Good practice

More efficient laser cutting saves materials and reduces scrap

More efficient laser cutting saves materials and reduces scrap
© Microgen, image #133105712, source: Fotolia.com
Resources:
Waste
Sector:
Manufacturing of machinery and equipment
Cost:
High cost
Payback time:
5 Year(s)
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)

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