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Moulders that want to reduce their energy bills must look at the entire process chain ' from product design and machine technology to process control and production planning ' to save money. ARBURG applications expert Lukas Krueger showed more than 100 attendees at ARBURG Ltd.'s open house in May, celebrating 100 years of the Hehl company, that adjustments covering eight steps of the entire moulding process can achieve savings of £ thousands per year, depending on the installed machine base and the measures taken.
All these key stages can produce energy savings for the moulder:
Product design
Mould technology
Machine technology
Peripheral technology
Configuration
Process integration
Process control, and
Production planning
Firstly, choose the right material, maintain tolerances suitable for plastics, and look to reduce wall thickness and material quantity. Then, energy can be saved by insulating the mould and clamping platens, tubes and even hot runners, if these are used. You can adjust the tube sizes and measure the energy consumption to find the most efficient tube size. Next, cooling in the mould can be modified to use water more effectively. An efficient design and close contours can reduce cooling time, cutting energy in the water pump.
Machine technology is the biggest single factor to reduce energy. Hybrid and all-electric machines are the most energy efficient, closely followed by energy-optimised hydraulic machines. Regular hydraulics, while robust and capable machines, can use twice the electricity of a modern electric machine. Insulate the cylinder heating zones, using full cylinder insulation if possible. When designing cylinder insulation, consider the optimum temperature regulation for your moulding process. ARBURG has run energy usage tests of fully insulated versus non-insulated cylinders and moulds, for different size machines. Energy savings depend on the electricity rate and machine size, varying from £240 to up to £2,280 for an ARBURG 820 S at 40p / kWh.
Using peripherals, the design and choice of temperature control units can also affect total energy usage. The configuration of the machine for different purposes and volumes will consume energy very differently. It depends on the machine technology; hydraulic, servo-hydraulic or electric.
High volume packaging typically requires a lot of energy due to the constant closing/injecting/opening, whereas low volume parts usually need more cooling time during which, with a servo-hydraulic machine, almost no energy is consumed (the pump idles during holding pressure). So, for packaging, an electric versus servo-hydraulic machine will register much higher energy-saving, but this difference is smaller for low volume work.
The relative energy gain per cycle (or energy saving per part) is higher on slow cycling parts. The energy gain per individual part is lower on fast cycling parts, but many more parts are produced per hour/day so the absolute energy gain over time is higher.
For process integration, automating operations can also reduce some energy used. Automation increases the machine's productivity by having consistent operations on de-moulding or other secondary activities. This leads to reduced cycle times and reduce the overall time required for the machine to be used, cutting energy albeit in small amounts.
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Injection molding is an energy-intensive process, between heating plastic to the melting state and using high-powered injection tools to fill the cavities. Because high energy usage leads to higher financial and environmental costs, which can drive up your per-unit costs, we're exploring ways to increase the energy efficiency of injection molding.
If you're using 20-year-old hydraulic machines, you're using about 25 percent more energy than a hydraulic injection molding machine manufactured and purchased today. It's not surprising that newer equipment is more energy-efficient than older equipment, but what may be surprising is the jump when you switch to an all-electric machine. These oil-free, all-electric options are up to 80 percent more energy efficient than a hydraulic machine made in .
While you may feel that new equipment is impossible, it's important to look at the energy costs required to run a plastic injection molding machine over a period of 10 years. Rarely is the cost of the machine less than the cost of 10 years of energy costs. Choosing to invest in more efficient equipment will save you a significant amount of money, allowing you to lower costs or increase profits while optimizing the energy efficiency of injection molding.
While one of the lowest operating costs of an injection molding company is from the hydraulic oil used in the machines, it often gets overlooked. However, just like a car needs regular oil changes and top-offs, so does the injection molding machine.
Compression, heat, and shear stress break down the oil at a molecular level or cause oxidation, so your equipment is having to work harder and is more likely to break down. Switch to an oil with a high viscosity index that can extend the life of the oil and minimize maintenance.
Hydraulic machines with a fixed-speed motor and variable volume pump require the most care as the oil is used at a higher rate than machines equipped with a servo motor drive which operates with a smaller base energy load.
Another way to enhance the energy efficiency of injection molding is by heating and maintaining the temperature of the barrel, which uses up to 25 percent of the energy input. By fitting proper insulation around the barrel, you can significantly minimize heat loss and reduce the start-up time, thus decreasing energy usage by up to 50 percent.
Trying to manufacture multiple parts from one single machine may save money on overhead at first, but this method of production can quickly increase costs. If you're using a part size or machine whose press tonnage is too large or small for the product, it's impossible to maximize energy efficiency when producing the part. Too much energy will be expended to keep within the machine's capabilities.
It's not uncommon for injection molding companies to simply default to the largest shot size. However, a lower volume can improve how the application nozzle pulls color and works the check ring fully. Consider reducing by just 10 percent in order to make cleanup faster and reduce material waste as well as reduce energy usage.
If you are seeking injection molded plastics or plastic components, reach out to Advanced Plastiform, Inc. Our injection molding company specializes in efficient injection molding that ensures low per-unit pricing and quick lead times. We provide custom plastics across the Southeast and Mid-Atlantic, including North Carolina, South Carolina, Pennsylvania, Maryland, Tennessee, Georgia, and Virginia.
To get in touch with our experts to receive a quote on thermoformed and injection molded projects, call 919-404- or fill out our contact form today.
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