SHRINK UNITS ARE POWER GUZZLERS
A strong argument for switching to hydraulic clamping is the high energy requirements for shrinking. In its own factory, MAPAL ascertained that a shrink unit that is used in three shifts per day can consume between 10,000 and 12,000 kilowatt hours per year. This corresponds to the electricity consumption of five energy-conscious two-person households.
This energy consumption not only entails high energy costs but also emits a large amount of CO₂. According to the statistical analysts at Statista, the current energy mix in Germany results in approximately 366 grams of CO₂ being emitted for each kilowatt hour. Each shrink unit therefore emits 3.6 tons of CO₂ into the atmosphere every year. Nowadays, this has an impact on the entire supply chain, where the sustainability of manufacturing is becoming increasingly important. Many first- and second-tier customers only want to source from suppliers that can prove that they are reducing their carbon footprint.
In addition to the tool life of a chuck and energy requirements of the device, time is also a factor when calculating return on investment. It takes at most two minutes to swap a hydraulic chuck, whereas six to eight minutes are needed for shrink chucks, depending on the size. If tools are changed often in manufacturing, this results in considerable labour costs. The space required in the tool-setting area for the shrink unit would also no longer be needed.
SIMPLER AND SAFER
The social aspects of sustainability shed light on the topic from the user’s perspective most of all. A product where the performance is obvious to the naked eye is likely more agreeable to users than one with a rusted sleeve. When it comes to handling and safety, there are even more arguments for switching to the hydraulic clamping technology.
A shrink unit is not only cumbersome to handle but also a safety hazard. Almost every user has burned their finger once on a hot chuck during a
busy workday. There is no such risk with hydraulic chucks. In general, they are very simple and straightforward to use – the tool only needs to be inserted and tightened. The workers benefit from processes that run more smoothly and require less reworking. The fact that a shrink chuck subject to material fatigue might be the cause for increasing tool wear or deteriorating surface quality is not always immediately obvious in practice.
The comparison result is clear: If you want to manufacture responsibly, then you should consider switching to hydraulic clamping technology. For new purchases, hydraulic chucks are the first choice from a sustainability perspective.
Dear business partners
and readers,
In this issue of Impulse, we are focusing on our newest business area: the die & mould sector. We were well aware that we were venturing into a competitive environment when we decided to enter this market segment. We had to offer a technological plus if we wanted to provide an advantage to our customers. Our comprehensive portfolio is the key. In addition to tools for milling, drilling and reaming, we can offer clamping technology and the entire tool logistics as well as regrinding and repair services. The advantage: our customers get everything from a single source.
Today, we can take a look at a market segment that has developed positively for us. The application reports in this issue attest strongly to the fact that MAPAL tools and services have proven themselves capable for the die & mould sector. In addition to the favourable development in the die & mould sector, there was another also special event: my father, Dr Dieter Kress, celebrated his 80th birthday in May. As a visionary and entrepreneur, MAPAL grew from a small, local company in Aalen to an internationally active group under his leadership. Today, 5,000 employees work for MAPAL in 25 countries. He cultivated the spirit of an owner-operated family business where customers and employees are treated as partners. These values still define our DNA today.
My father shaped the industry significantly by taking a leading role in national and international associations and commissions. His exceptional social commitment to his hometown of Aalen was dear to his heart. He was honoured many times for his life’s work. The many birthday greetings he received attest to the fact that he is still held in high esteem in the machining industry as well as by our customers worldwide. Of course, he was very delighted by this. I have the honour of passing along his heartfelt thanks to all those who congratulated him.
Have a good read!
Yours,
Dr. Jochen Kress
