ecoPlus – Technology that pays off
ecoPlus saves resources and costs
Energy, time, material and personnel – conserve these precious resources
and save cash with ecoPlus technologies from the HOMAG Group, helping
you to make your company more productive. ecoPlus is an integral part
of nearly every machine made by the HOMAG Group. The innovative,
environmentally friendly technologies are instantly recognisable by the
ecoPlus sign.
Contents
04
Saving as standard – with ecoPlus
06
Saving energy on standby
08
Selective extraction technology
10
Reducing pressure – lowering consumption
12
SORB TECH – greater stability, maximum
precision
14
Always at your disposal: higher productivity
16
Powerful drive systems, frugal consumption
18
BARGSTEDT: intelligent material flow
20
BRANDT: state-of-the-art technologies and
innovative drive systems
22
BÜTFERING: fine finish efficiency
24
FRIZ: raising the profile of savings
26
HOLZMA: optimum material usage
28
HOLZMA: intelligent air cushion tables
30
HOLZMA: thin kerf saw blades
32
HOLZMA: good for the climate – and for your
bottom line
34
HOLZMA: a competitive edge through continuous
improvement
36
HOMAG: the laminating technology of the future
38
HOMAG: so that everything runs smoothly
40
HOMAG: edge banding with laserTec
42
HOMAG: efficiency for processing centres
44
HOMAG: always the right vacuum
46
HOMAG: resource savings made easy
48
LIGMATECH: intelligent technologies that save
money and protect the environment
50
WEEKE: on course for higher cost-effectiveness
52
WEINMANN: more economy for the house
54
Technology that benefits the environment
Saving as standard – with ecoPlus
The 100-plus ecoPlus technologies from the HOMAG Group make production
even more profitable for you. After all, we place a great deal of importance
on progress and continuous improvement in our machine building. That’s
what counts, and that is what we understand by genuine sustainability. In this
brochure, you can discover how we make success measurable with the help
of ecoPlus.
ecoPlus
Your benefit
The basis for calculations
Consumes up to 30 % less energy
In order to quantify potentials for savings,
it is necessary to define uniform general
conditions and costs. For this reason, the
following values are used as the basis for
calculations in all efficiency examples in this
brochure, unless stated otherwise:
Any company that makes consistent use
of HOMAG Group solutions – from the saw
through to the edge banding machine, and
from the processing centre through to the
sanding machine – can benefit by energy
consumption cuts of up to 30 %!
Electrical energy:
0.12 € per kWh (value varies with country
­and price scale)
Compressed air costs:
0.04 € per Nm³ at 6-7 bar
Extraction system:
rgy
ss ene
s. You
3 0 % le with ecoPlu
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o
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mption
cons u e a g r eat d e
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can sa st!
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ex tra c
04 |
HOMAG Group
| The basis for calculations
Required electric power approx. 1.8 kW per
1 000 m3/h at 2 500 pascal negative pressure
at the connection to the machine and 4 200
pascal negative pressure at the fan.
Utilisation:
We assume that the machine is operated
for 50 weeks a year, for 80 hours per week
using a two-shift operation (40 hours per
week using a one-shift operation).
The ecoPlus effect – you can ­count
on it!
To show you in advance just how
much you can save with ecoPlus,
we have developed the ecoPlus
calculator.
Ask your HOMAG Group sales advisor
for more details. He will be happy to
use the ecoPlus calculator to show
you your potential savings in a clear
way and with no obligation.
Tip: Look into any possible sources
of governmental support for planned
new investments. Your chances of
qualifying are particularly good with
the help of ecoPlus!
HOMAG Group
| 05
Saving energy on standby
One of the central components of the ecoPlus concept is the standby
function. This puts the machine into an energy-saving standby mode – either
automatically after a certain period of time, or when the ecoPlus button is
pressed. All the energy-consuming systems go into sleep mode. If you press
the button again, the machine returns to its normal operating mode within a
few seconds.
Resource: Energy| Standby
Your benefit
The technology
Efficiency example 1
Efficiency example 3
The ecoPlus button saves hard cash. This
is an ideal solution for businesses where the
machine does not need to work around the
clock, but has to be available immediately if
needed.
The ecoPlus button is clearly visible on the
innovative user interface. In addition, many of
the HOMAG Group machines automatically
go into standby mode after a certain time
interval has elapsed, even without a button.
As soon as the standby mode is started:
HOMAG processing centre BMG 512
with a connection value of 26 kW:
Energy consumption at a glance
The standby function has already proved
its value many times. That is why almost all
the machines from the HOMAG Group are
equipped with the ecoPlus button.
• The machine interrupts normal operation
• Energy-consuming units are switched off
• All servo drives are disconnected from the
mains
• A signal automatically deactivates the
extraction system
• Standby operation alone can reduce
energy consumption when the machine is
idle by up to 8 160 kWh p.a.
• Up to 5.7 t less CO₂ per year
• Cost savings of up to 980 € p.a.
Efficiency example 2
button
Anyone looking to increase the energy
efficiency of their production process,
needs to know the current consumption
of their machine. The HOLZMA energy
monitor allows you to do exactly that, for
example using panel saws from model
series 3, 4 and 5. The CADmatic operating
software displays how much energy the
saw is consuming for processing steps at
any given time. Savings potential can be
accurately pinpointed.
KF 520 sizing and edge banding system
(complete furniture line) for lengthwise
and crosswise processing:
• Connection value: 350 kW including
transport
• Yearly savings of up to 30 000 kWh
• Up to 21 t less CO₂ per year
• Cost savings of up to 3 700 € p.a.
HOLZMA energy monitor
06 |
HOMAG Group
HOMAG Group
| 07
Selective extraction technology
The amount of energy required by extraction systems in woodworking
applications has always been formidable – that is, until now. The new ecoPlus
technologies from the HOMAG Group can reduce the energy consumed
during extraction by up to 40 %.
Resource: Energy
| Extraction
Your benefit
The technology
Efficiency example 1
Efficiency example 3
The amount of energy required for chip
removal is reduced by up to 40 %, thanks to
process-dependent, needs-based extraction
concepts such as:
Process-dependent extraction controlled
on the basis of individual flaps and with
two separate negative pressure areas:
HOMAG KFL 326 with ecoPlus:
BÜTFERING Series 300 with ecoPlus:
Every extraction unit that is not permanently
in use has its own gate at the connection to
the tool. This opens and closes automatically,
depending on its operating status.
