Techno CNC routers introduce new PRO Series CNC
router, specially produced for panel process manufacturing

Techno, Inc. CNC Routers announced the introduction of the Pro Series CNC Router to their current product line of CNC machining solutions. Designed to meet the high demands of panel process manufacturing, the Pro Series is constructed of large heavy tubing that is both welded and stress-relieved, the perfect foundation for Techno's precision drive system. Also comprised of precision ball screw drives on all three axes, THK rails and bearings, high-speed closed-loop servomotor and drives, the Pro Series drive system ensures minimal maintenance, machine longevity and superior machine performance.

Techno's New Pro Series is available in a variety of standard sizes ranging from 4 ft x 8 ft through 6 ft x 20 ft. "We are welcoming special sizes and customization requests with this model because we understand that size and usage vary from shop to shop," says CNC Router Sales Manager, Roy Valentine. "The Pro Series machine can be equipped with a variety of spindle options including automatic tool changer, collet spindles, drill banks, or multi-spindle setup for high volume part production. Multiple zone vacuum table, reverse engineering lasers, and 4^th axis rotary tables are just some of the additional accessories compatible with this new machine."

Additionally, the New Pro Series' machine features a CNC Servo G-Code Interface that is both easy to learn and operate. This Windows-based interface is a fully comprehensive CNC program that includes unique high-end features such as toolpath preview with viewing tools and adjustable screens, built in G-Code editor, machine speed and spindle rpm override, X/Y axis orientation swapping, program skip ahead (in case of tool breakage), built in basic nesting, and production logging.

For additional specifications and detailed information about the New Pro Series CNC Router, view website: www.technocnc.com   Refer to page 94

ENSINGER introduces the TECASINT product line

Plastics processor ENSINGER has extended its program within the area of amorphous, infusible high-temperature polyimides. The new product line, TECASINT, includes several new developments and modifications, as well as proven materials which have been established in the market under the brand name SINTIMID. The company introduces semi-finished products and direct formed parts made of the new material TECASINT 2000 which is characterized, amongst other things, by improved toughness. The polyimide portfolio is to be further developed this year.

Semi-finished products and direct formed parts made of TECASINT have outstanding long-term thermal stability. The broad temperature range of these materials extends from -270°C to 300°C. TECASINT materials will even withstand short-term heating to 350°C, without melting or softening. Material strength, dimensional stability and creep resistance under mechanical load also remain high in continuous use

New technical possibilities
The sintering material, TECASINT 1000, (refer to the top picture), was introduced twenty years ago to the market under the name SINTIMID. The newly developed products from ENSINGER include the high-temperature polyimides in the TECASINT 2000 series, (refer to the centre picture). These rigid and hard materials exhibit a high Young's modulus and improved thermal stability and sliding friction characteristics compared to TECASINT 1000. A further advantage of the new development is the clearly reduced moisture absorption, which permits narrow construction tolerances to be achieved. In addition, the material can be machined with high precision thanks to its high degree of toughness.

TECASINT 2000 is eminently suitable for the direct forming procedure, which allows economical volume production of parts, for example, in the automotive industry and mechanical engineering. ENSINGER offers the new product in different tribologically optimized variations for use in sliding friction applications.

The basic monomers, TECASINT 1000 and 2000, can be categorized in the "high purity" class which is important for wafer production, i.e. they are characterized by outgassing and a particularly low level of ionic impurities. These characteristics are also a prerequisite for their use in space-related or high vacuum applications.
TECASINT 5000 (previously: SINTIMID PAI), (refer to the bottom picture), is a non-thermoplastic processible high-temperature polyamide-imide. The sintering material is particularly suitable for applications in semiconductor manufacturing. TECASINT 5000 is available as the pure material, glass-fibre reinforced or in different electrostatic dissipating variations, which can achieve surface resistances from 10¹² to below 10³ Ω.

Products in the TECASINT 8000 series (SINTIMID 8000) are proven materials for sliding friction applications. The base material PTFE is reinforced by PI powder in proportions of 7% to 40%. TECASINT 8000, which is available as semi-finished products (plates, rods) and as sliced film sheeting, is suitable for soft counterparts such as aluminium, brass or bronze.

Compared to non-reinforced PTFE, TECASINT 8000 excels through decreased creep under load and a higher abrasion resistance. The material is already successfully being used with lip seals, sliding strips for textile and packaging machines as well as for bearings and sliding elements under higher loads.

