How to Recognize When Modernization Makes More Sense Than New Equipment Purchase
The decision between purchasing new equipment and modernizing a mixing mill is not always straightforward. While buying new equipment may seem like the obvious solution at first glance, professional modernization can often be the more economical and sustainable alternative. In this article, we'll show you five clear signs that indicate modernization of your existing mill is the right choice.
1. Frequent Maintenance Work and Breakdowns
The Problem: Your energy bills are continuously rising even though your production volumes haven't changed significantly? This is a clear sign of outdated drive technology.
The Solution: Modern torque motors with 98 percent efficiency can reduce your energy consumption by up to 30 percent. These permanent magnet synchronous drives combine the advantages of hydraulic motors and three-phase motors without adopting their disadvantages.
Specifically, this means: A mill that previously cost $60,000 annually in energy costs would only cost $42,000 after modernization – a savings of $18,000 per year.
Additional Benefit: The regenerative drive power is reused, which further increases energy efficiency.
2. Frequent Maintenance Work and Breakdowns
The Problem: Does your maintenance team know your mill better than their own workshop by now? When repairs and maintenance become routine, they not only consume time and money but also jeopardize your production planning.
The Solution: Modernization can reduce maintenance requirements by up to 80 percent. Modern planetary gearboxes, for example, require only a fraction of the oil for annual changes – up to ten times less than conventional gearboxes.
The Calculation: If you previously spent $15,000 annually on maintenance and repairs, these costs drop to approximately $3,000. The saved $12,000 annually pays for modernization within just a few years.
Additional Advantage: The compact design and minimization of forces transmitted into the machine frame by approximately 85 percent increases mechanical stability and reduces wear from fatigue.
3. Safety Standards No Longer Meet Current Regulations
The Problem: Your employees' safety comes first. If your mill no longer complies with current safety guidelines of EN 1417:2023, urgent action is required.
The Solution: Modernization brings your mill up to the latest safety technology standards:
- Brakes with brake angle monitoring for wear-free braking during emergency stops
- Safety switching rods on front and rear sides
- Hydraulic nip gap adjustment for quick opening of the roll gap in emergencies
- Optimized arrangement: The fixed roll is located on the operator side, the movable roll faces away – eliminating pinch point areas
The Risk: Outdated safety technology not only endangers your employees but can also lead to costly operational interruptions and legal problems.
4. Limited Flexibility in Formulations
The Problem: Your market demands increasingly individualized rubber compounds, but your mill can only work with fixed friction? This limits your product variety and thus your business potential.
The Solution: Modern individual drives with variable frequency drives enable stepless friction adjustment. This allows you to:
- Process various formulations flexibly
- Precisely adjust compound parameters
- Implement new product developments faster
- Increase production efficiency through optimized settings
The Advantage: A modernized mill can, through its variability, handle the tasks of several conventional mills.
5. Noise Pollution for Employees
The Problem: Workplace noise is not only unpleasant but can also have health consequences and impair your employees' productivity.
The Solution: Modern mills are installed at ground level on a base frame without requiring pits or extensive foundation work. This decoupling from the building minimizes:
- Noise through reduced vibration transmission
- Vibrations throughout the production area
- Disturbances in adjacent work areas
Additional Benefit: Ground-level installation offers greater flexibility during renovations and significantly reduces installation and assembly costs.
Conclusion: Modernization as a Sustainable Investment
Modernizing a mixing mill is more than just a repair – it's a strategic investment in your company's future. With up to 40 years of additional service life, 30 percent energy savings, and possible payback within five years, modernization often represents the more economical alternative to new equipment purchase.
Particularly Sustainable: By reusing existing components, you not only save costs but also CO2 emissions and valuable resources.
Check Your Savings Potential Now
Do you recognize one or more of these signs in your mill? Then modernization could be the right solution. A thorough analysis of your current situation helps make the optimal decision.
Next steps
- Evaluate your current energy costs and maintenance expenses
- Review your facility's safety standards
- Analyze your flexibility requirements
- Consult with experts
Do you have questions about modernizing your mixing mill? We are happy to help evaluate your individual situation and develop the optimal solution together with you.
