The European Association of the Machine Tool Industries

The Ecodesign Directive

Energy Efficiency Targets for Machine Tools

Magdalena Garczynska, Technical Manager Project manager of the CECIMO energy efficiency working group Magdalena.garczynska@cecimo.eu
Magdalena Garczynska, Technical Manager

" where manufacturing begins"

Agenda
CECIMO and the Machine Tool Industry in Europe Legislation Environmental evaluation Preparatory study CECIMO Self Regulatory Initiative

Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

CECIMO is the European Association of the Machine Tool Industries It represents:
15 National Associations 1500 companies 80% SMEs almost the entire metalworking machine tool production in Europe (97%) 21 bn sales in 2011 of the production is exported of the global production of the worlds exports

Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

3 main types of processes

Cut a pattern from a sheet of metal, for instance. The technology used includes cutting tools, laser, jet of high pressure water

To shape the piece by bending, stamping

Sculpt a metallic block by removing material by processes like drilling, milling, electrochemical discharge

Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

The machine tool industry comprises

Material removal / machining

Metal forming

Accessories

Tools

Other machines and equipment

Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

Examples of end-user products:

Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

Machine tools help Europe tackle grand challenges. Advances in machine tools have a direct impact on:
efficiency and productivity in all industrial sectors competitiveness
grand societal and economic challenges

Alternative New power plants Process efficiency powertrains

Weight reduction

Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

About CECIMO
Founded in 1950 CECIMO: Comit europen de Coopration de lIndustrie de la Machine-Outil First main purpose: European exhibitions of machine tools
First E.M.T.E. (European Machine Tools Exhibitions) held in 1951

Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

CECIMO Members Key producing countries in 2011
Turkey 2% France 3% Spain 4% Austria 3% UK 2% Czech Rep. 2% Others 6% Germany 46%

Switzerland 12% Italy 20%

Source data: CECIMO statistics

Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

Examples of recent and current CECIMO activities To maintain a Market Intelligence Service gathering and distributing statistical and economic data and reports.
Economic and market reporting: production, exports, imports and consumption including forecasts

World statistics on the advanced machine tools by CECIMO

CECIMO Statistical Toolbox

Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

Examples of recent and current CECIMO activities To co-ordinate European and international standardization.
Ecodesign and Self-Regulatory Initiative (SRI) Directive 2011/65/EU on the restriction of the use of certain hazardous substances in electrical and electronic equipment (RoHS) and the Directive on waste electrical and electronic equipment (WEEE) Participation in ISO TC 39 standard
Energy Efficiency Targets for Machine Tools

CECIMO and the Machine Tool Industry in Europe

Examples of recent and current CECIMO activities To promote innovation and exploitation of research results.

DEMAT

EMC2Factory
EFFRA, Manufuture

Energy Efficiency Targets for Machine Tools

Legislation Environmental evaluation

Energy Efficiency Targets for Machine Tools

Current legislative developments

Europe 2020 target 20%

Energy efficiency action plan

Roadmap to a Resource Efficient Europe Energy efficiency Directive 2012

Ecodesign Energy-related Products Directive, 2009

Energy Efficiency Targets for Machine Tools

EU Legislation Energy Efficiency: EU Instruments Environmental evaluation

Energy efficiency of products main instruments
Ecodesign Directive 2009/125/EC: framework defining the rules for setting product-specific requirements/legislation on energy efficiency and further parameters. Energy Labelling Directive 2010/30/EU: framework defining the rules for setting product-specific requirements/legislation on standard information of the consumption of energy and other resources

Other related instruments

Ecolabel: The EU Ecolabel helps identify products and services that have a reduced impact on the environment throughout their life cycle, from the extraction of raw material through to production, use and disposal. Green Public Procurement: Voluntary instrument. GPP can help stimulate a critical mass of demand for more sustainable goods and services which otherwise would be difficult to get onto the market.
Source: European Commission

Energy Efficiency Targets for Machine Tools

Energy efficiency index of industry

Energy efficiency index of industry (ODEX) a weighted average of the specific consumption index of 10 manufacturing branches The 10 branches considered in the calculation are:
chemical,

steel, non ferrous, cement, other non metallic, paper, food, machinery, transport equipment textile.
Source: ODYSSEE database (last update : August 2009) available at http://www.odyssee-indicators.org/

Energy Efficiency Targets for Machine Tools

Eco Design Directive-Not only Machine Tools

This directive applies to all energy related products Examples:
Air-conditioning and ventilation systems; Electric and fossil-fuelled heating equipment Machine tools Industrial and laboratory furnaces and ovens Network, data processing and data storing equipment Refrigerating and freezing equipment Sound and imaging equipment Transformers Water-using equipment
Energy Efficiency Targets for Machine Tools

EU Ecodesign & Energy Efficiency: Story so Far. Legislation

Environmental evaluation

39 'Lots' with some 50 product groups to carry out preparatory studies.

