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Global energy issues are escalating, and the pressure of carbon emissions weighs heavily on every business, especially the manufacturing sector, where power consumption remains a major challenge.
But there's good news! The Precision Machinery Research Development Center (PMC) has joined forces with the Ministry of Economic Affairs Energy Administration to develop the "Proximity Preheating Technology." Simply put, this technique is like giving a metal workpiece a custom-made "electric blanket." It eliminates the need for bulky external heating methods used in traditional furnaces, allowing the metal to heat up from the inside out.
This innovative method is projected to help the metal manufacturing industry cut energy consumption by up to 70%! This is more than just saving money—it's a massive contribution to reducing global carbon emissions.
I. Industrial Power Consumption is Alarming: Energy Saving is the Top Priority
Did you know? According to the latest 2024 statistics from Taiwan's Ministry of Economic Affairs Energy Administration, the industrial sector's electricity consumption accounts for a staggering 55.6% of the nation's total power usage! This high figure is growing year by year, signaling that industrial production is our country's biggest power consumer and the area where efforts for energy saving and carbon reduction are most critical.
With global initiatives like the Paris Agreement and the European Green Deal driving decarbonization regulations, energy efficiency is no longer optional—it's an international imperative. Therefore, maximizing energy efficiency to ensure every kilowatt-hour is utilized to its fullest potential has become a top governmental priority.
Mr. Chien-Hsun Lee, General Manager of PMC, puts it well: "The industrial manufacturing process is like a massive energy converter, but currently, most of that energy is wasted as heat, dissipating into the air. Our mission is to design more precise energy-saving equipment to ensure every unit of energy is utilized effectively." This perfectly highlights the need for a smarter way to use electricity.
Imagine a company that can drastically reduce its energy consumption. It not only saves substantial electricity costs but also lowers carbon emissions, ensuring compliance with international environmental regulations. This boosts the company's financial health and enhances its brand image, attracting sustainability-focused clients. Ultimately, this strengthens the company's competitiveness in the global market.
II. Traditional Preheating is Slow and Energy-Intensive
Many steps in metal manufacturing, such as aluminum alloy forging or steel plate stamping, require heating the metal workpiece to very high temperatures. Why? Because high temperatures make the metal softer and more ductile, preventing fractures during processing and ensuring better product quality.
For instance, the aluminum alloy crank arms on our bicycles must be preheated to about 500∘C before forging. Structural steel plates used in automobiles require temperatures as high as 850∘C! Imagine how much energy traditional methods consume to heat a large piece of metal to these extremes.
How does the traditional continuous furnace preheating technique work? It's like using a large steamer: it relies on hot air to slowly transfer thermal energy to the metal workpiece. This method has a very low thermal efficiency, only between 5% and 40%. Furthermore, the entire furnace must be preheated well in advance, wasting substantial energy.
This traditional heating method is not only inefficient but also causes hidden problems. Prolonged high temperatures inside the furnace lead to equipment wear and tear, requiring more frequent maintenance. Moreover, extended heating times directly impact the production line's rhythm, lowering overall efficiency.
Beyond being energy-draining, this "steaming" method often leads to uneven heating. Since heat conducts from the outside in, the metal part's surface might reach the target temperature while the core remains cool. This can affect the precision of subsequent forging or stamping and potentially cause product defects. Uniform temperature is essential for consistent material properties.
III. New Technology Unveiled! Direct Heating is Faster and Saves More!
PMC's "Proximity Preheating Technology" completely overturns traditional practices. It functions like a "highly precise, enveloping electric blanket," directly running electricity through the metal workpiece itself. Because metal has electrical resistance, current flow generates heat, a principle known as Joule heating. Since the heat source is the metal workpiece itself, the efficiency is significantly higher!
This technology offers numerous benefits:
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Extremely High Thermal Efficiency: Since thermal energy is generated directly inside the metal, there is almost no energy lost to the air, making it far more efficient than traditional methods.
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Significantly Shorter Preheating Time: There is no need to wait for a massive furnace to slowly warm up. The metal workpiece reaches the required temperature quickly once the power is applied, translating into a huge efficiency boost for the production line.
