Energy savings pay back the investment
Peter Bengtsson and Peter Lundahl work with preventative maintenance at Akzo Nobel Functional Chemicals AB in Stenungsund. Their objective is that all installation downtime should be planned. To achieve this they use measurement systems for vibration checks and alignment of the machines. Aligning machines using lasers is a given for the majority of larger industries today, but smaller companies have a lot to gain as well. Especially as the costs of current measurement systems are extremely reasonable. Less downtime minimises production losses, a not insignificant cost in many processes. Use of replacement parts is reduced, the working environment is improved with reduced leakage and reduced vibrations. In addition, correctly aligned machines use less energy, something which is soon noticed on the utilities bill, and in the long term even on the environment.
"Together with vibration control, machine alignment is the largest cost saving within maintenance work," explain Peter and Peter.
"One of the foremost reasons that we use Easy-Laser® is the fast support we receive. Something that is, of course, important because we work against the pressure of time when something occurs regardless of whether it is planned or unscheduled"
says Peter Bengtsson.
"I also appreciate that the products are so easy to use, because it allows us to concentrate on the alignment work"
Peter Lundahl adds, and continues:
"I am convinced that an investment in a laser measurement system pays for itself many times over. Which maintenance or operations manager can say no to it?"
Easy-Laser® measurement and alignment systems have frequently paid for themselves within a year through large replacement parts and energy savings. Just one unscheduled stoppage less often means large cost savings.
The department for Functional Chemicals for example has 100 connected machines. They use nearly 7000 kW per hour (6000 hours/year) (2005). The total energy cost is then:
6960 kW x 6000 h x 0.3 SEK = 12,528,000 SEK/year.
If the energy reduction with a good alignment is 1% (125,280 SEK), the investment is repaid within 3–6 months.
In addition, there are 20 sheave/pulleys with an energy consumption of 600 kW per hour (8000 hours /year). Total energy cost for these:
600 kW x 8000 h x 0.3 SEK = 1,440,000 SEK/year.
1% energy reduction corresponds to 14,400 SEK, but for sheave/pulleys this can mean savings as much as 5–10%. Here the repayment period is, in other words, even shorter.
Total saving more than 140,000 SEK/year!
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