Sustainability at heart – innovation in every workpiece
As the impact on the environment continues to grow with negative consequences for us all, there’s no denying the fact that it is time to act. Our fossil fuel reserves will start to run out sooner or later, which will go hand in hand with rising energy prices. This has prompted companies to rethink their approach to business. Sustainability in industrial production has therefore become a decisive matter when it comes to the future. WFL sells MILLTURN complete machining centres worldwide and serves a wide range of industries. The machines therefore bear a lot of responsibility when it comes to both our environment and our future.
Only energy-efficient components with the option of energy recuperation or use of waste heat are used in the MILLTURN turning-boring-milling centres. Frequency-controlled pumps are used alongside highly energy-efficient motors and drives, meaning that electricity is drawn only in the exact amounts required. When the spindle drives brake, the machine works as a generator and feeds valuable electrical energy back into the grid. The additional energy-saving standby mode for organisational downtimes requires around 90% less energy compared to conventional idling.
The three pillars of WFL Greenside Technologies:
- Resource-optimised construction
A high level of component rigidity is achieved while at the same time reducing the moving masses (finite element calculations).
- Efficient operation
From energy-efficient processes to the latest drive technology with energy recovery, energy consumption is minimised in operations.
- Strong and durable
Durability and reliable precision throughout the entire service life ensures minimal resources are used. At the end of a long machine life, both the environment and the customer benefit from recyclable materials.
- With the MILLTURN complete machining principle, the machining focuses on highly productive machine tools.
- The number of auxiliary units is reduced to a minimum.
- The complex, energy-intensive transportation of semi-finished parts is, for the most part, no longer required.
At WFL, various aspects of sustainability are taken into account:
- Resource efficiency: WFL strives to use raw materials and energy-efficient motors efficiently.
- Life cycle approach: WFL considers the entire life cycle of the machines. This includes designing them in an environmentally friendly way, using more sustainable materials and reusing and recycling components and entire machines.
- Sustainable machine components: The integration of cooling units helps to dissipate heat in a sustainable way.
- Circular economy: WFL advocates a circular economy in order to minimise the waste of resources. The company supports this concept by developing products with a long service life, supporting repair and maintenance processes and implementing re-manufacturing processes, which involves refurbishing used machines to return them to as-new condition.
- Digital solutions: CrashGuard Studio provides preliminary simulations without operating the machine, while WFL Adaptive Control helps to minimise unproductive machine movements. Integrated process monitoring ensures more efficient machining processes and prevents damage.
- Supply chain management: Sustainable supply chain management is extremely important to us. By working closely with suppliers and promoting a sustainability standard, we are helping to reduce the environmental impact across the entire supply chain.
|Machine||M40 MILLTURN / 2000mm|
|Workpiece / batch size||Cutter spindle / 11 pcs.|
|Production hours||4160 (8 hrs x 2 shifts x 5 days x 52 weeks)|
|Average power consumption||Approx. 30kW|
Calculated based on the following assumptions:
- 52 weeks of production per year
- 5 days of production per week
- 2 shifts per day
- Reduction in consumption due to energy-saving mode on average around 6 kW
Savings thanks to energy-saving mode:
Reduction in consumption due to WFL energy-saving mode 6 kW
Reduction in consumption x production hours = saving
6 kW x 4160 hrs = 27,456 kWh / 13.9 t CO2
Savings thanks to frequency-controlled high-pressure pumps:
Energy-saving potential compared to fixed pressure and value setting of up to 70% of 7.5 kW pump performance.
Thanks to demand-based machine control (pump with 60% in operation)
13,103 kWh / 6.6 t CO2
Savings thanks to cooling units with water-to-water heat exchangers:
12,480 kWh / 6.3 t CO2 with customer-side coolant supply
Savings thanks to CrashGuard Studio:
6,200 kWh / 3.1 t CO2 with 52 new NC part programmes per year