50 Tips for Reducing 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 machine itself, reducing the overall energy consumption of injection molding factory needs to be considered comprehensively from production management, processing technology and materials, and production workshop support.、
The layout of the production plant focuses on two aspects: meeting the production demand conditions, optimizing the layout according to the production process, while meeting the requirements of flexible energy use under specific production conditions.
1、power supply, in order to meet the stable production of the required power at the same time there is an appropriate margin, not too much surplus to cause excessive reactive energy consumption.
2、Construct efficient cooling water circulation facilities and equip cooling water system with effective insulation and heat preservation system.
3、Optimize the overall production layout of the workshop. A lot of production with sequential processes, reasonable coordination can reduce the time required for turnover and energy consumption, improve production efficiency.
4、to lighting and other plant equipment as far as possible to consider the most effective small unit for separate control.
5、Do regular maintenance of workshop equipment to avoid damage to utilities, which will affect the normal operation of production and thus increase energy consumption.
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 cart" type of injection molding process often means a lot of energy waste.
2、The use of all-electric injection molding machine and hybrid injection molding machine, with excellent energy-saving effect, can save 20-80%.
3、the use of new heating technology, such as electromagnetic induction heating, infrared heating, etc., can achieve 20-70% of the heating energy saving.
4、for heating and cooling systems using effective insulation measures to reduce heat and cold losses.
5、to maintain good lubrication of equipment transmission parts, reduce the increase in energy consumption caused by increased friction or equipment operation instability.
6、Choose low compression hydraulic oil to reduce the waste of energy for hydraulic system work.
7、The use of parallel action, multi-cavity injection, multi-component injection and other processing technologies can significantly save energy.
8、the 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 remarkable.
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、Make sure the injection molding machine is in good working condition. Unstable process may lead to defective products and increase energy consumption.
11、to ensure that the equipment used is suitable for the products processed, such as PVC processing often requires the use of special screws.
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, the number of cavities, heating and cooling water channel, etc., all help to reduce energy consumption.
2、the use of hot runner mold, not only can save materials, reduce energy consumption of material recovery, its molding process itself also has a significant energy-saving effect.
3、Fast cooling and heating molds can significantly save processing energy and achieve better surface quality.
4、Ensure the balanced filling of each cavity, help shorten the molding cycle, ensure the uniformity of product quality, and have excellent energy-saving effect.
5、The use of CAE-aided design technology for mold design, mold flow analysis and simulation can reduce the energy consumption of mold debugging and multiple mold repair.
6、Under the premise of ensuring the quality of products, using lower clamping force for molding can help extend the life of the mold, 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 waterway conditions.、
1、Choose the auxiliary equipment suitable for the capacity, both to meet the work requirements, but not too much affluent.
2、do a good job of equipment maintenance, to ensure that the equipment is in normal working condition. Auxiliary equipment that is not working properly will cause unstable production or even poor quality of the parts, resulting in increased energy consumption.
3、Optimize the working and operation sequence of the host and peripheral devices.
4、Optimize the mutual position of peripheral equipment and production equipment, and make peripheral equipment as close to the host as possible without affecting the operating conditions.
5、Many auxiliary equipment manufacturers provide on-demand energy supply systems, which can achieve significant energy savings.
6、Use quick mold change equipment to reduce the waiting time needed to switch products in production.
Different materials are processed with different energy consumption, while poor management of materials or improper management of recycled materials can cause an increase in production energy consumption.
1、in the premise of meeting the performance of the product, should be preferred to lower processing energy consumption of the material.
2、Under the condition of satisfying the use performance and cost optimization, high flowability materials are preferred.
3、Note that materials from different suppliers may have different process conditions.
4、material drying treatment, it is best to dry with the use, to avoid drying the material back to moisture and waste energy.
5、do a good job of material preservation, to prevent materials mixed with impurities or foreign objects, 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.
1、Use the shortest molding cycle under the premise of meeting the product performance.
2、If there are no special factors to influence, use the processing technology recommended by the supplier for processing as far as possible.
3、For specific products and molds, all stable equipment and process parameters are saved to shorten the transfer time for the next production change.
4、Optimize the process, adopt lower clamping force, shorter cooling time and holding time.
Seven:the use of new technologies
1、Adopt auxiliary molding technology, such as gas-assisted, liquid-assisted, steam-assisted, micro-foam injection molding technology, etc.
2、Using unitized molding solution to reduce intermediate links.
3、Adopt new technologies such as in-mold welding, in-mold painting, in-mold assembly and in-mold decoration.
4、New low-pressure molding technology is adopted to shorten the molding cycle, while the melt temperature can be reduced.
5、Adopt energy regeneration system.
1、Produce high quality products at one time and reduce the defective rate is the biggest energy saving.
2、The maintenance of the whole production system is closely related to the energy consumption. This involves not only the host, but also the surrounding and factory equipment, for example, if the workshop mold change crane failure, the need for manpower to change the mold, is bound to extend the equipment waiting time, resulting in increased energy consumption of equipment. , ,
3、Equipped with workshop energy consumption monitoring system, it is easy for enterprises to implement energy analysis and improvement with purpose.
4、equipment downtime maintenance, not only to check the equipment itself maintenance content and projects, but also to pay attention to the equipment and other systems connected to the condition of the work performance is reliable.
5、Compare with the industry benchmark regularly to see if there is room for further improvement.
6、Establishing reliable contracts and cooperative relationships with suppliers is beneficial to the energy-saving management of enterprises.