For an injection molding product factory, injection molding process accounts for approximately 60% of energy consumption. Therefore, effectively reducing energy consumption of injection molding machine is an important way for injection molding factories to save energy. As energy-saving technology of injection molding machine itself continues to improve, reducing overall energy consumption of injection molding factory requires comprehensive consideration from aspects such as production management, processing technology and materials, and production workshop facilities.

 

Layout of production workshop focuses on two aspects: to meet production needs, to optimize layout according to production process, and to meet requirements for flexible energy use under specific production conditions.
1. Power supply must have an appropriate margin while meeting power required for stable production, so as to avoid excessive reactive power consumption caused by excessive margin.
2. Build efficient cooling water circulation facilities, equip cooling water system with effective insulation and heat preservation systems.
3. Optimize the overall production layout of workshop. Many productions have sequential process coordination. Reasonable coordination can reduce time and energy consumption required for turnover, improve production efficiency.
4. Try to consider the most effective small units for separate control of lighting and other factory equipment.
5. Perform regular maintenance on workshop equipment to avoid damage to public facilities, which may affect normal production operations and increase energy consumption.

Injection molding machine is a major energy consumer in injection molding workshop, and energy consumption is mainly composed of motor and heating.
1. Choose appropriate injection molding machine according to characteristics of product. "Big horse and small cart" type injection molding processing often means a lot of energy waste.
2. Use all-electric injection molding machines and hybrid injection molding machines, which have excellent energy-saving effects and can save 20-80% of energy.
3. Using new heating technologies, such as electromagnetic induction heating, infrared heating, etc., can achieve 20-70% heating energy saving.
4. Use effective insulation measures for heating and cooling systems to reduce heat and cold losses.
5. Maintain good lubrication of equipment transmission parts and reduce increase in energy consumption caused by increased friction or unstable equipment operation.
6. Use low-compression hydraulic oil to reduce energy waste in hydraulic system.
7. Use of processing technologies such as parallel action, multi-cavity injection molding, and multi-component injection molding can significantly save energy.
8. Traditional mechanical hydraulic injection molding machines also have a variety of energy-saving drive systems. Energy-saving effect of mechanical hydraulic injection molding machines replacing traditional quantitative pumps is significant.
9. Regularly maintain heating and cooling pipelines to ensure that there are no impurities, scale blockage, etc. inside pipelines to achieve designed heating and cooling efficiency.
10. Make sure injection molding machine is in good working condition. Unstable processing can lead to defective products and increased energy consumption.
11. Ensure that equipment used is suitable for products being processed. For example, PVC processing often requires use of special screws.

 

Mold structure and mold conditions often have a significant impact on injection molding cycle 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. Use of hot runner molds can not only save materials and reduce energy consumption in material recycling, but molding process itself also has significant energy-saving effects.
3. Profiling quick-cooling and quick-heating mold can significantly save processing energy consumption, achieve better surface quality.
4. Ensure balanced filling of each cavity, which helps shorten molding cycle, ensures product quality uniformity, and has excellent energy-saving effects.
5. Using CAE-assisted design technology for mold design, mold flow analysis and simulation can reduce energy consumption of mold debugging and multiple mold repairs.
6. On the premise of ensuring product quality, using lower clamping force for molding will help extend life of mold, help mold to be filled quickly, and help save energy.
7. Do a good job in mold maintenance to ensure effective heating and cooling water channel conditions.

1. Choose auxiliary equipment that suits your ability, which not only meets work requirements, but will not be too large.
2. Do a good job in equipment maintenance to ensure that equipment is in normal working condition. Auxiliary equipment that is not working properly can cause unstable production and even poor quality of parts, resulting in increased energy consumption.
3. Optimize cooperation and operation sequence of host and peripheral equipment.
4. Optimize mutual positions of peripheral equipment and production equipment, and keep peripheral equipment as close to host as possible without affecting operating conditions.
5. Many auxiliary equipment manufacturers provide on-demand energy supply systems, which can achieve significant energy savings.
6. Use quick mold changing equipment to reduce waiting time required to switch products during production.

Energy consumption of processing different materials is different. At the same time, improper management of materials or improper management of recycled materials will cause an increase in production energy consumption.
1. On the premise of meeting product performance, materials with lower processing energy consumption should be given priority.
2. Under conditions of satisfying performance and cost optimization, give priority to high-fluidity materials.
3. Note that materials from different suppliers may have different process conditions.
4. When drying materials, it is best to use them immediately after drying to avoid wasting energy when materials return to moisture after drying.
5. Preserve materials well to prevent them from being mixed with impurities or foreign matter, which will eventually cause defective products.
6. Some products are allowed to add a certain amount of recycled materials, but attention should be paid to preservation and cleanliness of recycled materials to avoid defective parts due to unclean materials.

 

1. On premise of meeting product performance, use the shortest molding cycle.
2. If there are no special factors, use processing technology recommended by supplier for processing as much as possible.
3. For specific products and molds, save all stable equipment and process parameters to shorten machine adjustment time for next production change.
4. Optimize process and use lower clamping force, shorter cooling time and holding time.

1. Use auxiliary molding technology, such as gas assist, liquid assist, steam assist, micro-foam injection molding technology, etc.
2. Adopt a unitized molding solution to reduce intermediate links.
3. Adopt new technologies such as in-mold welding, in-mold spraying, in-mold assembly, and in-mold decoration.
4. Use new low-pressure molding technology to shorten molding cycle and reduce melt temperature.
5. Use energy regeneration system.

1. Producing high-quality products at one time and reducing defective rate is the greatest energy saving.
2. Maintenance of the entire production system is closely related to energy consumption. This not only involves main machine, but also peripheral and factory equipment. For example, if mold-changing crane in workshop fails and requires manual mold change, waiting time for equipment will inevitably be prolonged and energy consumption of equipment will increase.
3. Equipped with a workshop energy consumption monitoring system to facilitate enterprises to implement energy analysis and improvement in a targeted manner.
4. When equipment is shut down for maintenance, not only maintenance content and items of equipment itself should be checked, but also condition of connection between equipment and other systems, and whether working performance is reliable, etc.
5. Regularly compare with industry benchmarks to see if there is room for further improvement.
6. Establishing reliable contracts and cooperative relationships with suppliers is beneficial to enterprise energy conservation management.