On occasion of German Casting-Day, Foundry Planet took the opportunity to pay a visit to Dr, Tannberger Company located in Radebeul close to Dresden (Germany). Dr.Tanneberger is manufacturer of Padicon®, a highly effective system that helps casting industry to save electricity costs.
Dr. Ralf Tanneberger (CEO)
In simple terms, the system is based on load distribution during the fusion process thus reducing power peak permanently.
Through the low power peak, many foundries already save above 80.000 € on their yearly electrical expenses. This fact is well known to all foundry managers. The energy costs are escalating causing massive pressure on the casting industry as their requirement is quite high.
So far, the frequently utilized load limitation process for energy control works according to the principle of restriction. Once maximal performance has been attained a furnace is driven down to minimal technical load i.e. at that point single furnaces are in turn entirely detached from the network for several minutes and later are switched on.
This full brake-application hinders operational procedures which lead to an enormous loss of melting- time. Dr.Tanneberger replaces this procedure by a „parallel differential current-regulation“.
At a constant production extent and an undisturbed process, the fusing times are automatically allotted to diverse furnaces by a mild- process adapted regulation. This way an adjustment of fluctuation in the performance is attained. This unit- registered as patent is applicable for mid- as well as mains frequency furnaces.
It should be mentioned here that, since there is no load shedding, the melting process runs without interruption, thus causing furnaces are exposed to a marginal thermal and electrical burden. This increases durability and diminishes deterioration.
In addition, Padicon can track down through consistent monitoring certain deficiencies optimizing the potential power consumption of the connected unit. Thus providing a clear overview at any time.
What especially impresses us about Foundry-Planet: A ROI (return on investment) is often done within a year or so.
The systems are manufactured in a stylishly refurbished old villa in Radebeul, a town near Dresden. Each system is planned and manually assembled according to the individual needs and requirements of foundries.
Beside the assembly in the basement and ground floor, there are other rooms available in the same villa of Dr. Tanneberger for management and marketing. Four mechanics, two managers as well as marketing project-planer support the managing director Dr. Ralf Tanneberger.
The units are not only put into practice in Germany, but also in neighbouring countries too. Worldwide projects are still under plan-development, as reduction of power costs and Co2-emissions are not only issue in Germany. Many foundries in other nations are struggling with the same problems. Such a system offers product safety for countries with weak electrical circuit.