Environment industries archive
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By replacing infra-red ovens with a new induction oven, Bordex Wine Racks has reduced energy consumption in the wine rack making process by approximately 60 percent. Through installation of the new oven and the purchase of new steel processing equipment, productivity was increased by 80 percent. A total outlay of $64,300 resulted in annual savings of $30,000 with an expected payback period of 2-3 years.
Bordex Wine Racks Australia Pty Ltd is an Adelaide based commercial wine rack manufacturer with a strong export focus and a philosophy of continuous improvement in all aspects of manufacturing. The company sells its uniquely designed product to restaurants, bottle shops and hotels in Australia and overseas. Employment at its Dudley Park factory has more than tripled since 1995 to reach 18 in 2001. Current turnover is over $3 million, of which 40 percent is derived from exports.
Bordex wine racks are made from hand-oiled recycled and plantation timber mounted on galvanised steel frames, which are coated with an oven baked polyester paint.
The racks are made as standard units for a wide variety of applications or can be custom made to suit any special shape, size or purpose.
To manufacture the ends of wine racks, large coils of steel strips pass via a fully automated system through a powder coating booth and then through infra-red ovens. Fumes are emitted as the powder is heated and cured to the steel to form the coating. Large volumes of water were required to cool the heaters. Once painted the steel is re-coiled prior to cutting.
The ovens were very inefficient in their use of electrical energy, requiring 40kW of energy to run the production line at 1 metre per minute.
To overcome its production line inefficiencies and improve productivity, the company purchased three new machines: a reel to reel press; a pneumatic steel guillotine and a Unipower induction oven and cooling plant.
The cost of the equipment, including installation, totalled $64,300. The investment was partly financed by an interest free loan of $30,000 provided by the South Australian Environment Protection Agency under its Cleaner Industries Demonstration Scheme.
Under the new process, steel was purchased in rolls, run through the press, painted as coils, heated in the induction oven to cure the paint, and then recoiled. In a separate process, the steel was cut into lengths by the computerised pneumatic guillotine.
The new oven enabled the production line to run at 2 metres per minute, twice the speed of the previous system. The production line could potentially be run at 2.5 metres per minute, thus further increasing productivity. The press and cutter have the capacity to operate 40 percent faster.
Powder coating line and the Induction oven
The new induction oven reduced energy consumption from 120 kW to 5-6 kW, saving annually around $5,000.
Wastage was reduced considerably: oven heat losses were minimised; the new powder coating process ensured that no powder was wasted; the number of rejects from incorrectly cured steel was reduced significantly; and the fully enclosed water cooling process minimised water wastage
Productivity was increased substantially, with savings estimated at $25,000 per annum: the number of production runs was increased from 2 to 3.6 per 8 hour day (a net rise of 80 percent); labour was been saved with the elimination of certain manual tasks.
The main aim of the initiative was to increase productivity and reduce energy costs. The 2000 mē factory now utilises the most modern machinery and production processes available. All production inputs are fully recycled and all harmful emissions have been eliminated.
No problems or obstacles were encountered.
Bordex Wine Racks has continued to benefit from these initiatives.
Since the initial project, a new duplicate line has been added to increase production volume.
Mr Siva Selva Snr
Bordex Wine Racks Australia Pty Ltd
2a Oldsmobile Terrace
SOUTH AUSTRALIA 5008
Ph: 61 8 8340 1660
Fax: 61 8 8340 2215