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More efficient laser cutting saves materials and reduces scrap

Resources:
Waste
Sector:
Manufacturing of machinery and equipment
Cost:
High cost
Payback time:
5 Year(s)
Read more
Total cost savings:
More efficient system means less material and waste-management costs, and savings on sheet-cutting subcontracts
Premises and operation areas:
Production processes
Size of company:
Medium (less than 250)
Advancement in applying resource efficiency measures:
Advanced
One off investment:
1200000€

New laser tech shaves costs

  • Company replaces its inefficient mechanical steel cutters for boilers
  • New laser cutting units use 94.1 % of the sheet, saving money and reducing waste

DOMUSA Teknik makes and sells heating, ventilation, and air-conditioning (HVAC) products with a particular focus on solar systems for domestic water heaters, cast-iron and steel gas/oil boilers, biomass boilers, hot-water heat exchangers, electrical boilers, and diesel burners.

Until 2014, the company used a punching process to cut steel sheets for boiler manufacturing. This process involves cutting the cold sheets with a mechanical device formed by two tools: a punch and a die. The punch is compressed into the steel under force. The cut piece is separated from the sheet leaving off-cuts which cannot be used, resulting in signifcant waste raw material.

To improve efficiency, DOMUSA purchased two new fibre laser-cutting machines to replace the steel-punch system. Laser cutting directs a high-power beam at the material, and can be programmed for precision-cutting jobs which maximise raw material use and minimise losses, reducing waste generation.

Key benefits

More efficient material consumption:

  • Lower sheet consumption for the same amount of production unit
  • 94.1 % of the sheet is actually used
  • 8 % reduction in scrap waste generation

Cost savings:

  • Lower cost related to sheet consumption
  • Lower internal cost related to waste collection and management
  • No need to subcontracting sheet cutting during busy periods (laser cutters can keep up with demand)
Source

Ihobe (2018). First results report from the studies of hazardous waste minimization in the Basque Country, http://www.ihobe.eus/publicaciones/primer-informe-resultados-estudios-minimizacion-residuos-peligrosos-en-pais-vasco

Company website, http://www.domusateknik.com

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