• Negative pressures: 2 500 Pa for finish
processing, 1 800 Pa for sizing
• Savings: up to 33 000 kWh p.a.
• Payback period for the additional
investment: 2-3 years
• With control of the individual flaps
• Annual energy savings in the range
of 18 000 kWh, achieved by lowering the
extraction volume
Furthermore, there are two separate areas
with controlled fans and different negative
pressures. This allows the extraction of the
individual units to operate as needed.
Efficiency example 2
Efficiency example 4
Profile trimming unit with i-tools on a
HOMAG edge banding machine:
HOLZMA has reduced the required
extraction volume by up to 15 %:
• Extraction requirement cut by up to
­3.8 million m³ a year
• Energy consumption reduced by up to
4 200 kWh p.a., or 47 %
• CO2 emissions cut by up to 3 t a year
• Cost savings: up to 500 € p.a.
• Optimisation of all components relevant
to the extraction system
• New geometry of the saw carriage and
the chip channel
• Cost savings of approx. 170 € p.a.
• Individual flap control and two separate
negative pressure areas
• i tools
• Multi-section extraction hoods
• Tools with chip guidance and fitted
extraction hoods
In order to coordinate when the extraction
system is switched on and off precisely
with the operation of the saw, HOLZMA
has been equipping the panel saws of its
­3 series with intelligently controlled switching
contacts since 2009. As a result, the units
are only activated when they are actually
needed, which significantly reduces energy
consumption.
08 |
HOMAG Group”
HOMAG Group
| 09
Reducing pressure – lowering consumption
Compressed air is a major issue for many machines when it comes to energy
efficiency. Several consumption reduction measures can yield annual savings
that run into four figures.
Resource: Energy
| Reduction in compressed air consumption
Your benefit
The technology
Efficiency example 1
Efficiency example 2
The amount of energy used to supply your
machines with compressed air can be
reduced by up to 40 %. This is achieved by
optimising or eliminating consuming units.
2-line compressed air supply reduces
compressed air consumption
HOLZMA HPL 400:
HOMAG KF 500:
• Implementing all measures, including the
options available for the compressed air,
can achieve savings of up to 28 %
• Cost savings of up to 403 € p.a.
• Energy consumption cut by up to
1 209 kWh p.a.
• Up to 0.85 t less CO2 per year
• Depending on equipment, potential
savings of up to 25 % for compressed air
• Cost savings of up to 7 700 € p.a.
• Energy consumption cut by up to
23 100 kWh p.a.
• Up to 16 t less CO2 per year
The technology
HOLZMA panel saws:
• Shortening the length of the hose between
valves and cylinders
• One cylinder instead of two for the lift drive
of the main saw
• Scoring saw lifted by means of motor
instead of pneumatic drive (optional)
• Clamp cylinders dimensioned according
to blade projection, thus avoiding
unnecessarily filling unused cylinder
capacity
• Reduction of cylinder diameter and
capacity for pressure beam cylinders
HOMAG decided to divide the compressed
air supply system into two parts: an actuating
air network and a blowing air network. As
a result, only those consumers that require
high pressure are operated using high
pressure (in the same way, consumers that
only require low pressure are only supplied
with low pressure).
• Reduced operating pressure in the blowing
air network
• Reduced total compressed air
consumption by approx. 25 %
HOMAG processing centres:
The basis for calculation 1
• A cost of 0.04 €/Nm³ for compressed air
• One-shift operation
• Triple Mix cutting patterns
• Eight hours per shift
• 250 working days
The basis for calculation 2
• A cost of 0.04 €/Nm³ for compressed air
• Two-shift operation
• Eight hours per shift
• 250 working days
• Automatic central lubrication with semifluid grease
• Use of optimised blowing nozzles, for
example for better results when blowing
away chips
HOMAG throughfeed machines:
• Use of Laval nozzles
• Use of sensor system without cleaning air
• Improved use of cleaning air
10 |
HOMAG Group
HOMAG Group
| 11
SORB TECH – greater stability,
maximum precision
The HOMAG Group produces its machine frames – the “supporting
platforms” for the processing units and the workpiece supports – from the
mineral material SORB TECH. SORB TECH stands for a low-vibration, stable
machine design promising improved work results and maximum precision.
Complete with savings potential.
New material
| SORB TECH
Your benefit
The technology
Efficiency example
The basis for calculations
The primary energy input for producing
SORB TECH is three times lower than the
input required for steel.
SORB TECH absorbs vibrations very
effectively, and its high weight allows it to
absorb almost 100 % of all machine jolts.
The result is faster acceleration coupled with
improved precision and smoother operation.
HOMAG processing centre BMG 511
with SORB TECH machine bed:
In terms of resources, SORB TECH provides
a substantial increase in efficiency as early
as the manufacturing phase. The amount
of primary energy required to produce a
tonne of steel is substantially higher than that
needed to produce a tonne of SORB TECH.
The advantages in day-to-day operation:
• Longer tool lives
• Higher feed speeds and faster acceleration
• Saves time
• Saves money
The fibre-reinforced mineral mix also
makes far more efficient use of energy
and resources than steel does and offers
significant cost advantages in comparison
with a welded steel design.
• Energy input reduced by up to
4.48 MWh/t*
• Energy input for machine bed reduced by
up to 12.15 MWh/t*
• Primary energy savings of up to 63 %*
SORB TECH is used in manufacturing:
The bottom line: the production of a tonne of
steel requires 3.6 times more energy.**
• BÜTFERING wide-belt sanding machines
SWT 500 and SWT 900
• HOLZMA panel saws of the 5 series
• WEEKE CNC processing centre BMG 400
• HOMAG CNC processing centre
BMG 500/600
* When manufacturing a machine bed
12 |
HOMAG Group
• Primary energy required to produce a
tonne of steel: 6.236 MWh/t
• Primary energy required to produce a
tonne of SORB TECH: 1.752 MWh/t
** Sources:
• Stahl-online: Energy management – CO₂ monitoring
of the steel industry
• Agreement between the government of the Federal Republic of
Germany and German industry on climate targets
HOMAG Group
| 13
Always at your disposal: higher productivity
There is also another way to achieve energy efficiency: by producing more
without increasing energy consumption. Over recent years, productivity in
HOMAG Group machines has risen on average by up to 30 %. The machines
produce more in the same time period – and use no more energy than before.
