Parts are forged at around 1150 °C and then cooled to room temperature, only to be reheated in a furnace to 860–900 °C. This process was both energy- and time-intensive.
“We were consuming huge amounts of energy to reheat parts from 25 °C to 900 °C,” explains Lukáš Andrášik, a technician at HKS Forge. “That’s why we started looking for a way to make this process more efficient.”
One of the furnaces was relocated directly behind the forging press. After forging, the parts pass through a cooling tunnel, where they are cooled to less than 500 °C, and then immediately inserted into a furnace maintained at 900 °C. This way, the accumulated heat is used, and the parts no longer need to be reheated from room temperature. At the same time, the required mechanical properties for the forgings are achieved.
Energy Savings and New Opportunities
It is expected that this change will save 30–40 percent of electricity in the heat treatment process. Moreover, the furnace will automatically insert the parts from the conveyor, increasing automation, and the worker will only need to load the parts onto the conveyor after forging and trimming.
“The biggest benefit is energy and cost savings,” emphasizes Andrášik. “We expect the investment to pay off within one to two years.”
However, the new system does not only bring savings. Relocating the furnace frees up space, opening up possibilities for future investments. The optimization is therefore not only a technological advancement but also a strategic step. The saved funds could be used for additional modern equipment for a new heat treatment line, which HKS Forge is discussing with suppliers in China.
“It is clear that actual figures may slightly differ from calculations,” concludes Andrášik. “But we already know this is a step in the right direction – towards more efficient production and better preparedness for the future.”
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