LTH Comparison

Economic Shape Moulding Production
Methods in comparison
Kurtz GmbH
10.02.wb.smv1
page 1

Steam Usage of Different Processes
Explanation of process methods

- Conventional, ECO LTH, Classic- LTH
Production limits for different methods in different markets

- Europe, Indonesia, China, USA
Kurtz helps you save

- Comparison of production costs: conventional/ ECO-LTH
- Comparison of production costs: conventional/ Classic-LTH
Kurtz GmbH
10.02.wb.smv1
page 2

Comparison of the various processes
1. Vacuum Technology
2. Classic-LTH
3. Eco-LTH
Kurtz GmbH
10.02.wb.smv1
page 3

1. Vacuum technology
Design :
Steam / Air
Ejector
Water
Water
Steam chamber is part of the

machine
Nozzles in mould walls
Relatively inexpensive
Fll injector
mould construction
Cooling of total mould mass
to demoulding temperature
Vacuum /
Kondensate
Kurtz GmbH
10.02.wb.smv1
page 4

Determination of steam requirement

Mould mass is heated up and cooled down in every cycle
steam quantity
mmould O cpAl O DT
msteam =
Dh
Kurtz GmbH
10.02.wb.smv1
page 5

Example calculation (without losses)

Mould for shape moulding machine
with a foaming area of 1 m
mmould = 160 kg
cpAl
= 0.92 kJ/kg/K
DT
= (120C 80C) = 40 K
Dh
= 2203 kJ/kg
Kurtz GmbH
10.02.wb.smv1
page 6

Example calculation (without losses)

steam quantity / cycle
160 kg O 0.92 kJ/kg/K O 40 K / 2203 kJ/kg = 2.67 kg
steam costs / year in two-shift operation

2.67 kg O 60 cycles/h O 3520 h/a = 564,5 t steam
steam costs approx. 25 / t
steam costs approx. 14,100 p.a.
Kurtz GmbH
10.02.wb.smv1
page 7

Energy balance sheet with vacuum technology
Qzu
= Qfoam + Qpurging + losses + Qmould

foam
0,4%
purging and
losses
46,6 %
mould
58,0%
mould
foam
Energy shares
purging & losses
Kurtz GmbH
10.02.wb.smv1
page 8

2. Classic-LTH
3. Eco-LTH
Kurtz GmbH
10.02.wb.smv1
page 9

2. Classic- LTH: technology Design :

Steam distribution in mould
Media are directly supplied to
cavity = reduction of losses
Ejector
Steam /
air
Steam /
air
Vacuum
Vacuum
Fill
injector
Coating on all sides of areas

with steam contact
High mould costs
Fast mould cycle
Short cycle time =
high productivity
Kurtz GmbH
10.02.wb.smv1
page 10

2. Classic-LTH
3. Eco-LTH
Kurtz GmbH
10.02.wb.smv1
page 11

Design:
3. ECO- LTH
Nozzles as with vacuum

technology
Water
Water
Steam /
air
Steam /
air
Vacuum
Vacuum
Fill
injector
Ejector
Mould cooling with

spray nozzles
Steam distribution ca. 2 - 3x
bigger than Classic- LTH
No coating
of areas with contact to
material
No tempering channel
Kurtz GmbH
10.02.wb.smv1
page 12

Energy consumption comparison of the

various processes
Kurtz GmbH
10.02.wb.smv1
page 13

Explanation of energy usages in different process methods
[ kg / m / cycle]
1. Steam
4
3,5
3,5
3
2,5
1,7
1,1
1,5
1
0,5
0
1
Vacuum
technology
Eco-LTH
Classic-LTH
Kurtz GmbH
10.02.wb.smv1
page 14

[ m / m / cycle]
2. Air
2,5
2
2
1,5
0,9
0,8
0,5
Vacuum
technology
Eco-LTH
Classic-LTH
Kurtz GmbH
10.02.wb.smv1
page 15

[ l / m / cycle]
3. Water
100
90
87
80
70
60
41,5
50
31,5
40
30
20
10
0
1
Vacuum
technology
Eco-LTH
Classic-LTH
Kurtz GmbH
10.02.wb.smv1
page 16

Vacuum technology
Eco-LTH
Classic-LTH
100
87
90
80
70
60
5
4
50
41,5
3,5
31,5
3
2
1,1
40
30
1,7
Water [ l / m / cycle]
Air [ m / m / cycle]
Steam [ kg / m / cycle]
10
20
0,9 0,8
10
Steam
Air
Water
Kurtz GmbH
10.02.wb.smv1
page 17

Determination of production costs
Company specific data
Machine related data
Mould related data
Process specific data
Kurtz GmbH
10.02.wb.smv1
page 18

Company specific data
Calculatory interest
Wage per hour / operator
Non-wage labour costs
Building costs pro m
Energy costs per KW
Energy costs per to Dampf
Energy costs per m Luft
Energy costs l Wasser
Material costs per kg
Overhead costs (%)
Capacity
Kurtz GmbH
10.02.wb.smv1
page 19

Machine related data
Steam chamber dimensions
Purchase price
Amortization period
Space requirement
Maintenance
Installed capacity
Production duration
Workforce
Average cycle time
Number of identical machines
Kurtz GmbH
10.02.wb.smv1
page 20

Mould related data
Number of moulds per machine
Mould costs
Cavities
Moulding dimensions
Density
Moulding weight
Kurtz GmbH
10.02.wb.smv1
page 21