13 Ecodesign Regulations and 5 Energy Labelling Regulations have been adopted so far.

10 measures under preparation for adoption in 2012.

Energy Efficiency Targets for Machine Tools

EU Legislation Ecodesign Directive: Methodology & Timeline: 2 Environmental evaluation

Energy Efficiency Targets for Machine Tools

EU Legislation Ecodesign General Options for Action Environmental evaluation

Regulation (most common) based on findings of study, supplemented over several months by additional bilateral meetings/ information/ group meetings Voluntary Agreement (VA)/ Self-Regulation Initiative: Industry sector may prefer (has the "initiative" to lead the process) or not (less legal certainty for actors) Split or combine "Lots", depending on workability/ practicalities of sub-sectors that come to light, potentially involving part of Preparatory Study being revisited, if deemed necessary
Energy Efficiency Targets for Machine Tools

Ecodesign and Competitiveness (Policy-Making EU Legislation not Conducted in evaluation Isolation): 2012 ENTR Study Environmental

Source: Study on the Competitiveness of EU Mechanical Engineering Industry, Ecorys et al, Jan 2012, for DG ENTR Energy Efficiency Targets for Machine Tools

Ecodesign and Competitiveness: 2012 ENTR EU Legislation nd Table Study, 2 Environmental evaluation

Source: Study on the Competitiveness of EU Mechanical Engineering Industry, Ecorys et al, Jan 2012, for DG ENTR

Energy Efficiency Targets for Machine Tools

Preparatory study
Machine Tools and related machinery
performed by Fraunhofer Institute

Energy Efficiency Targets for Machine Tools

Product Group Study

Objectives

Assess the EU-27 market Quantify environmental impacts of the product group as a whole Quantify improvement potentials in terms of costs and environmental impacts Are policy measures needed to realise savings potential effectively?

Energy Efficiency Targets for Machine Tools

Source: Fraunhofer Institute CECIMO GA 2012

Environmental Assessments
Definition of Typical Machine Tools (Base Cases)
High market relevancy Metal working Wood working CNC

(1)
(2) (3) (4) (5) (6) (7) (8) (9)

CNC machining centres (and similar)

CNC Laser cutting machine tools CNC Bending machine tools (and similar) Non-NC metal working machine tools (and similar) Table saw (and similar) Horizontal panel saw (and similar) Throughfeed edge banding machine (and similar) CNC machining centre (and similar) Welding equipment

x
x x x x x x x x

x
x x

x x x x x x

Energy Efficiency Targets for Machine Tools

Source: Fraunhofer Institute CECIMO GA 2012

Base Case Assessment

Metal working CNC machining centres dominating (throughout all environmental indicators) No full market coverage through Base Cases!

Energy Efficiency Targets for Machine Tools

Source: Fraunhofer Institute CECIMO GA 2012

Technical Analysis
Improvement Potential
Survey (supported by CECIMO): Estimated savings potential per option
Component group 4: cooling lubrication system
4.1 Discontinuous operating pumps 4.2 Apply minimal quantity lubrication (MQL) when feasible 4.3 Adjustable pressure for cooling lubrication 4.4 Controlled flow rate 4.5 Inverter controlled motors for lubrication system

Ranking of options
Findings: Numerous savings options But none of them with a huge potential
Source: CECIMO/Fraunhofer Institute CECIMO GA 2012 Figure 5-26: Total machinery energy savings potential Cooling lubrication system

Energy Efficiency Targets for Machine Tools

Improvement Potential
(1) CNC machining centres
Hypothetical implementation of improvement options one-byone Life Cycle Costs Total Energy as environmental indicator

Total Energy and LCC per Option

Energy Efficiency Targets for Machine Tools

Source: Fraunhofer Institute CECIMO GA 2012

Improvement Potential
Conclusions
Savings potentials at point of Least Life Cycle Costs range from none to 12% Most options refer to energy in use, but also material choice and optimising gas consumption for welding have been addressed In general there is no single option with a huge environmental improvement potential Moderate savings as stated can be realised only with the implementation of several individual options and what should be called good machinery design

