Under the new requirements of environmental protection, how can the film slitting machine achieve energy saving and consumption reduction?

Under the new requirements of environmental protection, the film slitting machine needs to start from many aspects such as equipment upgrading, process optimization and intelligent management to achieve energy saving and consumption reduction, and the following are specific measures:

1. Equipment upgrading and technological innovation

• High-efficiency motors and inverter technology

The IE4/IE5 ultra-high efficiency motor is adopted, and the speed is dynamically adjusted with the inverter to avoid energy waste at no load or low load, and can save energy by 20%-30%.

Example: The spindle motor of the slitter adopts vector frequency conversion control, which automatically adjusts the torque and speed according to the change in the roll diameter.

• Low friction design

Use low-resistance components such as ceramic bearings and air bearings to reduce mechanical transmission losses; Optimize the structure of the slitting knife holder to reduce the cutting resistance.

• Thermal management system optimization

If the equipment involves heating (such as PE film slitting), infrared heating or electromagnetic induction heating is used instead of traditional resistance heating, and the thermal efficiency is increased by more than 30%.

2. Process optimization and material utilization

• Precise control of slitting parameters

Through the tension sensor and closed-loop control system, the unwinding/rewinding tension is adjusted in real time to reduce the increase in energy consumption and material tensile loss caused by excessive tension.

Data support: The tension fluctuation is reduced by 5%, which can reduce the waste film rate by about 2%.

• Thin knife slitting technology

The use of ultra-thin round knife or laser slitting reduces material cutting residues (such as PET slitting burr ≤0.1mm), improves the yield rate and reduces the energy consumption of waste disposal.

• Waste film recycling system

The integrated online crushing and recycling device can directly mix the leftover materials back to the raw materials and reduce the consumption of new materials (the recovery rate can reach more than 90%).

3. Intelligence and energy management

• Internet of Things (IoT) monitoring

Sensors such as electricity meters and gas meters are installed to monitor the energy consumption of the slitting machine in real time, analyze the peak load and optimize the production schedule through the MES system.

Case: An enterprise uses AI algorithms to optimize the slitting sequence, reduce the number of equipment starts and stops, and save 150,000 kWh of electricity per year.

• Predictive maintenance

Replace worn tools or bearings ahead of time with vibration analysis and temperature monitoring to avoid wasted energy and downtime due to equipment failure.

4. Clean energy and auxiliary system energy saving

• Photovoltaic power supply

Solar panels are installed on the roof of the plant to provide some green electricity for the slitter (especially in high-sunshine areas).

• Compressed air system retrofits

If pneumatic components are used, the frequency conversion air compressor + waste heat recovery device is used, and the comprehensive energy efficiency is increased by 40%.

5. Operational specifications and training

• Standardized operating procedures

Develop energy-saving operation manuals for slitters, such as:

◦ Avoid frequent start-up and shutdown of equipment and batch processing of orders;

◦ Clean the rails and cutters regularly to keep the equipment in optimal condition.

Evaluation of the effectiveness of the implementation

Through these measures, the energy consumption of a typical film slitting machine can be reduced by 25%-40% and the waste film rate can be reduced by 10%-15%, while meeting the requirements of the ISO 50001 energy management system. It is recommended that enterprises conduct energy consumption audits, prioritize the implementation of projects with high return on investment (such as inverter retrofits), and gradually promote comprehensive green upgrades.