Tecnema Dry Square 4.0: Energy Saving Technology

Energy saving and energy efficiency are amongst the most important and topical issues for the ceramic sector, especially in consolidated hi-tech markets where controlling and reducing production costs are key success factors for an organisation.

The Tecnema automatic dry squaring line [SQUARE DRY 4.0] transforms these aspects into added value and stands as the industry benchmark for energy saving.

But what does energy saving mean in practice?

Put simply, energy efficiency is the ability of a system to achieve a given result using less energy than other systems, thereby increasing its and efficiency.

DRY SQUARE 4.0 USES THE SMALLEST NUMBER OF CALIBRATING SPINDLES ON THE MARKET

Thanks to the high-speed spindle construction technology (SCT or Small Chip Thickness), the squaring line is equipped with only 32 calibrating spindles, guaranteeing the same removal capacity as a conventional machine with 48 calibrating spindles (40% higher removal capacity). The fact that no forced spindle cooling system is needed is particularly significant.

Based on production data for Tecnema squaring lines, the calculated EMF energy saving is 0.076 kWh/m² compared to a conventional machine with 48 calibrating spindles.

Considering an average kiln production of around 3,000,000 m²/year, this results in energy savings of approximately 228,000 kW/year, which at a cost of 0.15 €/kW is equivalent to savings of around 34,000 €/year.

The reliability of the SCT spindle also brings savings in terms of routine maintenance of the line due to the longer lifetime of the unit and the smaller number of spare parts that need to be purchased. Tecnema warrants its spindles for 2 years of continuous operation over 3 shifts (zero maintenance with lifetimes measured and documented on customers’ premises).

DRY SQUARE 4.0 USES REGENERATIVE CONTROL MOTORS

Another key aspect for energy saving is the use of special high-efficiency motors whose operation is controlled by dedicated “Regenerative Control” software. The energy savings due to lower electricity consumption compared to standard motors amount to around 20%.

Considering the same average annual production of a kiln, this technology brings further energy savings of 170,000 kW/year, equivalent to around 25,000 €/year compared to the conventional lines currently on the market.

The reduction in cost corresponding to the total energy savings of the line is therefore around 60,000 €/year.

The reliability of these figures is guaranteed by measurements made on Tecnema squaring lines currently in operation.