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Problems and Causes
Two T-Die Extrusion machines operate for 26 days per month, running on electrical power for 16 hours per day. The heat-radiating surface area of each T-Die Extrusion machine is approximately 2 square meters, causing room temperatures to rise to around 38 degrees Celsius and resulting in unnecessary production costs from excessive electricity consumption. Additionally, there is a risk of accidents from workers coming into contact with uninsulated heaters.
Improvement Methods
Thermal imaging camera scans revealed that the average surface temperature of the T-Die Extrusion machines was approximately 220-250 degrees Celsius. Due to mounting challenges with traditional insulation, options for heavy and thick insulation were limited. Therefore, the company chose to use ZAVE® removable thermal insulation with a thickness of 25mm but high density (170 kg/m³) and hydrophobic properties to prevent liquid plastic absorption in case of leakage from the extrusion process.
Improvement Results
| Comparison Table: | Average Oven Surface Temperature (Celsius): | Annual Heat Loss (kW): | Annual Electricity Cost (Baht): |
| Before ZAVE® Insulation: | 222.0 | 22,560 | 85,729.00 |
| After ZAVE® Insulation: | 54.2 | 1,472 | 5,594.00 |
| Reduction: | 167.8 | 21,088 | 80,135.00 |