This can be done, for instance, by implementing intelligent production
processes, as the example of HOLZMA shows.
ecoPlus availability
Your benefit
The technology
Efficiency example 1
Efficiency example 3
Increasing output, more intelligent processes
and more productive hours of operation –
while consumption of energy and resources
remains unchanged or even falls. That is
what the new ecoPlus technologies promise,
thanks to:
Optimised processes at HOLZMA:
HOMAG edge gluing machines with the
new QA 65 application unit for low glue
levels:
HOLZMA Power Concept:
• A guaranteed steady production flow
• Prevention against exceeding the capacity
of individual components, thereby
eliminating the risk of bottle-necks
• Lower workloads for machine operators,
allowing them to take on other tasks
More output for the same or less input,
for example by reducing set-up periods
by means of:
• woodLine
• woodScout
• The HSK push button
• The new QA 65 application unit
14 |
HOMAG Group
Intelligent processes start with the feeding
system and continue right through to
destacking.
• Perfect saw/storage interface
• Cut Rite from HOLZMA is the best-selling
optimisation software worldwide, delivering
real cash savings
• Power Concept
• Pressure beam height control and prepositioning
• Cutting length limitation
• Simultaneous label printing
• Central side aligner
• AB-BA system for angular saws
• …and much, much more
• Production time increased by up to
30 minutes per shift and up to 125 hours
per year
• Cost savings: up to 17 500 € p.a.
| Productivity
The additional clamp, which can move
independently of the program fence,
prevents performance peaks and increases
performance by up to 40 %.
Efficiency example 2
The basis for calculations
BRANDT edge banding machine
KDF 1680 profiLine with workpiece gap
optimisation:
• Two-shift operation, heating up only once
• Machine-hour rates of 100-140 €
Calculation of the ideal gap between
workpieces in relation to the feed speed
and workpiece thickness guarantees up to
20 % higher output for the same input.
HOMAG Group
| 15
Powerful drive systems, frugal consumption
Efficiency begins with the drive system. This is why the HOMAG Group has
replaced all the three-phase asynchronous motors by new highly efficient
motors with IE2 energy efficiency rating. In addition to this, HOLZMA, for
example, employs frequency-controlled main saw motors, which allow
the rotation speed to be individually matched to the material. Thanks to
an integrated bypass circuit, the machine can still achieve short bursts of
maximum power exceeding the rated kW.
Resource: Energy
Your benefit
The technology
Efficiency example
You save from the word go thanks to
energy-efficient IE2 motors. HOMAG already
complies with the provisions regarding
IE2 drive units set forth in the relevant EU
Directive, even though it does not come into
force until 1 January 2017. Beyond that, the
HOLZMA frequency converter allows you
to...
IE2 motors:
HOLZMA HPL 300 with IE2 motor:
Regulation (EC) No. 640/2009 is applicable
within the European Union; there are other
directives in place in other parts of the world.
The key features:
• With energy-efficient 18-kW main saw
motor (optional)
• You can save up to 190 € a year
• Process many different materials
• Process plastic sheets
• Set a high value on precision
• Cut large books
• Subject the saw to high loads for short
periods – time and again
• Higher degree of efficiency
• Therefore lower energy costs
• Lower thermal loads achieved by greater
engineering precision
• Lower CO2 emissions*
| Drive systems
HOLZMA bypass circuit:
With a frequency-controlled 21-kW main
saw motor and 50 % use of the bypass
circuit, you can save up to 36 € a year.
HOLZMA bypass circuit:
The frequency converter improves the cut
quality and prevents short-term overload
operation of the motor. The integrated
bypass circuit allows you to work in a
particularly flexible way: You can use it to
deactivate the frequency converter and
switch to mains power at the push of a
button. The ideal solution for short periods
of high throughput or when processing very
hard materials.
* Applies to three-phase motors that are designed for 50 Hz or
50/60 Hz operation (for a more precise definition and exceptions
please refer to Regulation (EC) No. 640/2009).
16 |
HOMAG Group
HOMAG Group
| 17
Intelligent material flow
For an effective material flow, you need efficient machines. The ecoPlus
measures are another step in BARGSTEDT’s on-going commitment to
solutions that offer low total operating costs. BARGSTEDT machines are
known for their long service life, low wear and low maintenance – equipped
with ecoPlus features, they also save energy and considerably reduce costs.
Intelligent logistics for efficient material
flow
BARGSTEDT
| Efficiency included
Your benefit
The technology
Efficiency example
The basis for calculations
Increased process stability:
The more efficiently a company deals with
resources, the higher the added value
achieved by its products.
TLF 210 horizontal storage system with
ecoPlus:
• Total output of the three axes: 7 kW
• Based on one shift a day
• Approx. 30 panels to be processed and
approx. 200 movements per shift
• Up to 480 panels per shift at approx. 60
seconds per movement
• Easy, reliable panel handling even when a
large number of types is involved
• No disruption of production caused by lack
of material
Optimisation of the production process:
• The material flow is optimised – only
amounts that are going to be used in the
near future are stored
Closed resource cycles:
• Shorter delivery periods allow just-in-time
purchasing
• Optimum use of left-over material cuts
material costs
Loss-free infrastructure operation:
• Savings in human resources – the jobs of
cutting and preparing material are dealt
with separately
• Automated transport ensures high
utilisation of the processing machines
• All material is managed
18 |
HOMAG Group
BARGSTEDT provides its customers with
logistic solutions that optimise the entire
material flow from the receiving of the goods
to the processing machine, and also make
efficient use of available resources.
• Reduction of the moving masses
• Intelligent stand-by operation
• Optimised compressed air consumption
for parts handling
• Ultrasonic sensors for low compressed air
consumption
• Integration of storage system, saw, offcuts
store and cutting pattern optimisation
• High degree of process reliability in
separating parts
• Fewer storage movements
• Savings of up to 58 % achieved by
intelligent standby operation
• Savings of up to 50 % achieved by use of
ultrasonic sensors
• Savings of up to 14 000 € achieved
by reliable parts handling (i.e. books of
thin panels, weight measurement); the
operator does not need to intervene
woodStore analyser — simply better
woodStore analyser is a unique
software module offered by
BARGSTEDT for optimising
warehousing systems. The program
examines and analyses the main
functions of a customer’s warehouse
over an individually specified period
of time in order to determine if the
customer is using the warehouse
system optimally. If the analysis reports
a need for improvement, the integrated
expert system uses the findings as the
basis for suggestions for increasing
warehouse efficiency.
