For the injection molding factories, the energy consumption of the injection molding process accounts for about 60%. Therefore, effectively reducing the energy consumption of the injection molding machine is an important way to save energy in the injection molding factories.
With the continuous improvement of the energy-saving technology of the injection molding machine itself, reducing the overall energy consumption of the injection molding factories requires a comprehensive consideration from the aspects of production management, processing technology and materials, and supporting facilities for the production workshop.
Production workshops of the injection molding factories
The layout of the production workshop focuses on two considerations: to meet production requirements, while optimizing the layout according to the production process, it also meets the requirements for flexible use under specific production conditions.
Electricity supply, while meeting the power required for stable production, has an appropriate margin, so that the excess will not cause excessive non-functional consumption.
Build efficient cooling water circulation facilities and equip the cooling water system with effective insulation and heat preservation systems.
Optimize the overall production layout of the workshop. Many productions have sequential process coordination, and reasonable coordination can reduce the time required for turnover and energy consumption, and improve production efficiency.
Try to consider the most effective small units for separate control of lighting and other plant equipment.
Perform regular maintenance on workshop equipment to avoid damage to public facilities that affect normal production operations and increases energy consumption.
Injection molding machine in an injection factories
The injection molding machine is a big energy consumer in the injection workshop, and the energy consumption is mainly the motor and the heating part.
Choose the appropriate injection molding machine according to the characteristics of the product. The injection molding of small plastic parts with large-ton injection molding machines often means a lot of energy waste.
The use of all-electric injection molding machines and hybrid injection molding machines has excellent energy-saving effects, which can save energy by 20-80%.
Using new heating technology, such as electromagnetic induction heating, infrared heating, etc., can achieve 20-70% heating energy saving.
Adopt effective insulation measures for heating and cooling systems to reduce heat and cold losses.
Keep the transmission parts of the equipment well lubricated, and reduce the increase in energy consumption caused by increased friction or unstable equipment operation.
Use low-compression hydraulic oil to reduce the waste of working energy in the hydraulic system.
Using parallel action, multi-cavity injection molding, multi-component injection molding, and other processing technologies can significantly save energy.
The traditional mechanical hydraulic injection molding machine also has a variety of energy-saving drive systems, which replace the traditional quantitative pump mechanical hydraulic injection molding machine with a significant energy-saving effect.
Regularly maintain the heating and cooling pipelines to ensure that there are no impurities or scale blockages in the pipelines, and to achieve the designed heating and cooling efficiency.
Ensure that the injection molding machine is in good working condition. Unstable processing may result in defective products and increase energy consumption.
Ensure that the equipment used is suitable for the product being processed, such as PVC processing often requires special screws.
Injection molds in injection molding factories
Mold structure and mold conditions often have a significant impact on the injection molding cycle and processing energy consumption.
Reasonable mold design, including runner design, gate type, number of cavities, heating and cooling water channels, etc., all help reduce energy consumption.
The use of hot runner molds can not only save materials and reduce the energy consumption of material recycling, but the molding process itself also has a significant energy-saving effect.
The profiling of quick-cooling and quick-heating molds can significantly save processing energy consumption and achieve better surface quality.
Ensuring balanced filling of all cavities helps shorten the molding cycle, guarantees the same quality of products, and has excellent energy-saving effects.
The use of CAE-assisted design technology for mold design, mold flow analysis, and simulation can reduce the energy consumption of mold debugging and multiple mold repairs.
Under the premise of ensuring product quality, the use of lower clamping force for molding can help extend the life of the mold, facilitate the rapid filling of the mold, and help save energy.
Do a good job in mold maintenance to ensure effective heating and cooling water channels.
Peripheral equipment of injection molding factories
Choosing the auxiliary equipment suitable for the ability can not only meet the requirements of the work but not have too much wealth.
Do a good job in equipment maintenance to ensure that the equipment is in normal working condition. Auxiliary equipment that does not work properly can cause unstable production and even poor quality parts, resulting in increased energy consumption.
Optimize the coordination and operation sequence of the host and peripheral equipment.
Optimize the mutual position of peripheral equipment and production equipment, and keep the peripheral equipment as close as possible to the host without affecting the operating conditions.
Many auxiliary equipment manufacturers provide systems that provide energy on demand, which can achieve significant energy savings.
Use quick mold change equipment to reduce the waiting time required to switch products in production.
Materials of the injection molding factories
Different material processing consumes different energy, and at the same time, poor management of materials or improper management of recycled materials will increase production energy consumption.
On the premise of meeting product performance, materials with lower processing energy consumption should be selected first.
Under the condition of satisfying the performance and cost optimization, high liquidity materials are preferred.
Note that materials from different suppliers may have different process conditions.
Material drying treatment, it is best to use as soon as it is dried, so as to prevent the material from returning to moisture after drying and wasting energy.
Keep the materials well to prevent the materials from being mixed with impurities or foreign bodies, which will eventually cause defective products.
Some products are allowed to add a certain amount of recycled materials, but attention should be paid to the preservation and cleanliness of recycled materials to avoid defective parts due to unclean materials.
Processing technology of injection molding factories
On the premise of meeting the product performance, use the shortest molding cycle.
If there are no special factors, use the processing technology recommended by the supplier for processing as much as possible.
For specific products and molds, all stable equipment and process parameters are saved to shorten the adjustment time when the next production change is made.
Optimize the process, adopt lower clamping force, shorter cooling time, and pressure holding time.
Adopt new technology for injection molding factories
Adopt auxiliary molding technology, such as gas-assisted, liquid-assisted, steam-assisted, micro-foam injection molding technology, etc.
Adopt a unitized molding scheme to reduce intermediate links.
New technologies such as in-mold welding, in-mold spraying, in-mold assembly, and in-mold decoration are adopted.
The new low-pressure molding technology is adopted to shorten the molding cycle and reduce the melt temperature at the same time.
Adopt an energy regeneration system.
Production management of injection molding factories
One-time production of high-quality products, reducing the defect rate is the greatest energy saving.
The maintenance of the entire production system is closely related to energy consumption. This involves not only the host but also the peripheral and factory equipment. For example, if the mold changing crane in the workshop fails, manual mold change is required, which will inevitably extend the waiting time of the equipment, and increase the energy consumption of the equipment.
Equipped with a workshop energy consumption monitoring system, it is convenient for enterprises to implement energy analysis and improvement purposefully.
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.
Regularly compare with industry benchmarks to see if there is room for further improvement.
Establishing reliable contracts and cooperative relationships with suppliers is beneficial and harmless to enterprise energy conservation management.