Virtual Experience

The induction principle applied to the extruder's barrel

For us, the ability to innovate has always been the most important strategic resource: this is why we were the first to apply the principle of electromagnetic induction at an industrial level on extrusion machinery. Unlike traditional resistance-based systems, the barrel is heated without contact by means of an alternating electromagnetic field: a faster and more efficient method, which guarantees top performance by significantly reducing component wear and energy consumption by up to 35%. Bausano Smart Energy System is the effective answer to a concrete need: the optimisation of production processes with a view to sustainable development, respecting people and the environment.

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Smart energy system

The advantages
of Smart Energy System:

  • Energy Savings
  • Faster Heat-Up
  • Induced eddy currents generate powerful resistive heating directly within the barrel wall
  • Increased heating capacity
  • Faster, tighter temperature control
  • Higher temperature materials processability
  • Maximum coolingefficiency
  • Ease of installation through openable reel heater

System comparison

Resistance system MD 130 Induction system MD 130
Rated Power
No. of heating intervals Power intervals in Watts Total area power in Watts Interval control (sec) Time on (sec) % time on (sec) Absorbed power (kWh) Power reduction (%) Absorbed power (kWh) Energy saving kWh Energy saving %
1 10.000 10.000 60 36 60 6 30 4.2 1.8 30
3 5.000 15.000 30 50 7.5 5.25 2.25
3 5.000 15.000 30 50 7.5 5.25 2.25
1 7.500 7.500 12 20 1.5 1.05 0.45
1 7.500 7.500 12 20 1.5 1.05 0.45
1 6.000 6.000 12 20 1.2 0.84 0.36
1 6.000 6.000 12 20 1.2 0.84 0.36
1 7.500 7.500 12 20 1.5 1.05 0.45
1 7.500 7.500 12 20 1.5 1.05 0.45
Total areas 82,000 29.4 20.58 8.82
Energy saving forecasts - Depreciation calculation
Cylinder power consumption reduction kW A 8.82
System operating hours h/year B 6.000
Energy cost €/kWh C 0.14
Energy saving €/year D = A*B*C 7.409

Assumption calculated for active production cycle, based on estimated consumption of every single area, considering areas 4 to 9 active for 20% of the time.

SMART ENERGY SYSTEM
More efficient but also much more responsive

Our measurements indicate that the heating efficiency of a ceramic band heater may be 10-15% higher. The remaining energy is wasted by radiation and convection to the surrounding environment.
In contrast induction heating radiation losses are minimized by the insulating sleeves, which rise to a temperature of around 60-70 degree C during operation. The low-resistance induction coils remain cool enough to touch. The induction barrel heating can pay for itself within 18 months in energy savings.
Potential savings at a later stage comes from reduced wiring on new machines, less frequent replacement, savings due to fewer number of spare heater bands in inventory, reduced downtime and improved product quality.

Smart energy system Smart energy system
Smart energy system Smart energy system

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