HOMAG Group
| 19
State-of-the-art technologies
and innovative drive systems
BRANDT uses a number of ecoPlus technologies to benefit your bottom line.
Innovative drives optimise the performance/consumption ratio. State-of-theart sheet-type heating elements shorten the heat-up period in the gluing unit.
On top of that, intelligent management of the control voltage lowers energy
consumption during interruptions to work or breaks.
BRANDT snipping unit with workpiece
gap optimisation
BRANDT
| Resource efficiency
Your benefit
The technology
Efficiency example 1
Efficiency example 2
• Reliable processes thanks to the use of
servomotors: reducing set-up periods and
downtime
• Intelligent standby operation saves on
compressed air, extraction and energy
costs
• More efficient production in the same
processing time: optimisation achieved by
adapting workpiece gaps to the feed
• Optimised gluing system: development
and implementation of innovative heating
technology
• Minimising set-up times shortens the time
machines are running and thus yields
significant energy savings
• Standby operation is automatically
activated after machine has been idle for
15 minutes
• Flat heating elements in the QA 45 gluing
system for shorter heat-up period
• Online help minimises downtime
• IE2 motors for efficient energy yields
• Optimisation of workpiece gaps for higher
output in the same processing time
• Use of energy-saving lamps
• Automatic central lubrication of the feed
chain reduces frictional resistance
• Minimum edge overhangs achieved by
adaptive control technology
• Line-controlled blow-off device reduces air
consumption
• DFC post-processing tools ensure better
extraction performance and better chip
capturing
BRANDT edge banding machine
Highflex 1880:
BRANDT edge banding machine
Highflex 1440:
• More performance for the same energy
expense thanks to reduced gaps
generates energy savings of 1 280 €/year
• Up to a 20 % increase in manufacturing
capacity in the same period of time
• Use of synchronous motors
• Minimum set-up periods and downtime
due to automatic edge infeed
20 |
HOMAG Group
The basis for calculation 1
The calculated savings indicated here are
based on the following assumptions:
• 8 hours a day
• 2 800 edge metres per day
• 250 working days
• A cost of 0.12 €/kWh for electricity
• A cost of 0.04 €/Nm³ for compressed air
• Feed rate of 20 m/min
HOMAG Group
| 21
Fine finish efficiency
Innovative solutions for every type of sanding task — that’s what you expect
from the BÜTFERING brand. What’s more, innovation also covers resource
efficiency. Whether a wide-belt sanding machine or alternative solutions for
sanding panel-shaped workpieces: BÜTFERING and ecoPlus save you money
at every step.
Air jet cleaning of sanding belt
BÜTFERING
| Resource efficiency
Your benefit
The technology
Efficiency example 1
Efficiency example 2
• Electricity consumption reduced while
maintaining the same output
• Reduced extraction requirement and
improved dust extraction
• Reduction in the air output of the extraction
suction device
• Lower heating costs
• Reduced compressed air consumption
• Integrated sanding belt blasting device
• Five-stage control of the sanding belt
blasting device
• 3-section extraction hoods with individually
controlled blast gates
• Automatic activation of standby mode
when machine is idle
• IE2 motors
• Area-related control of vacuum
• Reduction of the no-load current in variable
frequency drive operation
Series 300 with ecoPlus:
BÜTFERING 5-belt sanding machine
SWT 955:
22 |
HOMAG Group
• Annual energy savings in the range
of 18 000 kWh achieved by lowering the
extraction volume
• Electricity consumption reduced by
approx. 12 000 kWh p.a.
• Energy requirements cut by approx.
8 000 kWh by controlled vacuum output
and reduced air output
• Total savings: 38 000 kWh a year
Equipped with variable frequency drives
and vacuum, powerful 140 kW machine
with SORB TECH machine frame:
• Potential savings of up to 35 %
• Energy consumption cut by up to
2 900 kWh
• Up to 2 t less CO₂
• Cost savings of up to 4 700 € achieved
by application-dependent air-jet belt
cleaning device
HOMAG Group
| 23
Raising the profile of savings
FRIZ Kaschiertechnik specialises in profile wrapping technology. The
company has been supplying special-purpose machines to the furniture and
structural elements industry since 1906. Across all its activities, FRIZ strives
towards a single goal: to wrap your products in a quicker, more efficient and
more flexible way. The energy-saving technologies of the ecoPlus package
are exactly the right approach.
The parabolic heater provides precision
heating with no loss due to dissipation
FRIZ
| Resource efficiency
Your benefit
The technology
Efficiency example
The basis for calculations
• Energy savings of up to 60 % achieved by
using new generation heaters
• Precision heating with no loss due to
dissipation
• Bonding of the surface already covered
remains intact
• Additional energy savings with standby
feature
• Intelligent standby operation with the
ecoPlus button
• New generation parabolic heater with
parallel outgoing rays. When wrapping
the profile edges, only the area required is
heated, i.e. there is no dissipation loss
• Precision heating, with no detrimental
effects on the bonding of the surface that
has already been wrapped
Profi PUM 310 with ecoPlus:
Standby operation approx. 800 h/year
• Potential savings of up to 80 % or
4 000 kWh with standby feature
• Potential savings of up to 60 % or
16 000 kWh per year thanks to parabolic
heater
• Up to 16 t less CO₂ per year
• Total savings of up to 2 900 € p.a.
Precision heating of the
area required with a
parabolic heater
Conventional heater with
wide heat dissipation
24 |
HOMAG Group
HOMAG Group
| 25
Optimum material usage
Every reject and every cutting scrap is wasted capital. HOLZMA software
solutions help you prevent any scrap from being produced – with HOLZMA,
you can process material in a careful and individual manner.
