Metal Finishing Guide Book

2012 Organic Finishing Guidebook Issue

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appendix d FINISHING CALCULATOR BY JOE SUBDA DUPONT, MT. CLEMENS, MICH. "Reduce costs while maintaining or improving quality" is a common cry heard in the finishing industry. Finishers are required to provide a high-quality product at an ever-reduced cost. Reducing costs can be tricky or impossible if the right infor- mation is not known. A hidden cost might be missed or an area with a higher return could be overlooked. This section will discuss how to calculate and determine some of the major costs that are associated with a finishing system. Calculations dis- cussed range from energy consumption to paint usage. The formulas and methods used in this section are for estimation purposes — actual cost could vary. The formulas and calculations are presented in an easy-to-follow, step-by- step format, with explanations and examples. Worksheets that simplify the use of the formulas and calculations are included at the end of the paper. ELECTRIC Motors consume the majority of electrical energy in a finishing system. Calcu- lations for energy consumption of a motor are straightforward. A formula for cal- culating energy consumption is listed below. Motors are used on pumps, blow- ers, conveyors, and cooling equipment. Motors consume a lot of electricity and it is beneficial to review the cost of operating them along with possible changes. Energy consumption for an electric motor can be calculated using the fol- lowing formula: The 0.746 is used to convert horsepower to kilowatts. This formula can be used to determine the cost savings for a motor if it was turned off when not needed. The savings for switching to a higher efficiency motor can also be calculated. Ex- amples on how to apply the formula are listed below. These are only two exam- ples; many other applications of this formula exist. Turning a Motor Off Finishing systems contain pumps that operate 24 hours a day. Motors that consume electricity run these pumps. Do all of the pumps have to operate 24 hours a day? If a pump were only needed during production, what cost savings would be incurred if it were shut off during nonproduction hours? Hours of nonproduction equal 88 hours a week — 8 hours a day during the week and 48 hours on the weekend. Savings of $3,793 a year would be incurred if this pump were shut off during nonproduction hours. High-Efficiency Motors When replacing a motor is it worth upgrading to a high efficiency motor? 319

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