50 Tips to Reduce Energy Consumption in Injection Molding

For an injection molding factory, the energy consumption occupied by the injection molding process accounts for about 60%, thus effectively reducing the energy consumption of the injection molding machine is an important way to save energy in the injection molding factory. With the continuous improvement of energy-saving technology of injection molding machines itself, the reduction of overall energy consumption of injection molding factories needs to be done from production management. Processes and materials. The production plant support and other aspects of comprehensive consideration.

I. Production workshop

The layout of the production plant focuses on two aspects: to meet the production demand, to optimize the layout according to the production process, and to meet the requirements of flexible energy use under specific production conditions.

1. power supply, to meet the stable production of electricity required at the same time there is an appropriate margin, not too much surplus caused by excessive reactive energy consumption.

2. build efficient cooling water circulation facilities and equip the cooling water system with effective insulation and thermal insulation system.

3. Optimize the overall production layout of the workshop. Many production processes have sequential coordination, reasonable coordination can reduce the time and energy consumption required for turnover and improve production efficiency.

4. Consider the lighting and other plant equipment as much as possible to the most effective small unit for separate control.

5. Do regular maintenance of workshop equipment to avoid damage to utilities, which may affect normal operation and increase energy consumption.

II. Injection molding machine

The injection molding machine is the major energy consumer in the injection molding workshop, and the energy consumption is mainly for the motor and heating.

1. Choose the right injection molding machine according to the characteristics of the products. The "big horse-drawn car" type of injection molding process often means a lot of energy waste. 2.

2. Choose an all-electric injection molding machine and hybrid injection molding machine, which have an excellent energy-saving effect and can save 20-80%.

3. Adopt new heating technology, such as electromagnetic induction heating. Infrared heating, etc., can achieve 20-70% heating energy saving.

4. for heating. The cooling system adopts effective insulation measures to reduce heat. Cold loss.

5. maintain good lubrication of equipment transmission parts to reduce the increase in energy consumption caused by increased friction or unstable equipment operation.

6. choose low compression hydraulic oil to reduce the waste of energy for hydraulic system work.

7. Adopt parallel action. Multi-cavity injection molding. Multi-component injection molding and other processing technologies can significantly save energy.

8. Traditional mechanical hydraulic injection molding machine also has a variety of energy-saving drive systems, instead of the traditional dosing pump mechanical hydraulic injection molding machine's energy-saving effect is significant.

9. regular maintenance of heating and cooling pipes to ensure that the internal pipeline is free of impurities. Scale blockage and other phenomena occur, to achieve the design of heating. Cooling efficiency.

10. ensure that the injection molding machine is in good working condition. An unstable process may lead to defective products and increase energy consumption.

11. ensure that the equipment used is suitable for the product being processed, such as PVC processing often requires the use of special screws.

III. Injection Molds

Mold structure and mold condition often have a significant impact on injection molding cycle time and processing energy consumption.

1. reasonable mold design, including flow channel design. Gating form. Several cavities. Heating and cooling water channels, etc., all help to reduce energy consumption. 2.

2. Using hot runner mold, not only can save material and reduce the energy consumption of material recycling but also the molding process itself has a significant energy-saving effect.

3. The shape-shifting, fast-cooling, fast-heating mold can significantly reduce processing energy and achieve better surface quality.

4. Ensuring the balanced filling of each cavity helps to shorten the molding cycle and ensure the uniformity of product quality, which has an excellent energy-saving effect.

5. Adopt CAE-aided design technology for mold design. Mold flow analysis and simulation can reduce the energy consumption of mold debugging and multiple mold repairs.

6. Under the premise of guaranteeing the product quality, using a lower clamping force for molding can help prolong the mold life, facilitate the mold to be filled quickly and help save energy.

7. Do a good job of mold maintenance to ensure effective heating and cooling water channel conditions.

IV. Peripheral equipment

1. Choose the auxiliary equipment with the suitable capacity to meet the work requirements without excessive affluence.

2. Do the maintenance of the equipment to ensure that the equipment is in normal working condition. Auxiliary equipment that does not work properly will cause unstable production and even poor quality of the parts, resulting in increased energy consumption.

3. Optimize the work and operation sequence of the main machine and peripheral equipment.

4. Optimize the mutual position of peripheral equipment and production equipment, and keep peripheral equipment as close to the main machine as possible without affecting the operating conditions.

5. Many auxiliary equipment manufacturers provide energy supply systems on demand, which can achieve significant energy savings.

6. Use quick mold change equipment to reduce the waiting time required to switch products in production.

V. Materials

Different materials consume different amounts of energy to process, and poor management of materials or improper management of recycled materials can cause increased energy consumption in production.

1. Under the premise of meeting the performance of the products, priority should be given to materials with lower processing energy consumption.

2. Under the condition of satisfying the use performance and cost optimization, priority should be given to high flowability materials.

3. pay attention to the material of different suppliers that may have different process conditions.

4. material drying treatment, the best with the drying with the use, to avoid drying the material back to moisture and waste energy.

5. Do a good job of material preservation, to prevent the material from being mixed with impurities or foreign objects, and ultimately causing bad products.

6. Some products are allowed to add certain recycled materials, but attention should be paid to the preservation and cleanliness of recycled materials to avoid bad parts due to unclean materials.

VI. Processing technology

1. Under the premise of meeting the performance of the products, use the shortest molding cycle. 2.

2. If there are no special factors, use the processing technology recommended by the supplier for processing as far as possible.

3. For specific products and molds, save all stable equipment and process parameters to shorten the time of machine adjustment for the next production change.

4. Optimize the process by using a lower clamping force. Shorter cooling time and holding time.

VII. Adopt new technology

1. Adopt auxiliary molding technology, such as gas-assisted, liquid-assisted, steam-assisted, micro-foam injection molding technology, etc.

2. Adopt a unitized molding solution to reduce the intermediate process. 3.

3. Adopt in-mold welding. In-mold coating. In-mold assembly. New technologies such as in-mold decoration.

4. New low-pressure molding technology is adopted to shorten the molding cycle and reduce the melt temperature at the same time.

5. Adopt an energy regeneration system.

VIII. Production management

1. Producing high-quality products at one time and reducing defective rates is the biggest energy saving.

2. The maintenance of the whole production system is closely related to energy consumption. This involves not only the main machine but also the peripheral and factory equipment. For example, if the mold-changing crane in the workshop breaks down and requires manpower to change the mold, it will inevitably prolong the waiting time of the equipment and cause an increase in the energy consumption of the equipment.

3. Equipped with a workshop energy consumption monitoring system, it is easy for enterprises to implement energy analysis and improvement with purpose.

4. When the equipment is shut down for maintenance, not only check the maintenance content and items of the equipment itself, but also pay attention to the condition of the connection between the equipment and other systems, whether the working performance is reliable, etc.

5. regularly compare with industry benchmarks to see if there is room for further improvement.

6. Establish reliable contracts and cooperative relationships with suppliers, which are beneficial to the energy-saving management of enterprises.