With HOLZMA saws and software,
you can process even particularly
demanding materials in an efficient and
careful manner
HOLZMA | Material
Your benefit
The technology
Efficiency example
The basis for calculations
Software
You can use material optimally with:
• Cutting patterns optimised to minimise
scrap and costs
• Optimisations on the fly possible
• No issues with ERP/PPS connections
• You always have an overview
• You are able to work in a targeted manner
• You can harmonise the saw parameters
with the material
• Cut Rite – the worldwide leading software
for cutting pattern optimisation
• CADplan, for optimisation at the saw
The use of an optimisation program can
save you over 14 000 € a year.
• 20 half-format panels per day
• 240 working days per year
• Price of the panels: 5 €/m², equates to
580 € per day
• Wages and ancillary labour costs: 30 € ­an
hour
Technology
This special technology can be used for:
• Scratch-sensitive surfaces
• Pressure-sensitive material
• Plastics
• Individual adjustment of the saw
• And much more
• Material savings: 5 %, equates to 6 960 €
a year
• Time saved: 240 hours a year
• Savings on wages and ancillary labour
costs thanks to automatic cutting pattern
creation: 7 200 € a year
• Gentle processing of pressure-sensitive or
scratch-sensitive material
• Labelling avoids errors and specifies the
next step
26 |
HOMAG Group
HOMAG Group
| 27
Intelligent air cushion tables
HOLZMA air cushion tables blow enough air out of their nozzles to move even
the heaviest books of panels. This process prevents damage to the material and
facilitates handling. The optional “load-dependent air cushion table control system”
builds up only the amount of air pressure required, thereby saving energy.
Intelligent air table with load-dependent
control
HOLZMA
Your benefit
The technology
Efficiency example
The load-dependent air cushion table
control system...
The load-dependent air table control system
works in conjunction with pressure sensors.
If there is material on the air table, the speed
of the fan motor increases until the ideal
operating pressure is achieved.
Depending on mode of operation and air
table size you can save up to 144 € a year.
• Protects the material
• Saves energy thanks to on-demand power
• Reduces noise
• Is ergonomic
• Minimises draughts
The principle: sealing balls that are springloaded, therefore closing automatically when
not under a load.
28 |
HOMAG Group
| Air cushion tables
If there is no material on the table, the fan
power is reduced to an individually adjustable
idle pressure.
HOMAG Group
| 29
Thin-kerf saw blades
The thinner the saw blade, the lower the energy consumption of the
main saw motor.
Thin kerf saw blades reduce energy
consumption and lower the amount of
scrap produced
HOLZMA
| Thin-kerf saw blades
Your benefit
The technology
Efficiency example
The basis for calculations
• Lower energy consumption
• Less scrap
• Blade changing is quick, trouble-free
and tailored to your needs thanks to the
HOLZMA Power Loc system – even with
differing steel plate thicknesses
HOLZMA studies show that if a saw blade
with a standard 4.8 mm thickness is replaced
by a saw blade that is only 3.8 mm thick,
the power required for a two-metre-long
cut through a book of 5 x 16-mm-thick
chipboards is reduced by up to 20 %.
HOLZMA HPL 300:
• One-shift operation
• Triple Mix cutting patterns
• 8 hours per shift
• 250 working days
• A cost of 0.12 €/kWh for electricity
• Efficiency example: Triple Mix operation,
80-mm high book of panels, saw carriage
speed of 50 m/min
30 |
HOMAG Group
Using a saw blade with a 3.8 mm kerf over
a 4.8-mm-thick saw blade, you can save
up to 230 €.
HOMAG Group
| 31
Good for the climate – and for your bottom
line
New for LIGNA 2013: Effective immediately, HOLZMA will be equipping the
switch cabinets of all machines with energy-efficient air-conditioning units.
These units reduce energy costs in production, protect the environment,
ensure fault-free electronics with ideal temperatures and thus increase the
service life of your HOLZMA machine.
HOLZMA
Your benefit
The technology
Efficiency example
The new, energy-efficient airconditioning units ensure
Thanks to innovative technologies, the new
air-conditioning units are not just extremely
energy efficient. Mounted directly on the
switch cabinet, these units also ensure
enclosed air circulation, similar to that
achieved by pressing the air-circulation
button in a car: The cool interior air is
completely separated from the exterior air,
keeping out dust and moisture.
The consumption of energy per year is
reduced by roughly 350 kWh in comparison
to previous switch cabinet cooling. This
global average value can prove to be
considerably higher in certain regions,
as seasonal and reasonable climate
differences are taken into account in the
calculation.
• A significant reduction in energy
consumption and therefore costs
• The optimal operating temperature – even
at very high external temperatures
• A completely dust-free and moisture-free
switch cabinet climate
• Fault-free control and drive technology
• Higher machine availability and service life
32 |
HOMAG Group
| Air-conditioning units
HOMAG Group
| 33
A competitive edge through continuous
improvement
Reduce costs and increase performance – this is the motto for HOLZMA’s
continuous optimisation of all cutting processes. The results: efficient
material usage, smooth-running production, maximum output and reduced
personnel costs.
HOLZMA
Your benefit
The technology
Efficiency example
With HOLZMA, you can optimise your
production at critical points and profit in the
long thanks to:
HOLZMA ensures progress and continuous
improvement with numerous technologies
that are perfectly matched to one another,
setting standards throughout the industry.
Examples:
• Optimum working conditions motivate
your employees, reduce illness-related
absences and thus lower personnel costs
• More efficient utilisation of resources
saves hard cash
• High machine availability lowers
your maintenance costs and raises
productivity
• Flowing processes prevent errors,
reduce unproductive waiting times and
unnecessary movements, and speed up
the entire production process
• Reduced personnel costs, as HOLZMA
continuously improves ergonomics, thus
promoting employee health
• Optimum usage of materials, as
HOLZMA technologies guarantee careful
material handling, thus reducing waste and
scrap
• High machine availability, as HOLZMA
saws have an impressively long service life,
low maintenance expense and minimum
downtime
• Flowing production processes, as
HOLZMA intelligently links together all the
work steps and technologies that relate to
cutting
34 |
HOMAG Group
• Protection of employees, for example
through low dust generation and increased
machine safety
• Optimum material and resource utilisation
thanks to Cut Rite – the world’s leading
software for optimising cutting patterns –
and special solutions for scratch-sensitive
and/or pressure-sensitive materials
• High machine availability thanks to wellthought-out design and the use of highquality components for uncompromising
quality
• Flowing processes thanks to intelligently
interlinked technologies such as the
HOLZMA Domino System or the new
intelligent HOLZMA destacking concept
with operator guidance
| Processes
HOMAG Group
| 35
The laminating technology of the future
With reacTec furniture laminating, HOMAG throughfeed machines are
redefining quality and economy in the manufacturing of construction
elements and furniture. Developed in cooperation with Henkel and Nordson,
reacTecscores high in nearly all important criteria. This innovative technology
combines the advantages of the hot melt process with the benefits of other
methods. reacTec impresses not only with low manufacturing costs but also
with a high degree of environmental compatibility.
