Induction Heating System
Bausano Induction Technology

The induction principle applied to the extruder's barrel

For us, the ability to innovate has always been the most important strategic resource: this is why we were the ﬁrst to apply the principle of electromagnetic induction at an industrial level on extrusion machinery. Unlike traditional resistance-based systems, the barrel is heated without contact by means of an alternating electromagnetic field: a faster and more efficient method, which guarantees top performance by signiﬁcantly reducing component wear and energy consumption by up to 35%. Bausano Smart Energy System is the effective answer to a concrete need: the optimisation of production processes with a view to sustainable development, respecting people and the environment.

The advantages
of Smart Energy System:

Energy Savings
Faster Heat-Up
Induced eddy currents generate powerful resistive heating directly within the barrel wall
Increased heating capacity

Faster, tighter temperature control
Higher temperature materials processability
Maximum coolingefficiency
Ease of installation through openable reel heater

A model of efficiency

The inductive barrel heating Smart Energy System has been designed with a special fan that allows cooling the hot parts of the machine in the most effective possible way. This new project, integrated by the openable reel system, also allows the customer to add a retroffit application on already existing extruders.

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Inductive Heaters performance

FEATURES:

Standard efficiency 95%
Barrel heating directly applied
Uniform barrel heating
No thermal inertia
Heaters with unlimited life
Material temperature very close to the barrel temperature

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Standard Resistive Heaters

FEATURES:

Maximum efficiency: 70%
Barrel heating through direct contact with the heaters
Barrel heating not uniformly applied
High thermal inertia
Heaters with short life
Materila temperature = barrel temperature about 20 degrees C lower

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System comparison

Resistance system MD 130							Induction system MD 130
Rated Power
No. of heating intervals	Power intervals in Watts	Total area power in Watts	Interval control (sec)	Time on (sec)	% time on (sec)	Absorbed power (kWh)	Power reduction (%)	Absorbed power (kWh)	Energy saving kWh	Energy saving %
1	10.000	10.000	60	36	60	6	30	4.2	1.8	30
3	5.000	15.000		30	50	7.5		5.25	2.25
3	5.000	15.000		30	50	7.5		5.25	2.25
1	7.500	7.500		12	20	1.5		1.05	0.45
1	7.500	7.500		12	20	1.5		1.05	0.45
1	6.000	6.000		12	20	1.2		0.84	0.36
1	6.000	6.000		12	20	1.2		0.84	0.36
1	7.500	7.500		12	20	1.5		1.05	0.45
1	7.500	7.500		12	20	1.5		1.05	0.45
Total areas		82,000				29.4		20.58	8.82

Energy saving forecasts - Depreciation calculation
Cylinder power consumption reduction	kW	A	8.82
System operating hours	h/year	B	6.000
Energy cost	€/kWh	C	0.14
Energy saving	€/year	D = ABC	7.409

Assumption calculated for active production cycle, based on estimated consumption of every single area, considering areas 4 to 9 active for 20% of the time.

SMART ENERGY SYSTEM
More efficient but also much more responsive

Our measurements indicate that the heating efficiency of a ceramic band heater may be 10-15% higher. The remaining energy is wasted by radiation and convection to the surrounding environment.
In contrast induction heating radiation losses are minimized by the insulating sleeves, which rise to a temperature of around 60-70 degree C during operation. The low-resistance induction coils remain cool enough to touch. The induction barrel heating can pay for itself within 18 months in energy savings.
Potential savings at a later stage comes from reduced wiring on new machines, less frequent replacement, savings due to fewer number of spare heater bands in inventory, reduced downtime and improved product quality.