Process related data
Steam usage
Air usage
Water usage
Kurtz GmbH
10.02.wb.smv1
page 22

Production cost charts

with a 2 cavity mold for the following machines:
K813
K813 LTH Classic
K813 LTH Eco
Kurtz GmbH
10.02.wb.smv1
page 23

Cost [ ]
K813 Vacuum technology
120.000
100.000
80.000
60.000
40.000
20.000
0
0
150.000
300.000
450.000
600.000
Quantity [ Pcs. ]
Kurtz GmbH
10.02.wb.smv1
page 24

Cost [ ]
K813 LTH-Classic
120.000
100.000
80.000
60.000
40.000
20.000
0
0
150.000
300.000
450.000
600.000
Quantity [ Pcs. ]
Kurtz GmbH
10.02.wb.smv1
page 25

Cost [ ]
K813 LTH-Classic
K813 LTH-Eco
120.000
100.000
80.000
60.000
40.000
20.000
0
0
150.000
300.000
450.000
600.000
Quantity [ Pcs. ]
Kurtz GmbH
10.02.wb.smv1
page 26

Savings: Comparing vacuum technology between the LTHClassic and LTH-Eco

with a yearly production of 699.840 Pcs.
Savings [ ]
45.877
40.342
50.000
40.000
30.000
20.000
10.000
-
Kurtz GmbH
10.02.wb.smv1
Classic-LTH
Eco-LTH
page 27

Capacity with a yearly production of: 699.840 Pcs.

100%
100%
Capacity [%]
76%
71%
80%
60%
40%
20%
0%
1
Kurtz GmbH
10.02.wb.smv1
Vacuum
Technology
Eco-LTH
Classic-LTH
page 28

Savings: Comparing vacuum technology between the LTHClassic and LTH-Eco

with a yearly production of 150.000 Pcs.
3.826
Savings [ ]
4.000
3.000
2.000
192
1.000
Classic-LTH
Eco-LTH
Kurtz GmbH
10.02.wb.smv1
page 29

Energy costs comparison of countries
USA
Germany
China
Singapore
Kurtz GmbH
10.02.wb.smv1
page 30

Country production cost chart comparison

with a 2 cavity mold for the following machines:
K813
K813 LTH Classic
K813 LTH Eco
Kurtz GmbH
10.02.wb.smv1
page 31

USA
K813 Vakuumtechnik
K813 LTH-Classic
K813 LTH-Eco
Cost [ ]
100.000
90.000
80.000
70.000
60.000
50.000
40.000
30.000
20.000
10.000
0
0
150.000
300.000
450.000
600.000
Quantity [ Pcs. ]
Kurtz GmbH
10.02.wb.smv1
page 32

China
K813 Vakuumtechnik
K813 LTH-Classic
K813 LTH-Eco
Cost [ ]
90.000
80.000
70.000
60.000
50.000
40.000
30.000
20.000
10.000
0
0
150.000
300.000
450.000
600.000
Quantity [ Pcs. ]
Kurtz GmbH
10.02.wb.smv1
page 33

Singapore
K813 Vakuumtechnik
K813 LTH-Classic
K813 LTH-Eco
120.000
Cost [ ]
110.000
100.000
90.000
80.000
70.000
60.000
50.000
40.000
30.000
20.000
10.000
0
0
150.000
300.000
450.000
600.000
Quantity [ Pcs. ]
Kurtz GmbH
10.02.wb.smv1
page 34

Summary:
LTH-Classic and LTH-Eco:

Advantages in countries with higher energy costs
LTH-Classic
unbeatable with larger production numbers
LTH-Eco
reduces production costs even at lower production
numbers
Kurtz GmbH
10.02.wb.smv1
page 35

LTH Comparison

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

LTH Comparison

Caricato da

Copyright:

Formati disponibili

Economic Shape Moulding Production

Economic Shape Moulding Production

Steam Usage of Different Processes

Explanation of process methods

Production limits for different methods in different markets

Kurtz helps you save

Economic Shape Moulding Production

Comparison of the various processes

Economic Shape Moulding Production

Steam chamber is part of the

Economic Shape Moulding Production

Determination of steam requirement

Economic Shape Moulding Production

Example calculation (without losses)

Economic Shape Moulding Production

Example calculation (without losses)

steam costs / year in two-shift operation

Economic Shape Moulding Production

Energy balance sheet with vacuum technology

= Qfoam + Qpurging + losses + Qmould

purging & losses

Economic Shape Moulding Production

Comparison of the various processes

Economic Shape Moulding Production

2. Classic- LTH: technology Design :

Coating on all sides of areas

Economic Shape Moulding Production

Comparison of the various processes

Economic Shape Moulding Production

Nozzles as with vacuum

Mould cooling with

Economic Shape Moulding Production

Energy consumption comparison of the

Economic Shape Moulding Production

Economic Shape Moulding Production

Economic Shape Moulding Production

Economic Shape Moulding Production

Economic Shape Moulding Production

Determination of production costs

Company specific data

Machine related data

Mould related data

Process specific data

Economic Shape Moulding Production

Company specific data

Wage per hour / operator

Non-wage labour costs

Building costs pro m

Energy costs per KW

Energy costs per to Dampf

Energy costs per m Luft

Energy costs l Wasser

Material costs per kg

Overhead costs (%)

Economic Shape Moulding Production

Machine related data

Steam chamber dimensions

Average cycle time

Number of identical machines

Economic Shape Moulding Production

Mould related data

Number of moulds per machine