In order to map the casting process for our customers in addition to die design and production, Heck + Becker’s Die Casting Technology Center samples the die casting dies, optimizes casting processes or produces small series of up to 3000 castings. More than 150 tons of aluminium are processed annually.
In 2013, Managing Director Martin Baumann already started a series of energy optimization projects. A new compressed air system with heat recovery and new illumination led to electricity savings of 40 percent and reduced CO2 emissions by 189 tons per year. “It was clear to us that we had to continue working on energy efficiency.” Baumann and Björn Velte, Head of Facility Management, continued this basic idea in the following years. In 2018, they analysed the production again. New furnace technology and energy generation options should make the company more efficient.
New melting furnace saves 347 tons of CO2
Until now, a natural gas melting furnace has been used for aluminium melting for the production of the castings and an electric furnace for keeping the aluminium hot. Together they keep the aluminium at a melting temperature of around 670 degrees Celsius 24 hours a day throughout the year. However, the natural gas melting furnace also caused combustion losses of around 3.5 percent of the valuable aluminium. An innovative aluminium melting and heat retention concept was developed for the Heck + Becker Die Casting Technology Center to reduce energy consumption, CO2 emissions and material losses due to combustion during the melting process. The aluminium combustion loss dropped to around 1.5 percent. The special innovation of the melting and heat retention furnace is based on the division of the furnace chamber into three zones: the preheating zone, a melting zone and a heat retention bath for the liquid aluminium. Together with the improved insulation of the furnaces, this leads to considerable energy savings, low material losses and uninterrupted availability of the melt for the die casting machine. The annual energy consumption is to be reduced by around 258,300 kWh, which corresponds to a CO2 saving of 347 tons per year.
30 percent subsidy from PIUS – amortization in just five years
Furthermore, the installation of a photovoltaic system (PV) and a combined heat and power unit (CHP) are planned, which will largely supply the Die Casting Technology Center with renewable energies in the future. “Thanks to PIUS, we will not only enhance our image but also create enormous potential for cost savings.” In addition to reducing energy costs, Heck + Becker will reduce CO2 emissions by a third. With the help of the “PIUS-Invest” investment promotion programme for the reduction of CO2 emissions within the framework of the European Regional Development Fund (ERDF) of the European Union, the amortisation period for the expenditure is only 3.7 years. Given 20 years of use and savings, there will be an excellent return on investment.
Automation, digitalization and networking via Internet will be important across all industries in the future. The “Bildungswerk der Hessischen Wirtschaft e. V.” (a non-profit educational organisation of the Association of Hessian Employers’ Associations) has therefore developed an additional qualification in which our trainees from the third year of training could successfully participate. Basic digital and interdisciplinary skills were taught in order to promote the professional ability to act in the digitalised working world. Our trainees enjoyed this further training very much and can highly recommend this additional qualification.
A total of nine pupils from the Dautphetal secondary school successfully took part in twelve consecutive appointments at the Schul AG at Heck + Becker from 27.08.2018 to 28.01.19 in order to get to know the profession of tool maker and to learn more about the company.
During the six-month period, the students were able to gain a first impression of the basic skills of a tool maker and also test the skills they had learned at the Heck + Becker Academy. For this purpose, the students produced a bottle opener and the game “Mensch ärgere dich nicht” (“Ludo”).
The company Heck + Becker would like to thank all participants as well as the “Mittelpunktschule Dautphetal” and is looking forward to an extended cooperation in the future!
Also in the year 2019 Heck + Becker is represented at the training and study fair in the “Dautphetaler Hinterlandhalle”. At our booth, our experts from training and further education together with current trainees will be available as expert contacts. In addition to technical information on training or dual studies, visitors will also get a personal impression of the working world at Heck + Becker.
From the 08th to the 09th of March 2019
Friday from 08:30 am – 14:00 pm
Saturday from 09:30 am – 16:00 pm
All those interested in training as a tool maker or for a dual study program.
Further information is available at:
In the rooms of the vocational school in Biedenkopf, our Heck + Becker training team will also be on hand at the next “Café Beruf” on February 21, 2019 to answer any questions interested in training as a tool mechanic with the technology leader.
February 21, 2019
From 16 – 19 pm
Vocational school Biedenkopf
Auf der Kreuzwiese 12
All those interested in an apprenticeship as a tool maker.
Further information is available at:
On September 28, 2018, the trainees of all apprenticeship years set off together for the team-building event in the Marburg climbing forest under the direction of training manager Marco Pfeifer. 15 trainees experienced many different team tasks throughout the day in order to take with them new ideas for everyday life and to strengthen the “sense of unity”. In a playful way, different stations tried to increase the ability to cooperate and communicate, to optimize the efficiency in the team and to strengthen the overall trust. After a refreshment in the adjacent “Dammühle” restaurant, all participants were able to try out all the stations in the climbing forest before heading home to Dautphe.
We are pleased to welcome new trainees to our company again this year. With the help of Heck + Becker, seven young colleagues will be completing their training as tool makers in the next few years. In addition to learning the basic skills of toolmakers, the training plan also includes getting to know and working in the individual departments. In addition, we also try to impart further training content within the framework of the Heck + Becker Academy. We wish them a good, interesting and successful training period at Heck + Becker GmbH & Co. KG.
Heck + Becker was also present in 2018 for customers, partners and interested visitors at the EUROGUSS in Nuremberg, Europe’s largest event for the complete value chain of die casting in one place. Very interesting conversations and the presentation of the K1 Heat Buster contributed to a successful fair. Below you will find some impressions.
We look forward to welcoming you to our booth in 2020!