Technical Report 2016-12-06

Content shown in the technical articles are the sole opinion and views of the authors or companies, which are not necessarily congruent to opinion and views of the editors.


An Energy-conscious Company

Ulrich Mangelsdorf, Werner Koch Maschinentechnik GmbH

Hehnke GmbH & Co KG consistently focuses on the manufacture of automotive parts. Nearly 80% of production goes to suppliers or directly to car manufacturers such as Daimler and BMW. With the trend to replace conventional materials with plastic, plastic processing has once again had the opportunity to significantly grow in recent years. Energy consumption has decreased, as Hehnke has wholeheartedly embraced the energy awareness idea and it has heavily invested in energy-efficient technologies. At it the new, energy-efficient drying system from Koch-Technik for pre-drying the pellets plays a supporting role.

The new Koch-Technik system for drying of pellets: A total of 40 drying containers and 3 CKT dryers are installed on a platform. The dryers are equipped with dew point control, Koch-Technik-Eco system control and frequency controlled drying fans for energy saving pellet drying.
The new Koch-Technik system for drying of pellets: A total of 40 drying containers and 3 CKT dryers are installed on a platform. The dryers are equipped with dew point control, Koch-Technik-Eco system control and frequency controlled drying fans for energy saving pellet drying.
Energy Efficient Drying of Pellets
When planning the new drying plant Hehnke prioritized energy efficiency. Today Koch already offers its pellets with energy savings of up to 50%: Dew point control, frequency control of the drying blower and the patented Koch-Technik-Eco-system control. All Koch-Technik dry air dryers of this size have a dew point control function that uses two drying cycles. While one cycle blows pre-dried air through a drying container where it absorbs the moisture of the pellets and later passes on to a drying agent, the second cycle regenerates a second container with drying agents. The dew point control is switched to the second regenerated tank as soon as the receiving drying agent is saturated with moisture. Compared to time based switching, the dew point control allows for a much better uniform drying quality and energy efficient drying process of ABS, PA, PPS, PPU and PPE materials, as well as special thermoplastics.

Dryer control via touch panel: all operating components can be easily operated via the touch panel on the CKT dryer. Thanks to the network and WLAN capabilities of the system controls, it is possible to control the system via a superior control centre or even a tablet.
Dryer control via touch panel: all operating components can be easily operated via the touch panel on the CKT dryer. Thanks to the network and WLAN capabilities of the system controls, it is possible to control the system via a superior control centre or even a tablet.
ECO-system-control prevents the over drying
The Koch-Technik-Eco-system control primarily prevents the over drying of hygroscopic pellets, so avoiding discolouration or degradation of the mechanical properties of the material. Once the pellets reach a residual moisture level required for processing, the heating is shutdown and the respective container is removed from the drying cycle. The container is reconnected only when material is removed or the temperature drops below a certain value. This rest phase of individual drying containers makes it possible to reach a high energy efficient process while drying materials in a gentle manner. Simultaneously, frequency controllers control the speed of the drying blower and the flow of dry air in the system is throttled as soon as individual drying containers are removed from the cycle. The decrease of energy consumption of the blower alone is disproportionately high. This allows savings of up to 50% of conventionally used energy.

Koch-Technik visualization software: The user is provided with an overview of the integrated Koch-Technik peripherals - e.g. view of the entire drying system shown here. All operating data can be edited, managed and archived for the purpose of traceability.
Koch-Technik visualization software: The user is provided with an overview of the integrated Koch-Technik peripherals - e.g. view of the entire drying system shown here. All operating data can be edited, managed and archived for the purpose of traceability.
The results prove the words of Peter Hehnke, Managing Director: An analysis of the first half of 2014 has shown savings of nearly EUR 20,000 in the drying process alone. And this was possible despite a higher material consumption in the first half of 2014 reaching 400t of material, which is as much as was used during 2013. All measured values were acquired independently as Peter Hehnke monitored the company's energy concept with independent energy advisers.