The heart of the reacTec furniture
laminating process: calender rolls
HOMAG throughfeed technology
Your benefit
The technology
Efficiency example
• The amount of glue applied can be
reduced by up to 20 g/m²
• Lower production costs
• Significantly improved surface quality
• High process stability due to “simple”
technology
• Performance characteristics on par with
urea
• As user-friendly as hot melt
• No formaldehyde emission
• New hot-sealing adhesive with high
temperature and moisture resistance
• Innovative hot melt application system:
new generation wide slit nozzle technology
• New machine design
reacTec reduces your energy consumption
by up to 50% – or more than one million
kWh a year. In the same period of time, you
can cut CO2 emissions by up to 700 t and
save up to 120 000 € on energy costs.
| reacTec
In addition to these savings, you also
benefit from higher productivity with fewer
rejects. The process as a whole can deliver
yearly savings of up to 400 000 €.*
* * Using the in-line method, in comparison with urea
36 |
HOMAG Group
HOMAG Group
| 37
So that everything runs smoothly
HOMAG throughfeed machines are team players: they integrate seamlessly
into your production lines and boost productivity. ecoPlus demonstrates
that these benefits work in perfect harmony with resource efficiency. The
machines reduce consumption and ensure a high degree of energy efficiency
with a number of standby options.
doubleEdge effect on edge
banding machine
HOMAG throughfeed technology
| Resource efficiency
Your benefit
As standard
As an option
Efficiency example
• Savings in time, material and energy –
and consequently higher productivity and
greater flexibility in your budget
• Enhanced process stability achieved by
minimising set-up times, non-productive
time and downtime
• More efficient production processes due
to the development and deployment of
innovative manufacturing technologies
• Temperature of heaters automatically
lowered to reduce electricity consumption
• Shorter heat-up periods with QA 65 for
increased productivity
• Energy-efficient machine lighting
• Sensor system without cleaning air for
reduced compressed air consumption
• Servo edge feed for lower edge banding
consumption
• Use of modern, decentralised control
technology (passive cooling, minimised
leakage currents and less use of copper)
achieves savings
• IE2 drive units as defined by EU
Directive; HOMAG already meets these
requirements, which will not come into
force until 1 January 2017
• i-tools in most of the refinishing units for
lower extraction output and improved chip
capture
• Noise reduction during throughfeed:
­10 dB(A) less for snipping saw processing,
1.5–2.5 dB(A) less for joint trimming. The
“whistling sound” when snipping has also
been significantly reduced
• Optimisation of the compressed air supply
by using a dual-circuit pressure system
• Measuring and display of compressed air
consumption
• Measuring and display of electrical energy
consumption
• HSK 63 push button
• Quality inspection systems
• woodLine
• woodScout
• Timer
• Process-dependent control of individual
flaps
• Synchronous motors for dynamic
refinishing units
• Tool-adjusted dust hoods
• MMR – machine monitoring and reporting:
for the systematic acquisition and analysis
of all machine data
HOMAG sizing and edge gluing
machine OKFL 326/C:
38 |
HOMAG Group
• Potential savings of up to 25 %
• Cost savings of up to 14 600 € p.a.
• Consumption cut by up to
77 000 kWh p.a.
• Up to 54 t less CO₂ per year
The basis for calculations
The calculated savings indicated here are
based on the following assumptions:
• Two-shift operation
• 8 hours per shift
• 250 working days
• A cost of 0.12 €/kWh for electricity
• A cost of 0.04 €/Nm³ for compressed air
HOMAG Group
| 39
Edge banding with laserTec
HOMAG laserTec is a completely new manufacturing technique for edge
banding – revolutionary in its quality, efficiency and economy. The innovation:
laserTec entirely eliminates the need to use conventional adhesives. Instead,
a laser simply melts a special adhesive coating on the edging, which can
then bond to the counterpart for a joint-free, long-lasting result – absolutely
precise and very easy to operate.
Joint-free workpieces
HOMAG
| laserTec
Your benefit
The technology
Efficiency example 1
Efficiency example 2
• Percentage of rejects reduced
• Simple operating processes
• Lower additional costs
• Highest level of availability
• No logistical cost for glues
• No complicated manual entries
• No auxiliary materials such as separating
and cleaning agents
• No waiting periods and set-up work for
colour changes
• No energy consumption without productive
results
• Unlike when using hot-melt glue
application units, there are no
contamination or cleaning problems
In comparison with conventional, gluing
methods, HOMAG laserTec is a clear
winner: With this method, a special adhesive
coating on the edging strip is melted by
a laser beam – and then pressed directly
onto the workpiece. An oscillating mirror
automatically deflects the laser beam to the
required height, depending on the thickness
of the edging. This simplifies processing
enormously.
In comparison with conventional hot
melt glue technology on throughfeed
machines:
In comparison with conventional
hot melt glue technology on CNC
processing centres:
• laserTec saves up to 36 911 kWh p.a.
• Energy savings: more than 40 %
• Reduction in CO₂ emissions: up to 26 t
a year
• Cost savings: up to 4 430 € p.a.
• laserTec saves up to 2 250 kWh p.a.
• Energy savings: more than 20%
• Reduction in CO2 emissions: up to 1.6 t
a year
• Cost savings: up to 270 € p.a.
HOMAG continues to increase the efficiency
by on-going optimisation of the laser system.
Under patent law in Germany, only for use with Rehau edges!
40 |
HOMAG Group
HOMAG Group
| 41
Efficiency for processing centres
HOMAG CNC processing centres are powerful one-man armies: They saw,
drill and trim – and deliver top performance. These processing centres are
a separate item in the balance sheet: Your productivity and consumption
figures cannot be “pushed” onto a production line – they stand alone. What a
good thing that ecoPlus scores high with plenty of efficiency here too.
