FOCUS ON ENERGY EFFICIENCY
Now , only the compressed air needed is generated .
Schattdorf , in the Reuss valley , is surrounded by high mountain peaks which cast long shadows in winter . Nevertheless , in summer , solar cells on the roof of the Brand Metallbau building produce up to twelve megawatt hours of electricity per month . The company consumes 85 per cent of this energy itself ; The finishing touches : Brand Metallbau has earned a the rest is fed into the strong reputation with its high-quality products . supply grid . Using the photovoltaic system , actual electricity costs account for a minor portion of the company ’ s energy costs . According to Alex Brand , supply grid charges and CO 2 taxes make up a much more substantial share of the overall costs .
“ For us , the most expensive factor is the load peaks that occur when several machines are running simultaneously . But since we reduced our baseline consumption , the peaks are now also lower ,” he explains .
To further reduce the load peaks , utilisation must be distributed more evenly – but that is a challenge , Alex Brand admits . The hustle and bustle of daily business frequently does not allow metalworking processes , such as cutting , bending and welding , to be carried out sequentially . Nevertheless , Brand tries to channel energy as economically as possible , for example by charging the company ’ s electric car at its own charging station when the machines are not in use .
Turning electricity into nitrogen
Recently , the company also started to convert the electricity it generates itself into nitrogen . This is enabled by a generator which produces nitrogen for the fibre laser and offers a carbon-neutral alternative to pressurised cylinders or liquid gas supplied by external companies . In addition to cost savings of around 30 per cent , Alex Brand values the independence from gas suppliers .
“ Naturally , I am also proud that we are one of the first companies to operate such a system ,” he says . The company no longer disturbs its neighbours ’ peace and quiet at night ; the old nitrogen tank would sometimes vent pressure with a deafening roar in the middle of the night .
In laser cutting operations , cutting gas is used to ensure that both the laser and the metal sheet always remain free of contamination . Nitrogen is used for fusion cutting , while oxygen is used for flame cutting . Nitrogen offers a major advantage ; it eliminates oxidation and therefore improves surface quality of the material . At Brand Metallbau , the nitrogen generated is used as the cutting gas for the manufacturer ’ s Bystronic ByStar Fiber laser cutting system .
“ The machine is too fast for the canton of Uri ,” jokes Alex Brand . This region of Switzerland is renowned for its tranquillity and slow pace . Only a stone ’ s throw away , in Altdorf , stands the monument to Swiss national hero ,
William Tell . The canton capital has a population of just 9,000 , and more than half of the mountainous canton consists
Nitrogen as a cutting gas
“ Autonomous nitrogen generation is a success story ,” commented Philipp Burgener , Managing Director , Bystronic Switzerland and South Africa . “ It all started in South Africa . Nitrogen is very expensive there , the differences in quality are enormous and supply is frequently tied to complex contracts . Consequently , the obstacle to purchasing a fibre laser has always been very high . Five years ago , we approached the South African company , Nitra Life . In a relatively short period of time , we succeeded in developing a generator capable of producing high-quality nitrogen ,” he explained . “ Customers responded enthusiastically because , suddenly , they were able to be completely autonomous . They no longer had to wait for trucks to deliver liquid nitrogen , which then had to be converted into gas . The generator has also resulted in new customers in Zimbabwe and opened new possibilities for cutting sheet thicknesses of between 3.5 and 5mm ,” he added . of non-arable land . Against this rural backdrop , the highly productive 10-kilowatt fibre laser takes on a ‘ spaceship-like ’ quality . It features the ByTrans Cross automation solution , which seamlessly connects the high bay warehouse with the cutting system .
Intelligent machines save electricity
The new fibre laser cutting system is significantly more energy-efficient than the old CO 2 laser . Using the same power input , it generates twice the output . The older machines also consumed electricity when they were unproductive . The three new
The high-bay warehouse is seamlessly integrated with the Bystronic Bystar Fiber laser cutting machine via an automation solution .
Bystronic has already sold several generators in Switzerland . Generating your own nitrogen not only makes sense , it told ISMR , it also reflects the spirit of the times . “ Ideally , our customers install solar panels on the roof of their factory and thus generate zero-carbon nitrogen . This energy-efficient solution offers nothing but advantages . There is no longer any need to transport gas . You only produce as much nitrogen as you need , and all the additional costs – from filling gas cylinders to replacing them – are eliminated . You operate fully autonomously while contributing towards protecting the environment ,” continued Burgener . “ In the future , we want to equip the majority of our laser cutting systems with a nitrogen generator . If customers are not locked into long-term nitrogen contracts , it is time for them to generate their cutting gas independently , cost-effectively and in an environmentally friendly manner . From April next year , interested customers can see the nitrogen generator in our Experience Centre in Niederönz , Switzerland ,” he concluded .
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