We are therefore grateful that the company HANSA-Flex has a branch just a few metres away from our location which is always ready to advise us.
The complexity of our shapes is illustrated in the article marked below. The piping of the die-casting moulds plays a major role. Thanks to the close cooperation with HANSA-Flex, we are usually able to react directly to new situations.
You can find the full report here: Download PDF
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.
Almost 5 years ago, in cooperation with Pfleghar, the FCS zero-point clamping system was introduced in our company. The first implementation of the FCS system took place in April 2014 at the machining centre DMU 125 of DMG Mori.
Today a total of 11 of our machines are equipped with the FSC zero-point clamping system.
By introducing this system, our net milling time per machine increased by an average of 30 percent per year after only 12 months. This saves also important capacities in production, overall machining times and the machines are better utilized, which means that larger component quantities can be produced.
You can find the full report here: Download PDF
In the IHK magazine “Ausbildungsinitiative”, two of our trainees, Yves-Elias and Justin, report on their way to training and how they feel about the decision to complete their training with us. You can find the complete article under the following link, in the magazine on page 34.
Here you find the link to the report:
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.