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No Equipment Pre-Heating Required: This is a major advantage! Traditional furnaces waste energy preheating the entire body every time they power up. The new technology heats the workpiece directly, offering "instant-on" capability and saving not just electricity but precious time.
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Drastically Reduced Energy Consumption: Combining the points above, the final result is a massive reduction in energy consumption, with energy saving effects of up to 70%!
This internal heating approach also ensures a more uniform temperature distribution. Because the heat is generated consistently throughout the metal's interior rather than being slowly conducted from the exterior, all parts of the workpiece reach the target temperature more evenly. This is vital for subsequent processing quality, ensuring uniform material ductility and reducing defects caused by uneven stress.
Furthermore, the "instant-on, instant-off" nature greatly increases production line flexibility. Previously, factories might opt for large-batch production to avoid energy waste from preheating. With the "metal-specific electric blanket," small-batch or diversified production needs can be quickly accommodated without long warm-up times, aligning with the modern manufacturing trend toward variety and customization.
IV. Successful Experience is Visible: Excellent Energy Savings Across Industries!
The collaboration between PMC and the Ministry of Economic Affairs Energy Administration already had a success story last year (2024), with the development of an electromagnetic drying system for the rubber and plastics industry. This equipment uses electromagnetic waves, much like a microwave oven, to directly heat the moisture within plastic pellets. Combined with negative pressure technology to lower the dew point, moisture is removed much more easily. This method saved a full 60% of energy compared to traditional hot-air drying—an already astonishing figure.
This year, that successful experience was cleverly applied to the metal manufacturing industry, specifically targeting high-temperature processes like hot forging and hot stamping to develop the new preheating technology. This technology is expected to bring even more significant energy benefits to metal manufacturers, proving that the combined technologies of PMC and the Energy Administration are field-tested and effective across various industries.
V. Future Outlook: Beyond Preheating, More Metal Processes to Join the Energy Saving Plan!
PMC has a clear and ambitious blueprint for future development. They plan to further collaborate with the Ministry of Economic Affairs Energy Administration and the industry to promote these innovative energy-saving technologies to a wider range of metal processes. Beyond preheating, key metalworking crafts like heat treatment and die-casting will be included in future energy-saving programs!
Mr. Chien-Hsun Lee, General Manager of PMC, reiterates: "Improving energy efficiency in every process is like adding a green leaf to the Earth." This poetic statement underscores their core philosophy: through these technical innovations—which may seem small but are substantial when cumulative—they hope to work with the industry to contribute to Taiwan's energy saving and carbon reduction goals. This is more than just a technological revolution; it's an environmental commitment.
Expanding energy-saving technology to heat treatment and die-casting means PMC aims to establish a comprehensive green metal manufacturing ecosystem. If these high-energy-consuming segments can achieve significant savings, it will have a profound impact on the entire metal processing supply chain, serving as a powerful catalyst for industrial transformation.
VI. PMC Calls for Action: Contact Us to Start Saving Energy!
PMC strongly encourages metal manufacturers keen on improving energy efficiency to contact them proactively! PMC is eager to explore and identify the most suitable energy-saving optimization plan for your specific process characteristics. Let's work together toward a greener, more sustainable manufacturing future!
About the Precision Machinery Research Development Center (PMC): PMC is Taiwan's leading machinery technology research and development institution, dedicated to enhancing the competitiveness of Taiwan's manufacturing industry. Their expertise focuses on the R&D and promotion of precision machinery, smart manufacturing, and green production technologies. Partnering with PMC means you have found the most professional consultant to keep your business abreast of the latest technological trends.
If you are interested in this technology or would like to learn more details, please contact:
PMC System Application Department Phone: +886-4-2359-5968, Ext. 692 (Deputy Manager Yao-Jen Fan 范耀仁)
PMC's experts are ready to answer your questions and provide customized energy-saving solution proposals. Don't hesitate—this is an opportunity not just to save costs for your business, but to contribute to the planet!
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