Businesswise,
the Best you can get is
How you can benefit from tHe world’s only enamelling
macHine tHat Has an oven running on zero electric energy.
cut your energy costs!
Drastically!
MAG’s years of R&D are paying off now – for you!
With MAG’s new Zero technology you could save
55% of your enamelling machines’ total electric
energy. And thereby 55% of their energy costs.
How is this possible? 55% of the total electrical energy for horizontal
enamelling machines has been, until now, used for heating the process air. And this is already the figure for the most efficient machines.
MAG’s revolutionary ZERO technology cuts the heat loss by far more
than half, so that during production far less than half of the initial
power will be needed.
This allows the oven to run on zero electric energy for heating, thereby
cutting your energy costs dramatically – and increasing your margins.
12% Blowers
10% Drawing
2% others
3% Take-up
18% Annealer
55%
Electric heating
Typical energy consumption values for a 2-line Mozart machine
(Diameter 0.5mm, vxd=200) – up until today, one of the world’s most
efficient machines.
investing in energy
savings now pays off –
literally. anD quickly.
MAG’s Mozart Zero reduces energy consumption
so drastically that it amortises itself, through saved
electricity costs within a few years.
What makes this so impressive is that this highly conservative amortisation calculation is only based on energy savings: without taking all
the other advantages of producing on MAG machines into consideration. The result of this is an even better bottom line.
After all, MAG machines are proved to produce more than any of its
competitors. This means, for the same output you need fewer lines,
less capital expenditure, less staff and less total running costs. So,
however you look at it, ZERO pays off. And this is how quickly:
exemplary calculation of potential cost savings
(amortisation)
MAG´s Mozart Zero vs. competitor’s production line
for the same output:
Assumed energy cost (€ / kWh):
Assumed annual output (tons):
€ 0.09
2898
This output can be achieved on only six lines of MAG Mozart Zero
– or more than six lines of competitors’ machines due to their lower
productivity.
Competitor’s machine specific energy demand (kWh / kg):
0.98
Competitor’s total annual energy cost:
€ 255,604
MAG Mozart Zero’s specific energy demand (kWh / kg):
0.37
MAG Mozart Zero’s total annual energy cost:
€ 96,503
annual energy saving through Mag Mozart Zero:
€ 159,101
Within only six years these drastic savings alone can finance the
complete acquisition costs of a MAG Mozart Zero.
Don’t waste Money
on scrap. eliMinate it.
Mozart Zero constantly produces better quality than
any competitors’ machines. Partly, because it uses
fully automated process controls. Sparing you the
nuisance and, more importantly, the costs of scrap.
The cheapest machines are often the most expensive ones. After all,
the cost of scrap must not be underestimated: wasted copper, missed
quality requirements, missed deadlines, penalties, write-offs and so
forth. This is why MAG invests heavily in R&D: to produce the most
reliable enamelling machines worldwide.
With our latest, fully automatic wire temperature regulation technology,
we achieve fully controlled wire temperature at the enamel applicator.
This ensures:
Unrivalled efficiency and productivity.
Minimal risk of blistering through optimum drying and curing
conditions.
stable conditions and process reliability through a fully automated
process.
lower personnel costs through simple operability.
no downtime costs due to a failure-free, long-term operation without
the necessity of constant quality checks.
all in all, this is
how Much you
profit forM Zero:
• The highesT oUTpUT of enamelled wire.
• The lowesT energy cosTs by far.
• The besT enamelling qUaliTy.
• The lowesT personnel cosTs.
• Zero scrap dUring prodUcTion.
MoZart Zero
Technically speaking,
The besT you can geT is
The facTs behind The world’s only enamelling machine
wiTh an oven running on zero elecTrical energy.
Join The revoluTion
in magneT wire
producTion!
years of r&d have resulted in a revolutionary recovery and energy-saving system that allows mozart
zero’s new oven to run with zero external electricity
under production – saving 55% energy.
The basic concept for mozart zero is simple: the heat input for the
oven system is provided by solvent combustion and electric heating.
as a basic rule, the total input of energy equals the total energy losses
at all times.
so, if we can reduce the losses to a value that lies in the same range
as the released combustion heat of solvents, external electricity for
heating is no longer necessary. simple enough in theory. but slightly
more complex in practice. and only achieved through a combination
of these technologies:
heat transfer enhancement between the wire/air interface through
improved flow conduction in a specifically designed baking tube
geometry.
recovery of exhaust air via highly efficient heat transfer units.
prevention of wire heat loss through thermal insulation of contact
zones between the wire and free airspace.
reduction of oven wall heat loss due to multilayer insulation, which
decreases heat transmission across the oven walls.
regulation of wire temperature based on fully automatic cooling –
avoiding unnecessary wire heat loss under controlled conditions.
ensure highesT qualiTy.
as all of mag‘s machines, mozart zero regulates process parameters automatically to ensure the highest
quality. so that you can, too.
As you know, the enamelling process is based on the convective
drying of liquid polymer solution films applied on the wire surface.
And, therefore, product quality mainly depends on the profiles of the
polymer concentration across the films formed at given drying rates.
Large gradients may lead to skin/core morphology, and, beyond
boiling temperature, to the formation of vapour bubbles in the liquid
(blistering). This then leads to low coating quality.
The best way to avoid such quality problems is the complete automation of the machine, giving you full control of all crucial process
parameters – achieved by a combination of different technologies:
The adjustment of convective flow situation and temperature
control in the drying zone guarantees sufficiently smooth solvent
evaporation.
The regulation of the baking zone temperature ensures constant
conditions for curing (cross-linking of polymers), based on chemical
reactions.
The Regulation of the recirculation airflow rate for heat transfer
control between the wire/air interface.
Optimum adaptation of the initial enamel film thicknesses to
facilitate uniform drying, resulting in a lower risk of blistering.
The regulation of wire temperature just before enamel application
secures steady-state conditions for drying and curing.
don’T worry abouT
scrap. ForgeT abouT iT.
mozart zero is, as all mag machines, by far more
reliable than any competitor’s. and not only when it
comes to avoiding downtime. mag’s process reliability is unmatched – due to a fully automated process.
Process reliability and constant enamelling quality require aound
operating conditions. with an unvarying cooler fan speed, even the
slightest changes in ambient temperatures will have considerable
impact on productivity, energy demand and the degree of cure.
a human operator will not be able to react appropriately and
quickly enough to the shifting of operating conditions. Which is
why machines that require manual adjustments can never ensure
optimised conditions.
This is why mag has researched and developed a fully automated
regulation of the wire temperature. here, the speed of the cooler fans
is coupled to the wire temperature, which is measured at the oven
entry with MAG’s specific measurement system, based on a noncontact principle.
as a result, the wire temperature serves as a major control parameter.
This ensures constant conditions for enamelling and the lowest energy demand for heating the wire – at all times and completely independent from ambient conditions. and, of course, all these technologies
are also used in mozart zero – in its very latest version.
all in all, This is why
you can counT on Zero:
• The highesT OuTpuT.
• The lOwesT eneRgy demand.
• The highesT qualiTy-enamelled wiRe.
• The wORld‘s highesT pROcess ReliabiliTy
wiTh The leasT downTime.
• The simplesT handling and failuRe-fRee,
lOng-TeRm OpeRaTiOn wiThOuT
conTinuous qualiTy checks.