularly to wood processing companies. For this reason, we have created the perfect combination of cost-efficiency and environmental protection with ecoPlus. That is our claim and that is how we will be measured.” Jürgen Köppel, Director of Sales, Service and Marketing for the HOMAG Group AG

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HOMAG Group

HOMAG Group

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HOMAG Group AG 72296 Schopfloch GERMANY www.homag-group.com As at 04/13. Subject to technical change, print errors and mistakes.

Ecoplus - Teknologi der betaler sig  

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