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Mapal tightens the sustainability screw from the tool to the chuck

From combination tools and tool reconditioning to the award-winning hydraulic expansion chuck, the sustainability initiatives at Mapal Dr. Kress SE & Co. KG in Aalen cover a wide range. Contributing to environmental protection and reducing emissions with every new tool is their credo. Responsibility extends across all product and company divisions. For instance, combination tools are key to machining more efficiently and sustainably. By combining various operations within a single tool, tool changes are eliminated, and travel paths are shortened. Reduced machine runtime also means lower energy consumption. Furthermore, combination tools require less material compared to individual tools. Mapal is also committed to researching minimal quantity lubrication (MQL)-saving tools. Tools compatible with MQL systems make machining more ecological by reducing the amount of cutting fluid required. This also limits the amount of chips contaminated by cutting fluid, which benefits the environment and simplifies disposal and recycling. Resource utilization is further enhanced through modular head systems and indexable inserts, as only drill or milling heads are replaced, and inserts are rotated instead of discarding the entire tool. Polycrystalline diamond (PCD) and solid metal tools, as well as indexable inserts and ISO elements, are distinguished by their durability thanks to reconditioning. Through regrinding, renewing guide pads, replacing cutting edges, or applying new coatings, tools regain their original performance. Finally, the Uniq hydraulic expansion chuck, which has received multiple design awards, serves as a sustainable alternative to traditional shrink-fit chucks. Its reduced energy requirements lower emissions, and the material does not fatigue as it eliminates the need for a shrinking process, as explained by the team in Aalen. This leads to a comparable tenfold increase in service life.

Kapp Niles optimizes energy consumption and material usage

Based on decades of experience combined with innovative ideas, Kapp Niles GmbH & Co. KG develops modern gear grinding and profile grinding machines. For many components, sustainable options have also been specifically developed. Finite element method (FEM) analyses, for example, are used to design components with high stiffness and minimal material usage. This reduces the inertia to be overcome during movement, thereby saving drive power. Hydraulic components have largely been replaced by electronic ones, and the remaining functional units have been optimized with efficient hydraulic systems that have low consumption. Compared to a hydraulic power of 13.5 kilowatts installed 25 years ago, frequency-controlled pumps with 2.2 kilowatts are now available, consuming just 0.04 kilowatts per hour during production. Reduced oil requirements, low-wattage valves, and frequency-controlled pump drives further lower operating costs and maintenance demands. Additively manufactured coolant nozzles increase the efficiency of coolant supply by 60 percent, contributing to a lower energy demand in the coolant system. Switching the machine bed material from cast iron to recyclable mineral casting saves approximately 1.6 tons of CO₂ per ton of material over the system's entire life cycle. "Smart" shutdown functions and a calendar-controlled warm-up program minimize machine runtime. Operating pressure has been reduced, and a demand-driven sealing air supply has been implemented, which reduces compressed air consumption. The EU Ecodesign Regulation 2024/1781 poses new challenges for machinery manufacturing in terms of product development and marketing. These include resource efficiency and the declaration of CO₂ or environmental footprints. Kapp Niles has consistently addressed these issues in the past, notably within the framework of the VDMA's Blue Competence initiative. The company sees its ambitious internal sustainability goals as an opportunity to secure competitive advantages in the future.