Integration into the monitoring system
The new Koch-Technik drying system is located in a spacious area with about 150 square meters in the company's newly built logistics centre. The three Koch-Technik dryers type CKT 300 and CKT 800 are sized generously and can be expanded. A total of 40 drying containers are available for various throughputs and residence times of materials. Every dryer has a touch panel controller with a direct connection to the Koch-Technik visualization software that represents all the processes of Koch-Technik peripherals in one place. This simple software can be used to control the entire system and to connect to the company's network, which is already running a powerful production planning and control system/ ERP system and an MDC system. The combination of these systems supports the implementation of flexible manufacturing processes and optimum utilization of existing resources.

Arburg injection moulding machine with Koch-Technik peripherals and automation cell as a single unit for the efficient production of components.
Arburg injection moulding machine with Koch-Technik peripherals and automation cell as a single unit for the efficient production of components.
Injection moulding with a high degree of automation
Hehnke boasts expertise in injection moulding of precision parts. Since 2010, the amount machinery used has risen from 25 to 32 Arburg injection moulding machines, which offer clamping forces of 250 to 2,750kN. All production systems are fitted with Koch-Technik handling technologies and KEM dying equipment. Two central conveyors installed by Koch-Technik bring material from the drying systems into the injection moulding machines. The vacuum generator used for the vacuum uses a frequency controlled in order to avoid unnecessary energy consumption during transport. On workdays, three shifts produce the highest quality precision plastic parts with weights ranging from 2g to 600g. A high degree of automation with close production tolerances has become standard; this is why the company has consistently oriented its production towards Industry 4.0: The latest Arburg injection moulding machines have manufacturing cells with connected automatic systems, where six-axis robots, conveying, mixing or dying accessories, as well as the injection moulding machine form a single unit for the more efficient production of components.

Example of a Hehnke series manufactured part "from one source": An operating unit for use in the Automotive industry
Example of a Hehnke series manufactured part "from one source": An operating unit for use in the Automotive industry
According to Arburg who offers these manufacturing cells as a total package, the integration of robotic systems and accessories is an important factor in order to make the injection moulding production even more efficient. Efficient injection moulding is strongly based on a high level of energy consciousness, which is annually confirmed in the Hehnke company thanks to annual recertification. It is therefore not surprising that Hehnke GmbH & Co KG achieved Company of the Year 2013, medium-sized businesses in Thuringia. 


Hehnke GmbH & Co KG
In 1995 Peter Hehnke, with decades of experience in plastics processing and with the support of his wife Anne and two system partners, Arburg and Koch-Technik,founded Hehnke Kunststoff-Spritzgieß GmbH (Hehnke plastic injection moulding, Ltd.). From a two-man operation, the company grew over time to employ 95 workers and relocated to the "Am Scherzer" industrial area in Steinbach-Hallenberg, Thuringia. In 1999 and 2006, additional production capacities were created at this location and the merger with the mould design and construction company Son Tommy Hehnke followed. Expansion carried on in 2010 by adding a tool storage and a technical centre, culminating in 2013 with the construction of a new logistics centre, which also houses the new drying system. Today the Hehnke GmbH & Co KG is led by three managing directors Peter Hehnke, Tommy Hehnke and Torsten Herrmann. The company is a system supplier, which makes it possible to offer the customer everything from a single source: Consulting, prototyping, tools and series production. In addition to this statement, much emphasis is placed on energy-efficient production and sustainable modernization.

Werner Koch Maschinentechnik GmbH
The Werner Koch Maschinentechnik GmbH, Ispringen is one of the few full service providers of peripheral equipment for the plastics processing industry. Their product portfolio includes equipment and systems for mixing, dosing, conveying, drying and stocking of plastic pellets. Koch-Technik, with its modular system provides customized solutions for diverse customer needs, regardless of whether it concerns the use of single devices or the installation of a comprehensive central systems. Devices and equipment used by more than 5,000 plastics processing companies worldwide document the acceptance and high usefulness of these systems in everyday production. 

Werner Koch Maschinentechnik GmbH

Industriestraße 3
75228 Ispringen/Pforzheim, Germany

Phone:  +49(0)7231 80 09 - 0
Fax:      +49(0)7231 80 09 - 60
Email: info@koch-technik.de

Internet: www.koch-technik.com


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