Optimising briquetting presses with compact and efficient hydraulic power units. HYDAC – Your partner for tailor-made hydraulic solutions in presses. Find out more.
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Presses & Forming Machines Customer Success Story Briquetting presses Hydraulic power unit
Optimising briquetting presses with compact and efficient hydraulic power unitsHYDAC – Your partner for tailor-made hydraulic solutions in presses
When residual materials and waste materials are recycled or further processed, it's not only our environment that benefits. With briquetting presses, a wide variety of waste materials generated in production processes, such as chips or dusts, can be pressed into high-quality briquettes – the reduction in volume saves space, time and costs for handling, storage and transport.
The chips and dusts produced during wood processing can be collected with extraction systems and separated in filter systems. Briquetting presses are often located right under the filter system so that the chips can be further processed. The briquetting press therefore partly determines the installation height of the filter system. As a result, factors such as tank optimisation and reduction in the installation area or installation height play an important role in the overall optimisation of the briquetting presses. Increasing connection costs and energy costs are leading to the desire to be able to use the most efficient drives possible in order to reduce the drive power and power dissipation.
With the help of our HYDAC experts, you can optimise your briquetting presses in terms of the factors mentioned above. Using the example of a customer, we will show you what a tailor-made hydraulic solution in your press can look like.
Reliable, fast and compactHYDAC offers the right hydraulic solution for every briquetting press
Developing the most compact hydraulic power unit possible for their new, more powerful machine – that was our customer's task for the HYDAC experts. The manufacturer of recycling systems with a focus on system solutions for extraction and dedusting systems produces up to 80 new systems per year. The briquetting presses, which are located below the filtration as part of these systems, compress dusts or wood chips into solid briquettes.
In close cooperation with the customer, our HYDAC specialists defined several goals at once: due to the limited installation height, a hydraulic unit that was as compact as possible was to be developed. The height and tank volume would need to be no greater than the height and volume of the existing, smaller machine size, in order to keep the overall height of the dedusting system the same. The main goals were to ensure an energy-efficient power unit and a reliable, fast machine with short cycle times. The customer also wanted individual support throughout the entire project phase.
The HYDAC solutionThe tailor-made hydraulic power unit for a 160 kN briquetting press
What was particularly important for us when developing the tailor-made solutions? Transparency and communicating as equal partners. It was precisely according to this motto that we defined the dimensions of the hydraulic power unit as well as the necessary technical and hydraulic requirements for the press control in several conversations with our customer.
How we developed the tailor-made solution:
First, we simulated the machine's sequence and calculated the cycle time. This allowed us to optimally adapt the pump drive to the machine requirements: a PPV101-45 axial piston pump with a power controller drives the cylinders and efficiently utilises the pump flow rate and motor power over the entire pressure range. Using the selected pump drive as a basis, the oil tank was then calculated and the air separation in the tank was optimised in conjunction with our Air-X filters and a CFD flow simulation. The oil tank size was reduced to a minimum. This measure doesn't just save installation space. It also aids better air separation and achieves an increase in the service life of all hydraulic components. Our compact press control block which was specially designed for the customer was equipped with an integrated pump circulation control to reduce power dissipation.
The tailor-made HYDAC solution exceeded our customer's expectations by far. Thanks to the efficient power-controlled axial piston pump, the pump flow rate and therefore the average power consumption could be significantly reduced compared to a pump combination with a flanged internal gear pump – as originally proposed by the customer; the nominal motor power fell from 7.5 to 5.5 kW.
As a result of the tank optimisation, we reduced the oil tank by as much as 52% (from 125 to 60 litres) compared to the size specified by the customer. We also reduced the height of the tank from 450 mm to 380 mm. This meant that the hydraulic power unit fitted perfectly into the intended space under the filter system. Thanks to the compact design, the customer saved 65 litres of hydraulic oil per filling, reducing their carbon footprint by 210 kg.
By eliminating the flanged internal gear pump, the power losses in (unpressurised) circulation could also be reduced; power losses were reduced by a further 0.2 kW, resulting in energy savings of around 500 kWh per year.
With this concept, the briquetting press even outperformed the required cycle time of 5.7 seconds (including 2.5 seconds for filling the press chamber with chips), leading to an increase in productivity.
As an additional extra, the unit's oil tank could also be used for the smallest size of the machine series, as its dimensions corresponded to those of the tank for the smallest size. As a result, all sizes now have the same oil tank, allowing a reduction in variants to be achieved.
Our customer's case shows that our tailor-made solutions increase your efficiency while protecting your budget. Talk to our industry experts now to optimise your system.