As the UK strives towards the ambitious goal of net-zero emissions by 2050, sustainability has become more important than ever. Industries like construction - which accounts for roughly 10 per cent of total UK energy consumption and 25 per cent of total carbon emissions - are rethinking how they operate to reduce their carbon footprint. In fact, a Pew Research Study found that 71 per cent of UK construction professionals believe that sustainability is a "top priority” for their future.
Silicone rubber’s versatility and durability make it a popular choice for various construction applications, primarily in seals, gaskets, and insulation. Building exteriors, windows, doors, and roofing systems rely on silicone rubber for watertight seals, while its non-toxic nature also makes it safe for use in food processing and medical devices.
However, traditional silicone rubber extrusion processes can be energy-intensive. Extruders must be watercooled to prevent the silicone curing in the barrel. Significant energy resources are also required to achieve the temperatures required to cure silicone quickly and completely. After extrusion, the silicone rubber material needs further post curing at 200°C consuming more energy resources.
Material handling also represents a potential energy hotspot in the extrusion process. Materials must be milled before extrusion and secondary operations such as cutting and joining require energy inputs.
To make silicone rubber products more eco-friendly, we need to find ways to use less energy in the process. By finding smarter ways to heat, cool, and handle materials, we can cut down on energy use while still making high-quality products.
One way to do this is by using machines that can control temperature more precisely whilst minimising heat loss and consuming less energy. Better insulation on machinery can reduce heat loss and energy consumption. Advanced cooling methods, such as variable-speed fans, water-based cooling systems with adjustable flow rates, or chilled air cooling, can improve cooling efficiency and reduce energy consumption.
Lean manufacturing principles and real-time monitoring systems can help to identify opportunities for energy savings in the extrusion process. By analysing production data, manufacturers can minimise energy waste and improve overall process efficiency.
Incorporating renewable energy sources, such as solar panels or wind turbines, into the manufacturing facility can offset energy consumption from traditional grid sources and reduce overall carbon footprint. This can help reduce energy costs whilst providing supplementary power during peak demand periods.
The future outlook for energy-efficient manufacturing in the silicone rubber extrusion industry is promising, driven by several key trends. These include the integration of smart manufacturing technologies that will enable real-time monitoring, data analytics, and predictive maintenance to optimise energy usage and streamline production workflows. Additionally, greater integration of renewable energy sources into manufacturing facilities, along with collaboration and partnerships across the value chain, will further drive energy-efficient initiatives.
To stay competitive, businesses should prioritise investment in research and development, embrace renewable energy solutions, and foster collaboration to ensure long-term success in the evolving energy-efficient manufacturing landscape.
Mathew Bishop, spokesperson for silicone rubber products supplier Viking Extrusions
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