Energy Efficiency Targets for Machine Tools

Source: Fraunhofer Institute CECIMO GA 2012

CECIMO Self Regularory Initiative

Energy Efficiency Targets for Machine Tools

Methodology milling and turning

Starting point: Life Cycle Assessment on whole life cycle of a machine tool Several data sets from European companies
energy consumption in the use phase is the dominating influence for all environmental impacts*

LCA scope: Materials for production of the machine tool with average consumptions for machining 100.000 hours productive operating with specific average energy consumption (20h/d, 250d/a, 20a ) Consumption of 4.000 kg coolant lubricant in 20 years (assumption) Consumption of 400 l hydraulic oil in 20 years (assumption) End-of-Life scenario with credits for recycling of metal and incineration of plastics * According to CML methodology 2007 Energy Efficiency Targets for Machine Tools

Method for the evaluation of machine tools / PRELIMINARY Modular approach

spindle

machine base work piece table operator panel drive unit

Energy Efficiency Targets for Machine Tools

CECIMOs SRI: cost/improvement scenarios investigations

Individual measure

Machine function
Machining (machine process, motion and control) Process conditioning and cooling Workpiece handling Tool handling Recyclables and waste handling Machine cooling/heating
Energy Efficiency Targets for Machine Tools

Measuring Energy Efficiency

According to ISO 9000, efficiency is the relationship between the result achieved and the resources used
The resources used and the result achieved must be measured

Resources used, i.e. power supplied to the machine tool: electricity, compressed air, cooling by cold water supply, ambient air, optionally at stabilized temperature, etc. Resources can be quantified, with time and effort Result achieved, i.e. parts produced: shape, material, features, surface quality, precision, etc. Quantification of results achieved is case-specific Energy efficiency of machine tools is difficult to quantify and difficult to judge.

Energy Efficiency Targets for Machine Tools

MEErP (1/2)
For Life Cycle Assessment under the ErP directive, MEErP methodology is mandatory MEErP is a suitable, relatively simple Life Cycle Analysis tool, but not for machine tools Three major obstacles when applying MEErP:
For machine tools intended for industrial use, only the use phase is relevant in respect to energy; MEErP imposes other irrelevant considerations Great variety of products within the machine tools category Low effectiveness of general measures derived from base cases as compared to selective measures, as confirmed by Fraunhofer/IZM

Energy Efficiency Targets for Machine Tools

Effectiveness
There are no general measures for the improvement of energy efficiency that would be of high effectiveness There is a large number of proposals for improvement, but each with little potential With selective measures, energy efficiency can be improved more effectively; Fraunhofer/IZM therefore predicts a higher potential for an industry driven, voluntary approach Effective measures require a consideration of the system design and adapted solutions On a case-by-case basis, selected single measures can be very effective focus on objectives, not on solutions

Energy Efficiency Targets for Machine Tools

Common Ground Clustering

Research will suggest primary fields of action
Preliminary examples for Common ground clustering Machine & Process design related targets
i) ii) No Added Value Idle state management Value Added Process optimization

Factory integration related targets i) Heat management Energy equivalent resources resources management
Energy Efficiency Targets for Machine Tools

ISO - ECO standards initiated

ISO: New Working Group under ISO/TC 39 established to deal with Environmental Evaluation of Machine Tools
First standards under the working group:
Guidelines - Integrating environmental aspects into design and development for machine tools Machine Tools Test methods for electric power consumption

The standard NWIP ISO 14955

addressing machine tools (metal-cutting and forming machines) trying to be independent from technologies cover the whole lifecycle (only Usephase)

explain limitations
no exceptions to be foreseen right now methods for evaluation Modular approach for all technologies Energy Efficiency Targets for Machine Tools

The Concept
WG in TC 39

Updating list of improvement potential Method/calculator for evaluation Machine tool manufacturers

Definitions/ descriptions Targets Open CECIMO task forces Reporting/ monitoring European Commission

Annual reports

Proposals for new improvements

Energy Efficiency Targets for Machine Tools

For the success of the CECIMO Self Regulatory Initiative

Any interested stakeholder can get involved in the formulation process For further elaboration of the methodology of the SRI implementation industry experts are needed Companies are invited to delegate engineers for the CECIMO energy efficiency working group Contact at CECIMO
Mrs. Magdalena Garczynska, Technical Manager

magdalena.garczynska@cecimo.eu

Energy Efficiency Targets for Machine Tools

thank you questions

Magdalena Garczynska, Technical Manager CECIMO The European Association of the Machine Tool Industries Avenue Louise 66 | 1050 Brussels | Belgium Tel.: 00 32 (0)2 502 70 90 Email: magdalena.garczynska@cecimo.eu Website: www.cecimo.eu