Novatec is the Industry Leader in fast, efficient and uniform Infrared Heating. Our G5 Infrared Die Ovens are the most advanced and energy and cost efficient Die Heating System worldwide. We will design a Custom Built Solution to maximize the return on your capital investment.
Our G5 Infrared Die Ovens improve production times, produce a superior profile surface finish, are energy efficient and all this leads to improved profitability for our Customers.
In the past, most Extruders have used Traditional Convection Ovens to heat their dies. These ovens heat up all the air in the chamber and then rely on the air to pass the heat onto the die. The disadvantage of this system is it requires more time, more energy and is more costly. Our Novatec G5 Infrared Die Ovens die heat up times are three to four times faster than the Traditional Convection Ovens.
Our Novatec Infrared Die Oven uses a band of waves to “excite” the metal particles in the die, much how your microwave oven at home functions. We have designed an Infrared Die Oven that singles out the wave length that effects carbon steel. By using this system of generating a small band of infrared waves, we use a lot less energy while still getting the benefit of infrared heating without the cost.
Our Heaters are denser than our Infrared competition, which results in fast, efficient and uniform heat up Die times of up to 35% quicker than our competition.
Five methods to justify the Novatec die oven
Reduction in die breakage
The Werner Extrusion Company (Greenville, PA) reports an almost 90% reduction in die breakage since installation of their die oven. Werner reported a die breakage rate (average) of 23 dies per quarter. Since installation of the Novatec oven, it is down to 3 per quarter. Reasons for this are quite simple. Where 99% of all dies broken are reported to happen with the first billet – improperly heated dies are the culprit. Traditional convection die ovens not only under heat dies, they heat them very unevenly. Under heated and unevenly heated dies make incredibly adverse forces during the first billet. The reason we do not see many, if any broken dies after the first billet is the fact that after pushing a billet through a die, that die becomes evenly heated.
Reduction in “die pulls”
Those customers who keep track of die pulls otherwise known as die failure report back that they see a great reduction of this. Reports show as much as a 90% reduction in die pulls. Example: Futura Industries (Clearfield Utah) prior the installation of the Novatec oven averaged 20 per month. After installation of the oven, this number was reduced to an average of 2.
Our infrared technology is extremely efficient. We will use less than half the electrical energy to heat dies vs. convection ovens. Also, since the die is heated properly and evenly, there is now no need to overheat the first several billets just to heat the die. Over heating of the first billets is not only a waste of energy but it also very hard on the die (bearings), not conducive to good finish quality and can jeopardize the structural properties of the extrusions.
As mentioned above, we heat dies VERY evenly, see graph. This even heat will reduce runnout (aka rod length) variation. We have all seen the first billet through a die to have a variation of 20 feet, the second billet – 5 feet and the third and remaining billets are even. Again, what is happening here is that the die (by virtue of pushing billets through it) has become evenly heated. If the die had been heated properly in the first place, recovery would indeed be higher.
Improved surface finish of extrusions
The Novatec oven will heat (to 850f) a 16” x 6” die in 90 minutes. This rapid heating reduces die bearing oxide to almost nil. The same die in a convection oven will take at least 6 hours to reach tempurature. Oxidation is a function of both time and temperature – reduce the time part of the equation and the oxide must reduce as well. The infrared oven does not use airflow, as do convection ovens. The airflow associated with convection ovens also damages the die bearings and deposits other oxides and impurities onto the die and die bearing, which, of course, ruins extrusion finish.
By far the best capital improvement we have ever madeJeff Bourgoine
These ovens have enabled us to extrude shapes we never thought possibleJohn Restall
Novatec offers a product far superior in technology and workmanship than their competitorsZane Carpenter