DEGUMA efficiency - energy-efficient second-hand machines

Mixing mills have been used in the rubber processing industry for many decades and for some time now also with individual drives. Until now, conventional drive systems with large spur gears have been used in connection with three-phase or DC motors or hydraulic drives with sometimes extremely high power capacities.

However, all established drive systems have different disadvantages. Drive concepts with spur gears are very large and have increased power loss in the entire drive train, as a large portion of power is lost in the multi-stage gears.

Due to the large design, such drives are installed diagonally opposite each other, resulting in enormous forces being introduced onto the machine frame. This negatively impacts the durability of the machine and must be compensated by a reinforced, heavy, and correspondingly resource-intensive machine frame design. The space requirement of such systems is enormous. In addition, conventional drive systems are maintenance-intensive.

Hydraulic drives require regular oil and hose changes. The large spur gears also require at least one oil change annually, sometimes with several hundred liters. In addition, they are less efficient.

Climate protection and efficient energy use

• Reduction in the total energy demand of the system by up to 30%: Significantly reduced power losses in the drive train due to highly efficient servo motors (up to 98%), the use of two-stage planetary gearboxes and spherical roller bearings, and reuse of regenerated drive power.

Resource-saving & raw material-efficient operation

• Reduced oil consumption: The planetary gear units installed require only 6.5 l of oil for an annual oil change (for comparison: a conventional standard gear unit requires at least ten times the amount). The motors are virtually maintenance-free, which minimizes operating costs and reduces the consumption of environmentally harmful operating materials.
• Waste heat can be used for heat recovery.
• When used machines are modernized, resource-intensive components such as cast-iron stands and rolls are also reused. This sustainably protects the environment.

Occupational safety and health

• Two-stage, wear-free braking system with an extremely small braking angle. This prevents the operator from being pulled into the nip if they get too close.
• Hydraulic roll gap adjustment with automatic emergency opening function. Should the operator become trapped, the rolls open immediately.
• In the event of an emergency stop, the rolls are first electrically braked via the frequency inverter. Mechanical brakes are only applied when the rolls are stationary or almost stationary. This means that the braking process is nearly wear-free.
• Low noise level (< 65 dB) thanks to fully enclosed, water-cooled, maintenance-free motors and prevention of dust turbulence caused by fan cooling protects machine operators in their daily work and improves working conditions.

Thanks to the advantages described above, customers save up to 30% on energy costs in economic terms. The maintenance effort is reduced by 70% - 80%, saving further costs. The braking system runs electrically, whereas conventional systems are pneumatic. Since compressed air is the most expensive medium in pneumatics, costs are also saved here. Operation of the electric braking system requires only marginal energy compared to a pneumatic braking system. The drive system with servo motors is more expensive initially, but the costs are recovered by the savings in the medium term. Additional benefits also include conservation of resources and energy savings.