Advanced Energy Savings with the Maguire ULTRA Dryer
18 September 2023
Advanced Plastics, a long-standing customer of Summit Systems, sought ways to reduce energy costs and increase sustainability in response to rising energy expenses. In collaboration with Summit Systems and Maguire, the leading provider of vacuum drying solutions, Advanced Plastics embarked on a trial to compare the energy efficiency of the Maguire ULTRA Dryer against a typical desiccant dryer.
As a leading provider of high-quality plastic solutions, Advanced Plastics offer a comprehensive range of products and services to a diverse range of industries, such as Automotive, HVAC, Filtration and Technical Plastics. With a strong commitment to innovation, sustainability, and customer satisfaction, Advanced Plastics has established itself as a trusted partner for businesses seeking reliable and tailored plastic solutions. Their state-of-the-art manufacturing facilities, combined with a team of experienced professionals, enable them to deliver cutting-edge products that meet the unique needs and specifications of their clients. With a focus on quality, efficiency, and environmental responsibility, Advanced Plastics continues to exceed expectations and drive positive change in the plastic industry.
With escalating energy costs and a focus on sustainability and productivity, Advanced Plastics recognised the need to reduce energy consumption and carbon emissions within their drying processes which comprised of 10 desiccant dryers. They contacted Summit Systems, a trusted partner for over 15 years, to explore the Maguire’s mammoth claims reenforced by Summit Systems made regarding the energy saving and productivity benefits of the ULTRA’s production technology.
Leveraging their exclusive partnership with Maguire, Summit Systems confirmed that the use of the Maguire ULTRA Dryer; a cutting-edge vacuum drying solution would be the ideal choice for this application proven extensively for energy-efficient drying within the plastics industry.
- Advanced vacuum drying technology: The ULTRA Dryer utilises vacuum technology instead of Desiccant which is more efficient. Material is heated for, on average, 30 mins, typically 6 times less than Desiccant so minimises energy consumption while maintaining high drying performance. This reduced exposure to heating, which improves material performances and reduces scrap rates.
- Advanced Performance: The ULTRA Dryer does not use desiccant towers which need to be frequently regenerated at high temperatures so consequently delivers substantial energy savings compared to traditional desiccant dryers.
- Advanced Sustainability Benefits: The ULTRA Dryer contributes to sustainability efforts by greatly reducing carbon emissions.
The Project
To genuinely assess the energy-saving potential, 10 existing desiccant dryers from reputable suppliers were monitored in turn against the equivalent Maguire ULTRA, utilising the same moulding tools and injection machine, operating over a 24-hour period. In addition to direct energy saving, because the ULTRA is faster at drying, it has provided a whole new level of flexibility in production by starting up machines quicker and make faster material changes and having less material in process. The results were remarkable. The existing desiccant dryer consumed £28.60 in energy costs over the 24 hours, while the Maguire ULTRA Dryer required only £10.57, demonstrating a significant 63% cost saving per day.
The ULTRA Dryer demonstrated a 55% reduction in energy usage compared to the typical desiccant dryer.
Considering the daily energy savings of 67 kW/h, the projected annual carbon emissions saved over a one-year period would equate to:
27,120 miles driven by an average gasoline-powered vehicle
1,286,869 smartphones charged
486 filled propane cylinders for home barbecues
And the equivalent to greenhouse gas emissions avoided by:
3.7 tonnes of waste recycled instead of landfilled
458 trash bags of waste recycled instead of being sent to landfill
Following the success of the trial, Advanced Plastics decided to adopt the Maguire ULTRA Dryer technology factory wide. Currently, they have implemented four ULTRA dryers, with further plans to convert the entire factory, imminently adding six more units. Consequently, Advanced Plastics can expect to achieve annual savings of over £60,000 collectively, alongside a remarkable energy reduction of 244,550 kW/h. Summit Systems will continue to support Advanced Plastics throughout the transition and provide ongoing expertise and assistance.
The Feedback
Rob Anderson, Joint CEO of ‘2022 PIA Processor of the Year’ Advanced Plastics Group, “Having previously been the first UK users of the first generation of Maguire LPD vacuum dryers, we were keen to understand how the technology had moved forward. We are extremely grateful to Summit Systems for introducing us to the Maguire ULTRA Dryer and supporting us throughout the implementation process.
The energy and cost savings we have achieved through the transition from our ‘not so old’ desiccant dryers have been truly remarkable. The ULTRA Dryer's contribution to reducing our carbon emissions aligns perfectly with our sustainability goals.
We have seen significant additional benefits in terms of flexibility, reduced start up times and the ability to change materials on the fly. We can dry material in the time it takes to tool change and don’t need to empty driers and re-bag materials with the added risk of contamination when we have an unplanned change. Planning is so much easier, and we do not risk over drying materials during any periods of downtime as we are only ever drying a small amount as we need it.
Downtime and maintenance are vastly reduced with no desiccant to change, and cleaning is easier and quicker requiring less resource and allowing our material technicians more time to focus on delivering materials when they are needed. We have seen a tangible improvement in OEE (overly equipment effectiveness) to date using the new technology which has allowed us to drive efficiencies forward and make further investment in this technology. The 5-year guarantee is also a huge added bonus.
We highly recommend Summit Systems for their expertise and commitment to delivering innovative solutions that drive efficiency and cost savings. The project went smoothly from start to finish and we’re looking forward to working with the team again on our next project."
The Partnership
The partnership between Advanced Plastics, Summit Systems, and Maguire has yielded significant results in terms of energy and cost savings. By adopting the Maguire ULTRA Dryer, Advanced Plastics has achieved a significant reduction in energy consumption, leading to substantial cost savings and a considerable decrease in carbon emissions. The expertise and support provided by Summit Systems throughout the implementation process have been invaluable, ensuring a seamless transition and successful outcomes. The longstanding partnership between Summit Systems and Maguire has played a pivotal role in delivering innovative and efficient solutions to the plastics industry, and a very success outcome for Advanced Plastics.