HOMAG CNC processing centre
­BMG 512
HOMAG stationary technology
| Resource efficiency
Your benefit
The technology
The technology
Efficiency example
Low consumption: Optimised machine
components reduce the consumption of
compressed air, extraction and electrical
energy.
HOMAG software gets you quickly, easily
and safely to the finished component:
collisionControl: Permanently monitors
for potential collisions between machine
components and spindle directly on the
machine.
HOMAG CNC processing centres with
ecoPlus semi-fluid grease lubrication.
Efficient workpiece programming: No
need for test runs when producing with
HOMAG software modules. Saves time,
saves material for test parts and avoids
rejects.
woodMotion: Simulates processing
programs using original machine data.
Positioning periods are not required.
Fast set-up: Time savings of up to 70 %
when setting up, and checks can be
performed at a glance with the help of LED
indicators.
Reduced unproductive downtime:
Software modules prevent collisions.
Malfunctions are quickly detected, located
and remedied.
woodNest: Makes optimum use of the
unfinished panel by nesting the parts.
woodWOP Wizard with technology
database: Creates programs for edge
banding automatically, including any
adjustments to the parameters for edging
material and contour that may be necessary.
The machine as powerhouse
The electrical energy generated by
braking the spindles and drives in
HOMAG CNC processing centres can
be fed back into the grid. That lowers
consumption, without requiring any
preparations on the power supply.
42 |
HOMAG Group
woodScout: Helps errors to be recognised,
located and remedied quickly.
Spindle sensor: detects critical vibrations in
good time and thus prevents chatter marks
or parts being released due to insufficient
clamping
Intelligent set-up aids: Patented LED
displays on consoles and machine frames
for easy and fast positioning of the vacuum
clamps and consoles.
The CNC machines work with an
automatic central lubrication system on
a hydraulic principle, which needs no
additional compressed air. Optimised air
jets and processes additionally lower the
consumption of compressed air.
The result:
• Up to 67 200 Nm³ less compressed air
per year
• 100 % savings in compressed air
consumption in comparison with oil-air
lubrication
• Up to 5.64 t less CO₂ per year
The basis for calculations
• Semi-fluid grease lubrication: savings
in compressed air of, on average,
350 NI/min compared with oil-air central
lubrication
• Oil-air central lubrication with a switch-on
time of approx. 80 %
HOMAG Group
| 43
Always the right vacuum
The pumps of the HOMAG CNC processing centres, which work with highvolume vacuum generation, are equipped with variable speed control.
Sensors measure the current negative pressure and control the air flow
of the pumps as needed. The machine only uses as much energy as is
necessary, even during interruptions and set-up periods, or when only a low
volume is needed.
Panel material is held in position by
suction for efficient vacuum production
HOMAG stationary technology
| Vacuum control
Your benefit
The technology
Efficiency example
The basis for calculations
Needs-based control of vacuum generation
matches the output to the current situation.
Speed-controlled vacuum pumps with
frequency converters in conjunction with
an intelligent closed-loop control adjust the
volume output to match the current need.
HOMAG CNC processing centres with
speed-controlled vacuum pumps:
• Two-shift operation
• 8 hours per shift
• 250 working days
• A cost of 0.12 €/kWh for electricity
• A cost of 0.04 €/Nm³ for compressed air
This way you never use more than is
necessary, even if demand varies. A
particular advantage for:
• Nesting processing
• Use of reinforced pumps
• Use of a certain amount of porous
materials
• Greatly varying part dimensions
44 |
HOMAG Group
Multi-pump systems with intelligent activation
and deactivation of individual pumps on a
needs basis.
• Energy savings: up to 6 320 kWh p.a.
• Up to 4.4 t less CO₂ per year
• Cost savings: up to 750 € p.a.
HOMAG Group
| 45
Resource savings made easy
Less is more – this is the basic principle that led lightweight construction
to become a successful trend. After all, anyone who can offer at least the
equivalent product features using less material and resource input can save
hard cash and protect the environment. However, challenging technical
requirements must be fulfilled during production if these goals are to be
achieved. The HOMAG Group identified this trend at an early stage and now
offers complete solutions for creating and processing lightweight panels that
are setting standards throughout the industry.
doubleEdge process in patented
lightweight design
HOMAG throughfeed technology
Your benefit
The technology
Efficiency example
Thanks to machines and systems from the
HOMAG Group, customers have control
over all processing steps for lightweight
construction and profit from:
The HOMAG Group offers technologies to
cover all process steps for producing and
processing lightweight panels – whether for
producing kitchens or furniture, or for shop
fittings, automotive engineering or interior
furnishings including doors.
The innovative doubleEdge process
• New design possibilities thanks to a variety
of processing options for lightweight
panels in almost any thickness or format
• A significantly extended material mix
• Lower panel weight and therefore more
cost-effective logistics
• A broadly diversified range of applications
and materials
46 |
HOMAG Group
The spectrum of machines and systems
covers the entire added-value chain: from
lightweight panel production with or without
rails, through panel sizing, coating and
edging in throughfeed or CNC processing, all
the way to applying fittings and installation.
| Lightweight design
• doubleEdge stands for the ultimate in
convenience, cost efficiency and simple
processing
• The support edge and the decor edge
are glued together in a gluing station and
then glued onto the narrow surface of the
panel in the same work step
• This process allows time savings of 80 %
in processing centres!
HOMAG Group
| 47
Intelligent technologies save money
and protect the environment
Assembly, packaging, automation – these are LIGMATECH’s areas of
expertise in the wood-processing industry. In all these areas, the subsidiary
of the HOMAG Group delivers production solutions designed for the future.
Cost-effectiveness and efficiency are at the top of the list – for customers
and companies alike. The new ecoPlus technologies allow LIGMATECH to
integrate efficiency and savings possibilities from the start.
Higher machine IQ with intelliCut
LIGMATECH
| Resource efficiency
Your benefit
The technology
Your benefit
Your benefit
Environment-friendly packaging with
LIGMATECH
Packaging with corrugated board:
Energy savings thanks to intelligent
control
By using the VKV 020 automated carton ­
closure machine and the VKV 710
carton closure machine, you are able to
significantly reduce material consumption.
