Embed Size (px)
Citation preview
1
Evolve in real lifeA case study
Matrix seminar – March 2011
Liviu BÂRSAN
2
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Who am I Liviu BARSAN
Diploma in Mechanichal Engineering, Politechnical University, Bucharest
Master in Biotechnical Engineering
In Valrom since 2005
R&D department – part design & engineering
Who am I?
3
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Who we are
Who are we?
VALROM Industrie srl
Romanian company headquarted in Bucharest
Shareholders: Valsir Spa (Italy) & Romstal Group (Romania)
Established: 1996
330 employees in 2010 (630 in 2008)
Sales of 45 mil. € in 2010 (75 mil. € in 2008 )
Market leader in plastic pipes & fittings
4
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Who are we
Ukraine• logistics• production
site
Moldovia• sales
Bulgaria• sales
Who are we?
• Branches in Bulgaria, Moldavia & Ukraine (production site)
5
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
What we do
Heating & sanitary systems; water, gas and sewage networks; waste-water treatment plants
Production: plastic pipes & fittings – PE, xPE, PP (homo & random) etc
Production facilities: Romania (2 sites) & Ukraine
Extrusion (12 lines); injection molding (8 machines)
Roto: 4 machines (Caccia & Polivinil)
Our business
6
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Roto shop
Established in 2003
Machines: 2 Caccia RT 3503F, 1 Polivinil 3500 3C, 1 Polivinil 4500 3C
Tools shop – reworking, new moulds, maintenance
Grinding process in house – Powder King PK DD 220
Consumption – 60 MT/month
Raw materials: PE – compact & foaming, PP (limited)
In house design & engineering
Roto shop
7
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Roto shop
Roto shop
8
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Roto shop
Products range: water tanks, sewage manholes, water-meter chambers, small waste-water treatment plants etc
Technology: single, multi-layer, foaming, lining
Roto shop
9
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Beginnings
Involved in this project since beginning (2009)
The material still under development
Valrom agreed to test it on industrial scale
Our goal – cost cutting by either decrease of oven temperature or cooking time
Steps: 1. preliminary evaluation on industrial mould & equipment2. limited production test (subject to material availability)3. full production test (at least 24 hours)4. economical evaluation
Evolve - beginnings
10
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Evaluation
Preliminary evaluation on industrial equipment: mould & equipment
Scope: evaluate how much we can decrease the oven temp and/or cooking time
Equipment: Caccia & Polivinil
Standard condition: 50 kg for 30 min @ 270 0C • PIAT 155 0C
Thickness: standard 6 mm
Material: Evolve M748F, powder, black
Part evaluation: Matrix lab
Evolve – preliminary evaluation
11
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
Evolve – preliminary evaluation
L. Barsan (Marh 2011) - © Valrom Industrie
12
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Evaluation
Evolve – preliminary evaluation
13
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Evaluation
Evolve – preliminary evaluation
14
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Evaluation
No. Cooking conditions
Density (g/cm3)
Impact strength (J)
Aspect
1 25 @ 260 0C 0.942 60.9 No pinholes; inside surface looks nice & smooth
2 23 @ 260 0C 0.939 60.9 No pinholes; inside surface looks nice & smooth
3 20 @ 280 0C 0.937 60.9 No pinholes; inside surface looks bumpy – slightly undercooked
4 20 @ 285 0C 0.943 60.9 No pinholes; inside surface looks nice & smooth
Evolve – preliminary evaluation
15
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
Evolve – preliminary evaluation
L. Barsan (Marh 2011) - © Valrom Industrie
16
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Evaluation
Conclusions for evaluation:
The new material performs well
There is no decrease in product performance
It allows decrease of oven temperature and/or cooking time
Further tests to follow on either time or temperature decrease
Evolve – preliminary evaluation
17
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Trial
Small scale trial
Scope: • confirm preliminary evaluation of product capabilities –
lower gas consumption; on larger scale• test effect of dry blending
Equipment: Polivinil machine running exclusively Evolve for one shift
Material: Evolve powder, natural, dry blend pigment (grey) in our facility
Lab evaluation: Matrix
18
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Trial
Small scale trial
Evolve cooks faster
Natural better than grey dry blend
5 7 9 11 13 15 17 19 21 23 250.920
0.925
0.930
0.935
0.940
0.945
N-307 N-307 EVOLVE N-307 GREY EVOLVE
Cook time (min)
Par
t D
ensi
ty (
g/c
m^
3)
19
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Small scale trial
Conclusions
Standard part thickness 6 mm
Standard cycle: 30 min @ 270 0C
Oven temperature reduction: 30 min @ 252 0C
Cycle time reduction: 22 min @ 270 0C
Part evaluation: Matrix labTrial
20
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Industrial run
Scope • record of primary data• perform economical calculation
Two days run on all machines
Product range: shafts, water tanks
Evolve used exclusively
Gas consumption measured accurately• before trial• during trial
Full industrial run
21
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Industrial run
Full industrial run
Results
2010 average:• 617.390 kg processed• 285.062 m3 consumption
24 h before:• 2.561 kg PE processed • 1.230 m3 consumption
Evolve, in 2 days:• 5.338 kg PE • 2.181 m3 consumption
22
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Industrial run
Full industrial run
2010 (average) 24h before EVOLVE0
0.1
0.2
0.3
0.4
0.5
0.4600.4802
0.4085
GAS Consumption
23
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
Conclusions
Gas consumption can be decreased by 15% (14,93%)
Cooking time can be reduced by 25%
The values depends on local conditions:• machine efficiency• type of material • processing conditions
Savings: it depends on your conditions
Conclusions
24
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
How to
1. Get a gas meter
2. Make it works
3. Register your average consumption • 1 month minimum
4. Get enough material for 24 h production
5. Register your consumption before trial
How to ... in 8 steps
25
What we do
Who we are
Who am I
Roto shop
Beginnings
Evaluation
Trial
Industrial run
Conclusions
How to
L. Barsan (Marh 2011) - © Valrom Industrie
How to ... in 8 steps
6. Run full day production• decrease your oven temperature with 18 0C or• decrease your cooking time with 26%
7. Register gas consumption during trial
8. Check quality of the final product • Matrix might run some lab test for you
Calculate the savings and take the right decision!
How to
26
Thank you !
Questions and comments...
