1. 1 Evolve in real life A case study Matrix seminar – March 2011 Liviu BÂRSAN

2. 2 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Who am I Liviu BARSAN Diploma in Mechanichal Engineering, Politechnical University, Bucharest Master in Biotechnical Engineering In Valrom since 2005 R&D department – part design & engineering Who am I?

3. 3 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Who we are Who are we? VALROM Industrie srl Romanian company headquarted in Bucharest Shareholders: Valsir Spa (Italy) & Romstal Group (Romania) Established: 1996 330 employees in 2010 (630 in 2008) Sales of 45 mil. € in 2010 (75 mil. € in 2008 ) Market leader in plastic pipes & fittings

4. 4 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Who are we Ukraine logistics production site Moldovia sales Bulgaria sales Who are we? Branches in Bulgaria, Moldavia & Ukraine (production site)

5. 5 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie What we do Heating & sanitary systems; water, gas and sewage networks; waste-water treatment plants Production: plastic pipes & fittings – PE, xPE, PP (homo & random) etc Production facilities: Romania (2 sites) & Ukraine Extrusion (12 lines); injection molding (8 machines) Roto: 4 machines (Caccia & Polivinil) Our business

6. 6 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Roto shop Established in 2003 Machines: 2 Caccia RT 3503F, 1 Polivinil 3500 3C, 1 Polivinil 4500 3C Tools shop – reworking, new moulds, maintenance Grinding process in house – Powder King PK DD 220 Consumption – 60 MT/month Raw materials: PE – compact & foaming, PP (limited) In house design & engineering Roto shop

7. 7 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Roto shop

8. 8 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Roto shop Products range: water tanks, sewage manholes, water-meter chambers, small waste-water treatment plants etc Technology: single, multi-layer, foaming, lining Roto shop

9. 9 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Beginnings Involved in this project since beginning (2009) The material still under development Valrom agreed to test it on industrial scale Our goal – cost cutting by either decrease of oven temperature or cooking time Steps: 1.preliminary evaluation on industrial mould & equipment 2.limited production test (subject to material availability) 3.full production test (at least 24 hours) 4.economical evaluation Evolve - beginnings

10. 10 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Evaluation Preliminary evaluation on industrial equipment: mould & equipment Scope: evaluate how much we can decrease the oven temp and/or cooking time Equipment: Caccia & Polivinil Standard condition: 50 kg for 30 min @ 270 0 C PIAT 155 0 C Thickness: standard 6 mm Material: Evolve M748F, powder, black Part evaluation: Matrix lab Evolve – preliminary evaluation

11. 11 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to Evolve – preliminary evaluation L. Barsan (Marh 2011) - © Valrom Industrie

12. 12 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Evaluation Evolve – preliminary evaluation

13. 13 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Evaluation Evolve – preliminary evaluation

14. 14 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Evaluation No.Cooking conditions Density (g/cm 3 ) Impact strength (J) Aspect 125 @ 260 0 C0.94260.9No pinholes; inside surface looks nice & smooth 223 @ 260 0 C0.93960.9No pinholes; inside surface looks nice & smooth 320 @ 280 0 C0.93760.9No pinholes; inside surface looks bumpy – slightly undercooked 420 @ 285 0 C0.94360.9No pinholes; inside surface looks nice & smooth Evolve – preliminary evaluation

15. 15 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to Evolve – preliminary evaluation L. Barsan (Marh 2011) - © Valrom Industrie

16. 16 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Evaluation Conclusions for evaluation: The new material performs well There is no decrease in product performance It allows decrease of oven temperature and/or cooking time Further tests to follow on either time or temperature decrease Evolve – preliminary evaluation

17. 17 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Trial Small scale trial Scope: confirm preliminary evaluation of product capabilities – lower gas consumption; on larger scale test effect of dry blending Equipment: Polivinil machine running exclusively Evolve for one shift Material: Evolve powder, natural, dry blend pigment (grey) in our facility Lab evaluation: Matrix

18. 18 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Trial Small scale trial Evolve cooks faster Natural better than grey dry blend

19. 19 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Small scale trial Conclusions Standard part thickness 6 mm Standard cycle: 30 min @ 270 0 C Oven temperature reduction: 30 min @ 252 0 C Cycle time reduction: 22 min @ 270 0 C Part evaluation: Matrix lab Trial

20. 20 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Industrial run Scope record of primary data perform economical calculation Two days run on all machines Product range: shafts, water tanks Evolve used exclusively Gas consumption measured accurately before trial during trial Full industrial run

21. 21 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Industrial run Full industrial run Results 2010 average: 617.390 kg processed 285.062 m 3 consumption 24 h before: 2.561 kg PE processed 1.230 m 3 consumption Evolve, in 2 days: 5.338 kg PE 2.181 m 3 consumption

22. 22 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Industrial run Full industrial run

23. 23 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie Conclusions Gas consumption can be decreased by 15% (14,93%) Cooking time can be reduced by 25% The values depends on local conditions: machine efficiency type of material processing conditions Savings: it depends on your conditions Conclusions

24. 24 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie How to 1. Get a gas meter 2. Make it works 3. Register your average consumption 1 month minimum 4. Get enough material for 24 h production 5. Register your consumption before trial How to... in 8 steps

25. 25 What we do Who we are Who am I Roto shop Beginnings Evaluation Trial Industrial run Conclusions How to L. Barsan (Marh 2011) - © Valrom Industrie How to... in 8 steps 6. Run full day production decrease your oven temperature with 18 0 C or decrease your cooking time with 26% 7. Register gas consumption during trial 8. Check quality of the final product Matrix might run some lab test for you Calculate the savings and take the right decision! How to

26. 26 Thank you ! Questions and comments...