Corrugated board is sustainable by nature
and combines both environmental and
financial advantages. With the cutting
technology of LIGMATECH VKS 200 and 250
cardboard cutting machines, customers can
profit from producing tailor-made packaging
themselves, at the right time and in the
quantity required. The benefits stem from:
• Less packaging material
• Less filler material
• Lower storage and transport volumes
• Fewer complaints thanks to optimum
product protection
What’s more, cardboard scrap can be further
reduced by up to 30 % thanks to intelliCut
cutting optimisation.
48 |
HOMAG Group
• Conserves resources
• Is environmentally friendly due to CO²
binding
• Is completely and cost-effectively reusable
• Is a single substance and therefore easily
recyclable
Machines driven by compressed air consume
an enormous amount of energy. LIGMATECH
therefore relies on new electronic drive
technology and more refined control systems
for maximum energy efficiency.
intelliCut – higher machine IQ
• Multiline processing
• Automatic selection of track widths and
rotation of the package design
The technology
The technology
• New MDE 120 electric continuous
operation press: The previous pneumatic
counterbalance has been replaced by an
electronic dead-weight counterbalance.
Reducing the pneumatics resulted in up to
50 % lower energy costs.
• Hot melt technology yields savings of
up to 85 % compared to adhesive tape
technology.
• BOOMERANG® ZHR 5xx gantry return:
The new electronically controlled Z-axis
allows energy savings of up to 30 %.
• Depending on the geometry of the material
to be packaged, using carton designs that
are closed on the side can save up to 40 %
of the cardboard.
HOMAG Group
| 49
On course for higher cost-effectiveness
Wherever wood has to be drilled, grooved or routed, WEEKE is the specialist
you need. In addition to precision drilling, WEEKE also offers a raft of ecoPlus
measures designed to save important resources. Whether energy, material,
time or space – WEEKE opens up enormous savings potential with its up-todate technologies.
BHX 050/055
WEEKE
| Resource efficiency
Your benefit
The technology
The technology
Efficiency example
• Environmentally aware machine design
‐‐Potential for marketing communication
regarding environmentally responsible
partnerships
‐‐Potential for applying for subsidies
• Savings in time, material, energy and
space ensure greater flexibility in your
budget
• Products with SORB TECH boast an 80 %
faster vibration absorption rate
• Longer tool service lives and higher
processing quality as a result
• Standby mode: with ecoPlus button, or
automatic:
‐‐switch-off of motors for drilling and
routing
‐‐switch-off of conveyor belts
‐‐closing of extraction system
‐‐switch-off of conveyor belt for chips
• Program-controlled, multi-position
extraction – only activates where needed,
thus saving energy
• Intelligent, energy-efficient vacuum system
adapts to the power required
• Clamp system instead of vacuum system
for clamping workpieces in the entire BHX
series
• Frequency-controlled drives
• Use of servomotors with high-efficiency:
‐‐Compact construction
‐‐High rotational speeds
‐‐Low power consumption
‐‐Low weight
• Only uses solvent-free paints
• Our software guarantees time savings
thanks to:
‐‐Optimised travel paths
‐‐Optimised tool changes
‐‐Optimised processing sequences
WEEKE BHX 055 vertical processing
centre with ecoPlus:
50 |
HOMAG Group
• Low energy consumption (less than
10 kW) thanks to efficient drive
technology
• Vacuum-free workpiece clamping and
low compressed air consumption
• Efficient extraction – total extraction
power max. 2 170 m3/h
Savings in time, material, energy and
space ensure:
• Potential for applying for subsidies
• Potential for alternative investments
• Potential for increasing your profitability
• Potential for marketing communication
regarding environmentally responsible
partnerships
HOMAG Group
| 51
More economy for the house
The use of wood as a building material for housing means a large amount
of material and particularly high demands. All the more reason for particular
attention to be paid to the economical use of resources. WEINMANN
excels here and has integrated a whole range of ecoPlus technologies in its
products. For wood processing on a large scale – with relatively low energy
costs.
High tech for timber construction: the
new, innovative Combi Wall System
WEK 100 from WEINMANN
WEINMANN
| Resource efficiency
Your benefit
The technology
Efficiency example
The basis for calculations
• Less cleaning time required for the
machine
• Increased tool service life
• Less dust exposure
• Cost savings
• Improved operational safety
• High time savings
• Energy savings due to needs-based
extraction
• The extraction systems delivers a negative
pressure of 1 800 pascal to the machine;
the difference in pressure up to 2 500
pascal for finishing is generated, for
example, by supporting fans
• Reduction of the extraction output and
the cleaning required for the machine and
workpieces, coupled with improved chip
capture due to tools with chip guidance
and fitted extraction hoods
• Installation of energy-efficient, three-phase
motors for a savings of around 7.3 %
• Savings in saw cuts, trimming and drilling
thanks to stack processing
WEK 100 combi wall system
• Two-shift operation
• 8 hours per shift
• 250 working days
• A cost of 0.12 €/kWh for electricity
• A cost of 0.04 €/Nm³ for compressed air
52 |
HOMAG Group
• Extraction costs reduced by 90 %
• Savings potential of 8 380 kWh due
to intelligent control of the extraction
system.
• Savings equate to 1 005 € p.a. and
potential CO₂ savings of 5.9 t
sts
tion co
E x trac d by 9 0 %!
reduce
HOMAG Group
| 53
Technology that benefits the environment
ecoPlus demonstrates very impressively: output and economy can well be
combined. The technologies use energy intelligently – that is what spurs
us on, that is why we set the standard across the entire industry for more
efficiency and increasing potential for savings. In this way, eco Plus benefits
the environment and your budget. Excellent prospects for today, tomorrow
and the future.
ecoPlus | Outlook
“Sustainable growth is only possible with cutting
edge technologies that pay off and protect the
environment. This applies particularly to wood
processing companies. For this reason, we have
created the perfect combination of cost-efficiency
and environmental protection with ecoPlus. That
is our claim and that is how we will be measured.”
Jürgen Köppel, Director of Sales, Service and Marketing for the HOMAG Group AG
54 |
HOMAG Group
HOMAG Group
| 55
HOMAG Group AG
72296 Schopfloch
GERMANY
www.homag-group.com
As at 04/13. Subject to technical change, print errors and mistakes.