Injection molding process to save money in a few sets! 

2022 is indeed an extraordinary year, this year's opening act can be said that everyone did not expect, the

We do not know exactly what path this extraordinary year will lead for the chemical plastics market, but we should all be fully prepared before embarking on a new journey.

As the saying goes: read a thousand books, travel a thousand miles. We hope the dry goods can provide you with the knowledge of ten thousand books and help you walk ten thousand miles in the business field!

For an injection molding product 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 the energy-saving technology of the injection molding machine itself, the reduction of the overall energy consumption of the injection molding factory needs to be considered comprehensively from the aspects of production management, processing technology and materials, and production workshop support.
 

Production workshop

The layout of the production plant focuses on two aspects: to meet the production demand conditions, 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 turnaround time and energy consumption, 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.
 

Injection molding machine

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

1. Choose the right injection molding machine according to the characteristics of the products. The "big horse and small 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. Adopting new heating technology, such as electromagnetic induction heating, infrared heating, etc., can achieve 20-70% heating energy saving.

4. Adopt effective heat insulation measures for heating and cooling systems to reduce heat and cold loss.

5. keep the equipment transmission parts well lubricated 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, multi-component injection, and other processing technologies that can significantly save energy.

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

9. Regular maintenance of heating and cooling pipes to ensure that no impurities, scale blockage, and other phenomena occur inside the pipes to achieve the designed heating and 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 products processed, such as PVC processing often requires the use of special screws.
 

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 runner design, gate form, number of cavities, heating and cooling water channels, etc., can help reduce energy consumption. 2.

2. The use of hot runner molds not only saves materials and reduces energy consumption for material recovery, but also has a significant energy-saving effect in the molding process itself.

3. The shape-shifting, fast-cooling, and fast-heating molds 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. Adopting 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 ensuring product quality, using lower clamping force for molding can help prolong mold life, facilitate mold filling quickly and help save energy.

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

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 or even poor quality of parts and increase 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 z
 

Materials

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

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

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 the recycled materials to avoid bad parts due to unclean materials.
 

Processing technology

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

2. If there are no special factors to influence, use the processing process recommended by the supplier as far as possible.

3. Save all stable equipment and process parameters for specific products and molds to shorten the transfer time for the next production change.

4. Optimize the process by using lower clamping force, shorter cooling time, and holding time.
 

Adopting new technologies

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. Adopting new technologies such as in-mold welding, in-mold painting, in-mold assembly, in-mold decoration, etc.

4. Adopt new low-pressure molding technology to shorten the molding cycle, and at the same time can reduce the melt temperature.

5. Adopt an energy regeneration system.
 

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 the energy consumption of the equipment to increase.

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, and 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.