Infrared systems optimize energy efficiency in plastics processing

The processing of plastics is complex and the energy consumption for the necessary heating processes is high. The electric infrared emitters of a manufacturer of special light sources and systems generate heat exactly where it is needed.

Plastics are laminated, embossed, welded, riveted or deburred. This is time-consuming and the necessary heating processes cost a lot of energy. It's good when the energy is only effective where it's needed. Electric infrared emitters can be precisely adjusted, making complex heating processes reliable and automatable. Infrared systems respond very quickly, ensuring that energy is not wasted through preheating, standby or losses to the environment. Heraeus Noblelight offers infrared emitters and systems that transfer heat in a particularly energy-efficient way.

An example from Great Britain shows how the use of infrared emitters can improve a plastics processing process. There, parts of an inspection tool for ducts are made from polypropylene by joining various pipes to a base unit. Previously, hot glue was used for this purpose. The British company Hepworth Drainage was looking for more efficient solutions to both save costs and meet environmental protection requirements.

The new infrared system now takes just 22 seconds to bring the different pieces together and weld them in a complex, automated process using robots. This has significantly reduced cycle times for plastic inspection chambers at Hepworth and significantly increased part quality. The new heat process is also environmentally friendly, as it now produces far fewer fumes than the previous hot glue method.

These process improvements are supported by infrared emitters that have been molded three-dimensionally to the product. This means that heat is generated exactly where it is needed. Infrared emitters only need to be switched on when the heat is actually needed, which additionally helps to save energy.

Infrared heating technology works by transmitting electromagnetic waves, which then generate heat in the product. This requires neither direct contact with the material nor a transfer medium such as gas or air.

Infrared emitters transfer energy into a plastic product and generate heat exactly where it is needed. This helps solve many requirements. Quartz infrared emitters can be precisely shaped to fit corners, edges and small surfaces. For example, the entire car door is not heated, but only the area to be riveted, glued or deburred. (OM-08/22)