February 2025 Volume 7

ENERGY

Reduced Energy Consumption and Faster Heating Times Custom induction heaters use just the right amount of energy to heat parts, resulting in reduced energy consumption. They are designed for faster heating, meaning parts reach the desired temperature quickly. This leads to lower power costs and improved effi ciency in production. Faster heating times also reduce cycle times, allowing more parts to be processed in less time. With less energy wasted and quicker results, these systems contribute to boosting your process output by improving both throughput and overall energy efficiency. Comparison with Generic Systems Now, let's compare custom induction heaters to generic, non-customized systems. While generic heaters are designed to handle a wide range of parts, they often end up being less efficient because they are not optimized for any one specific application. This can result in: • Excessive energy use: Generic systems tend to overheat certain areas or take longer to reach the desired temperature, which wastes energy. • Inconsistent results: Since they are not tailored for your specific part, these systems may not deliver uniform heating, leading to inconsistent quality in the final product. • Longer cycle times: With a generic system, the part may need more time in the heating process to reach the proper temperature, leading to longer production times.

Seamless Integration with Existing and New Production Lines Custom induction heaters are designed to easily integrate into both new and existing production lines. Whether you’re building a new facility or upgrading your current equipment, these heaters can be tailored to fit your exact needs. They help improve efficiency, performance, and energy use, without the need for major overhauls. For existing systems, custom heaters can be retrofitted, enhancing heating precision and speed while main taining smooth operation. The result is an efficient process that boosts overall production without causing disruption. How ThermESC Intl.'s Technology Saves Energy and Boosts Sustainability To truly understand the benefits of custom induction heaters in a real-world scenario, let’s take a closer look at ThermESC Intl., a leading company in the induction heating industry. They recently imple mented a custom-built induction heater at a facility that specializes in forging parts for the automotive industry. This case study highlights how their custom solution led to significant energy savings, boosted efficiency, and improved production. The Challenge: Outdated Equipment and High Downtime Before the upgrade, the facility was using a 30-year-old 750KW induction machine with outdated SCR technology. This machine had numerous issues that not only made it inefficient but also prone to frequent breakdowns. The result? Costly downtime and expensive repairs. The facility struggled to meet increasing demand, as their outdated system couldn’t keep up with the required production speeds and energy efficiency. The Solution: The ForgeMax Series Induction Heater To address these issues, the facility decided to replace the old system with the ForgeMax 750KW IGBT technology. This custom induction heater was specifically designed for their forging processes and provided several key improvements:

How Custom Induction Heaters Integrate with Existing Processes When it comes to improving your manufacturing process, the ability to easily integrate custom induction heaters into your existing setup is a game-changer. Whether you’re working with new production lines or looking to upgrade your current equipment, custom-built induction heaters can be seamlessly incorporated without causing disruption.

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FIA MAGAZINE | FEBRUARY 2025