Plates, rods and short tubes
Semi-finished materials from the TECASINT 1000, 2000, 5000 and 8000 ranges are available from stock as plates and rods in different dimensions. In addition, ENSINGER also supplies short tubes made of the materials TECASINT 1000, 2000 and 8000 up to a length of 180 mm with a maximum outside diameter of 120 mm.

For further information contact, Mary Morgan, ENSINGER Ltd, e-mail: marymorgan@ensinger.co.uk

Compressed air energy efficiency at Knauf Insulation

Over the past few years, a multimillion-pound investment at Knauf Insulation's rock mineral wool production facility at Queensferry in North Wales has resulted in all parts of the production line being either replaced or upgraded, including the plant's compressed air system. This £10 million upgrade programme has resulted in a capacity increase to 33,000 tonnes of product per year, together with significant advances in material and product development as well as the introduction of new items.

High quality compressed air plays a vital role, so keeping pace with the latest innovative technology and energy-efficient compressed air solutions has been an important role for Engineering Manager, Philip Bishop. As he explains: "In our specific applications, the quality of the compressed air is very important. It has to be very dry because condensation of water vapour deteriorates the quality of the insulation material.

"What is equally important to us is energy efficiency. Our corporate slogan is 'It's time to save energy' and we are very serious about it. Our company mission is to become world leader in energy efficient buildings, so we look at the energy efficiency of plant equipment involved in our production processes in much the same way. And we find that Atlas Copco's compressed air system solutions have met both of these important criteria."

Atlas Copco Compressors' relationship with the Queensferry plant started ten years ago when it was invited to recommend a replacement for a competitor's compressor plant installation which was subject to overheating, oil leaks, had no drying facility and was allowing damaging moisture into the air supply.

With the application of Atlas Copco's measurement (ME) box survey techniques it was possible to establish a true indication of Knauf's air usage. The ME box is an invaluable device providing a true indication of a plant's compressed air demand and, most importantly, any wastage that is incurred in producing it.

The unique software programme employed enabled simulated compressor comparisons to be made against the actual system operation and thus provide an indication of how the compressed air system could be improved for maximum efficiency and reduced costs. Based on that information, it was possible to submit recommendations for the installation of the most energy efficient compressed air solutions available to match the company's production needs.

Compressed air is utilised for the air-atomised rock wool binder sprays and for the reverse jet bag filters that handle fibre and dust, including recycling systems. It plays an important role in the plant's packaging machinery functions and for general plant air required for operating pneumatic cylinders, actuators for valves, dampers, bin doors, diverter chutes, etc.

Since compressed air does not come into direct contact with finished product within any stage of Knauf Insulation's Queensferry production operations, it was decided that two Atlas Copco oil-injected rotary screw compressors would fulfil the process need and were selected to replace the existing plant. So the company entered into a 5-year lease contract for the installation of a GA 75 Full Feature machine and a GA75 VSD Full Feature unit.

Some four years later, it was time to review the situation to ensure that the installation was still relevant to the manufacturing processes.  Were these the right machines? Were they the right combination of machines?  Had the process needs changed in any way or were they likely to do so in the future?

Atlas Copco's AIRScan audit team got to work once more and presented their new proposals based on simulations. The recommendation and agreement was for two GA55+ fixed speed machines and a GA55VSD, all full feature machines with integral dryers. Together with output controlled by an ES 130 unit  and AIRConnect remote monitoring, this combination allowed one fixed machine to run as a base load supply unit that could be topped up by the Variable Speed Drive compressor or, on low production demand, just to run the VSD machine by itself. This three-machine option also allowed for maintenance on any one unit without reduction in capacity.

Furthermore, this decision satisfied Knauf Insulation's primary considerations of total reliability and optimum energy efficiency. To ensure that those standards were maintained at all times, and for Philip Bishop's peace of mind, the equipment was covered by a Total Responsibility Service Plan 1 contract with 24/7 support coming from Atlas Copco's local Service Centre sited just 30 minutes away in Warrington.

This successful synergy between manufacturer and compressed air solutions provider is all the more significant because of the nature of the business it serves. With a global mission to conserve energy, and the prospect of an inevitable increase in demand for its products, Knauf Insulation is leading by its own example. When it comes to maximising energy-efficiency within its own production plant, the company has found in Atlas Copco a partner that is equally committed to optimising industry's productivity.

For further information, e-mail: gba.info@uk.atlascopco.com or view website: www.atlascopco.co.uk