Adopting Energy-Efficient Machines for Pipe Manufacturing

The Russia-Ukraine war has posed many newer challenges for several major and developing global economies. Just as the world was recovering from the coronavirus slump (see our previous blog on the pandemic effect on pipe manufacturing), it was struck by a fresh, deadly wave of challenges. From increasing economic and political risks to disrupted supply chains and global growth – the war has been a major tragedy for every industry. Since Russia reduced gas supplies to European countries for supporting Ukraine, the continent is preparing for an increasingly worrying energy crisis with worldwide consequences. The situation has worsened to a point where power cuts across Europe may become a reality and countries may require disaster relief as a worst-case scenario. The US economy has not been immune and as a result of the ongoing war inflation and unprecedented rise in the cost of living have left the country in turmoil.

How has the energy crisis affected the manufacturing world? 

According to a report by Eurostat, the industry sector, in 2020, consumed around a third of the final energy consumption in the EU and is the backbone of the European economy. Unfortunately, it is also the sector most affected by the crisis. The continent employs over 35 million people or 15% of the working population in the industrial sector. Moreover, small and medium-sized businesses – accounting for more than half of Europe’s GDP – are in dire need of support in these crucial times. 

Sadly, the rising costs have forced many European industrial companies to cut-down production, move their units to cheaper and affordable locations, or shut down production units altogether. Meanwhile, others are employing energy-saving measures like increasing the thermostat temperatures, using coal and other fossil fuels, or increasing the cost of their product to mitigate the rising production costs. 

The European Council has undertaken an emergency regulation that places great emphasis on reducing electricity usage as a way to tackle high energy bills. One of the measures urges users to voluntarily cut their electricity usage to achieve a 10% reduction in EU consumption till the next year. If you are a manufacturer with high electricity consumption experiencing the energy crisis, you can undertake the following steps to ensure limiting your overall usage: 

1. Energy monitoring is the foremost step. Acquiring data on the daily average consumption helps you ascertain which processes need more power as compared to others. Also, consumption will increase if the processes run at peak times in the day. Accordingly, manufacturers can schedule the processes, and replace the machines that require more power to run to save exorbitant energy costs. In addition, scheduling start-up and shut-down periods during weekends or off-shifts can help reduce a significant amount of energy wastage. Also, optimizing the air compressors and avoiding any leakages can conserve electricity to a great extent. 
2. Using energy-efficient machines for manufacturing units is the next crucial step. According to World Energy Outlook 2022 by IEA, the current global energy crisis will pivot the world towards cleaner and greener energy by 2030. However, the present ideal solution to save industries from going extinct is to choose machinery with low energy consumption. For instance, LEDs consume 80% less energy as compared to incandescent bulbs, and even a simple move as this can go a long way. 
3. In order to ensure that all the energy-saving measures are implemented and followed by the factory staff, you can consider creating an energy management team. Such a team will have complete knowledge of the average energy usage for every department and accordingly, alter or introduce measures to cut down energy costs.

Choose DRTS for energy-efficient pipe manufacturing 

As there are many measures that can be taken on the surrounding energy consumption in your factory, the true key to energy saving is using a more energy efficient machinery. Through our 35 years in the industry DRTS has established a product line that is built with the most advanced components to provide the most efficient production line possible. We provide options to track energy consumption of the machinery that will allow you to better manage your production. 

To further reduce electrical consumption DRTS adapted an approach of providing a larger sized extruder (larger screw and barrel L/D) with a smaller motor. This is to achieve the necessary output with a more energy saving machine

Beyond this, it is also critical to utilize the production time to the fullest. This means increased productivity. 

Achieving productivity is a result of:

• Higher production speed=more product during a shorter production period
• Less down time, utilizing the available time to maximize production.
• Lower scrap rate, less waste of material as well as less machine running while not producing compliant product. 
• Quick start up, get the line running during the shortest time possible.

At DRTS our aim is to provide you with everything in order to give you the most energy efficient and high productivity production lines.

If you’re looking for a reliable and expert partner for your pipe manufacturing factory, get in touch with us. With a free consultation, we can help you build a robust, energy-efficient, and long-lasting manufacturing unit.