Biomass proves to be an inspired decision for XYZ Machine Tools

The energy price crisis is well documented with bills doubling for many, which is leading individuals and businesses to look at alternative and environmentally-friendly ways of tackling the problem. At XYZ Machine Tools the issue was not just energy costs, but also the environmental and financial impact of disposing of over 100 tons of wood every year, the majority of which went to landfill.

The volume of wood is generated from the pallets that its machines are delivered on, XYZ Machine Tools investigated every option to re-cycle/re-purpose these pallets, but the costs involved to make the timber useful meant that nobody was willing to take them, meaning the only option at the time was landfill. “We tried everything we could to make use of these pallets, but the time and cost involved in removing nails and bolts and sorting the wood, given that we had two tons/week to deal with simply made it unviable for anyone to be interested,” says Nigel Atherton, Managing Director, XYZ Machine Tools.

Removing this volume of wood to landfill also came with the significant cost of over £50,000/year for transport and landfill charges. Add to this the then £25,000/year gas bill to heat the factory and with business growing and factory extensions in the pipeline these costs would only increase. An alternative had to be found and that came in the shape of a biomass boiler. XYZ Machine Tools’ initial research showed that the economic benefits of investing in this system were significant as well as the positive environmental impact of delivering near carbon neutral heat to the factory. The investment would be around £180,000 to include the biomass boiler, hot air distribution system, an industrial scale wood chipper, and a bulk fuel store and feed system that delivers fuel to the boiler as and when required.
The installation of a Froling TX200 250kW Woodchip Biomass Boiler with an attached Untha wood-chipper that feeds a silo that can contain 10 days worth of wood-chip, resulted in annual saving of around £100,000 as a result of eliminating costs for transport, landfill, and the gas bill, as well as a rebate for the energy saved. These savings were at a time prior to the current spike in energy costs, so savings generated now may well be £25,000/year greater. The rebate is due to the system at XYZ Machine Tools qualifying for the UK Government’s The Non-Domestic Renewable Heat Incentive (RHI) scheme [now closed to new applicants] which provided business with a cash incentive for every kWh of heat generated, which has to be monitored along with the volume of wood used, along with samples of the wood. Businesses that qualified for this scheme receive a quarterly index linked rebate over a 20 year period.

All of the wood used is sourced from pallets and packaging within the business, and XYZ Machine Tools had to register as a ‘self-supplier’ and work within the constraints of strict rules as to what type of wood can be used. As part of that process the company became certified by Woodsure, the UK’s only quality certification scheme that identifies responsible and trustworthy fuel producer or supplier. This certification demonstrates an ability to
produce fuel to the correct standard. This certification is further backed up by Ofgem that confirms that emissions are within acceptable standards.

While XYZ Machine Tools had a ready-made source of fuel for its biomass boiler the efficiency of the systems, especially in the current economic climate is compelling. A biomass boiler provides increased efficiency thanks to the burning process where the fuel is burnt at around 600˚C. The gas created in this burn is then subject to a secondary combustion with air being introduced to increase temperatures up to 1200˚C. These super-heated gases then pass through a heat exchange system containing water, this is then pumped around the building to maintain a comfortable working environment when outside temperatures drop.
www.xyzmachinetools.com

Tornos opens Poland factory

Tornos has opened its new factory in Kąty Wrocławskie, Poland. The factory was designed primarily to refurbish and modernise Tornos’ Deco 10, a flagship and best-selling bar-turning machine. By giving the Deco 10 new life as the Deco 10 Plus, Tornos highlights its heritage and know-how, while promoting the circular economy.

More than 200 invited guests took part in festivities marking the opening of the new factory in Kąty Wrocławskie. By establishing a permanent presence in Poland, Tornos is making more than a strategic choice. The new factory, located just a few minutes from Wroclaw, an important university centre, makes it easy to recruit highly competent research and innovation personnel.

The story of Tornos Poland began more than 10 years ago, with only two employees representing the brand on Polish soil. Today, Tornos Poland has more than 40 trained employees who know the machines inside out and are able to overhaul and repair them if necessary. Of course, service is about more than resolving technical issues and replacing machine parts. It includes the labour-intensive and important administrative work that Tornos’ new global Shared Services Centre is undertaking in Kąty Wrocławskie. Indeed, the Tornos Shared Services Centre provides these services to the benefit of Tornos sales companies and customers in Europe and, eventually, worldwide.

In Poland, Tornos executes its approach to industry’s circular economy. Since Tornos last year began offering its customers the opportunity to refurbish their Deco 10 machines by upgrading them to the Deco 10 Plus model in celebration of this iconic machine’s 25th anniversary, requests have been pouring in. So much so that Tornos Poland is set to expand even further in the coming months, offering staff the opportunity to train on the unique know-how of machine tool manufacturing and refurbishment.
For further information www.tornos.com

Vollmer holds majority stake in UltraTEC

Sharpening machinery specialist Vollmer now holds a majority share in start-up company ultraTEC Anlagentechnik Münz GmbH, which will be known as UltraTEC Innovation GmbH moving forward. UltraTEC launched its ultrasonic deburring systems in 2019 and is keen to advance its economic and marketing development. Vollmer was impressed by the start-up’s innovative spirit, its advanced ultrasonic deburring technology and the fact that UltraTEC is a fellow family-owned company from the Swabia region. The core expertise of ultraTEC Innovation lies in the contact-free deburring of metal and plastic components.
For further information www.vollmer-group.com

Aerospace giants to collaborate

Leonardo and BAE Systems are actively progressing UK-Italy collaboration opportunities on the demonstrator aircraft as part of the Future Combat Air System (FCAS) programme. The FCAS programme pursues the development of a technologically advanced multi-domain system of systems, underpinned by highly innovative and disruptive technologies, with a 6th generation core platform, and intended for the renewal of Eurofighter fleet.

This collaboration between Leonardo and BAE Systems will focus on the application of model-based system engineering (MBSE) design methodologies and the joint development of enabling technologies for the national sovereignty of the future system. These activities are the natural evolution of the innovation processes already initiated by the partner companies, and assume strategic importance as they explore a technological frontier not yet reached by European industry.
For further information www.leonardo.com

UK closer to net-zero steel

More sustainable, low-carbon steel and electric vehicle batteries are the target of a new two-year technology development programme between WMG at the University of Warwick and Tata Steel. The partners will come together to focus on developing environmentally friendly steel grades, coatings, films and battery structures, enabling the growth of steel application across key industrial sectors. The initial research activity will focus on five core themes: product metallurgy; surface state optimisation; non-metallic coatings; future material applications; and material forming/joining and associated characterisation.
For further information www.tatasteeleurope.com