For an injection molding factory, energy consumption of injection molding process accounts for about 60%, so effectively reducing energy consumption of injection molding machine is an important way to save energy in injection molding factory. With continuous improvement of energy-saving technology of injection molding machine itself, reducing the overall energy consumption of injection molding plant needs to be comprehensively considered from aspects of production management, processing technology and materials, and production workshop support.

Layout of production workshop focuses on two aspects: under conditions of meeting production requirements, while optimizing layout according to production process, it also meets requirements of flexible energy consumption under specific production conditions.
1. Power supply, while satisfying power required for stable production, there is an appropriate margin, so that excess margin will not cause excessive non-functional consumption.
2. Build high-efficiency cooling water circulation facilities, equip cooling water system with an effective insulation and heat preservation system.
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 and improve production efficiency.
4. Try to consider the most effective small units for separate control of lighting and other plant equipment.
5. Regularly maintain workshop equipment to avoid damage to public facilities, which will affect normal operation of production and increase energy consumption.

Injection molding machine is a large energy consumer in injection molding workshop, and energy consumption is mainly composed of motor and heating.
1. Select appropriate injection molding machine according to characteristics of product. "Big horse-drawn cart" type of injection molding often means a lot of energy waste.
2. Selection of all-electric injection molding machine and hybrid injection molding machine has excellent energy-saving effect, which can save energy by 20-80%.
3. Using new heating technology, such as electromagnetic induction heating, infrared heating, etc., can achieve 20-70% heating energy saving.
4. Use effective thermal insulation measures for heating and cooling systems to reduce heat and cold losses.
5. Keep transmission parts of equipment well lubricated to reduce increase in energy consumption caused by increased friction or unstable operation of equipment.
6. Use low-compression hydraulic oil to reduce waste of working energy in hydraulic system.
7. