Energy Saving TCS Heater Band System

Ritch WaterfieldProduct Manager, Injection End Services

Milacron

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TCS Heater Band Systems

Thermal Control Solutionfor

Heating & Cooling Barrelson Plastic Machinery… Any Make, Any Model…

Injection Molding Blow Molding Extrusion

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Energy SavingTCS Heater Band Systems

Overview• ServTek & Rex Materials Group Partnership• What’s Unique about the TCS system• Benefits of the TCS system for all brands and models• How the TCS System will save you money through

energy and maintenance savings• Comparison of the TCS system with competition

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Partnering to Serve Customers

ServTek and RMG (Rex Materials Group) Partner to bringthis Energy Savings Technology to our Customers

– Over the past few years ServTek has worked with RMG to testand prove the viability of this product.

– In 2007 ServTek / Milacron preformed intensive testing at ourmanufacturing facility in Afton, Ohio

– Based upon this testing, in June of 2008, we entered into anagreement with RMG to be an exclusive supplier of this product

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About RMG

Rex Materials Group has been manufacturing heatersfor OEM’s since 1973 in the following markets:

– Industrial– Laboratory– Commercial– Hobby– Specialty Heat ProcessingAchieve chamber temperatures to 2100 F– plastic processes max out around 750 F

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Example

Kendro Lab Furnace Lining

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Example

Lindberg Furnace Heating Panel

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What’s Unique about theTCS Heater Band System

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Two Designs…

• This product is offered in two designs• The two designs are necessary to

accommodate a larger range of barrel diameters

• The two designs are “Segmented”and “Clamshell”

• The “Clamshell” designaccommodates barrel diameters from2” - 9.9”

• The “Segmented” designaccommodates diameters from10” - 17”

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The Segment Design

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The Clamshell Design…

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TCS Heater Band System…

• Manufactured from a vacuumedformed ceramic fiber

• Completed segment design iscomposed of multiple segments, theclamshell two halves

• With the segmented design thenumber of segments is determined bythe barrel diameter

• Both designs are wired in series, thesegmented design is assembled withVelcro, the clamshell with metalclamps

• Both consist of embedded radiantheating elements

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TCS Heater Band System…

Elements areimbedded into achannel

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The Cooling Option

• The bands are designed to accommodate cooling if required

• The heating elements channels are also used for cooling

• Optional blower can be added• Air is pulled through the channels

directly across the surface of the barrel

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The Cooling Option

Faster & more effective air cooling directly on the barrel. Do not have to cool the band heaters or aluminum clamshells first. Does not depend on maintaining good barrel contact to conduct heat away from barrel.

High Radiant Energy release from exposed element permits much faster heat up and response time than conductive type band heaters. Does not depend on maintaining good barrel contact to conduct heat to the barrel.

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During Heating & Cooling

• This system totally encapsulates your barrel

• Heating elements do not require direct contact with the barrel

• Cooling is more efficient, air has direct contact with the barrel

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Benefits of the TCS System

• Reduced Energy Consumption of conventional bands by 30% To 50%

• Faster Heat Up Time 30% To 50% Faster • Tighter Temperature Control

+/- 1degree F• Improved Worker Safety Safe to the

touch under operating conditions• Reduction In Air Conditioning Costs• Lower Maintenance Costs

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How Saving & Benefits are Achieved

• Wattage of the TCS system is reduced by 30%

• Bands cycle less due to superior insulating• Additional savings with reduced heat-up

time• Conductive heat into your facility is almost

eliminated reducing air conditioning requirements

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Maintenance Savings

• Lower wattage equals longer band life– replacement costs are reduced

• The single segment or clamshell designallows for ease of replacement– maintenance time and cost is reduced with single

replacements– Lead wires and terminations run much cooler

• Replacement inventory is reduced– reducing inventory costs

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Energy Savings Estimate

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Energy Savings Estimate

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Actual Energy Study

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TCS Verses the Competition

• Typically 50-80% lower in cost than induction heating• Equivalent or better energy savings - Reduced ROI• Barrel cooling can be easily incorporated• TCS bands wire into existing relays, thermocouples, and temperature controllers• No converters, transformers, or additional power supply necessary• No safety or electronic equipment concerns due to signal noise• Minimal downtime for conversion• Superior reliability and replacement parts at a small fraction of the cost

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Sample Installations

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Sample Installations

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Sample Installations

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Success Stories…

Injection Molders• Automotive Molder – Converted 39 machines to TCS including 20

Milacron 725 ton machines. Average energy reduction was 36%.• Medical Molding Application – 35% energy reduction on a 225 Ton Milacron.

Payback less than 18 months. We are in the process of converting multiple machines at this location

• Packaging Application – 43% energy reduction on a Husky XL500PET. Payback less than 20 months.

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Extrusion

• Wire & Cable – Have purchased eight TCS systems with savings ranging from 32% to 70% less energy. Have reduced scrap and dimensional variability.

• Sheet Extrusion – 33% less energy. Eliminated the need to water cool the barrel. Payback less than 24 months.

• Blown Film – 52% less energy. Eliminated the need to oil cool the barrel. Payback less than 14 months.

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Summary

TCS System• Energy savings of 30 - 50 % over conventional bands• Reduced air conditioning costs• Lower maintenance and inventory costs• Faster heat up time• Uniform distribution of heat - tighter temp control• Optional efficient cooling package if required• Improve worker safety and comfort• Any make any model machine

Energy Saving TCS Heater Band System

Ritch WaterfieldProduct Manager, Injection End Services

Milacron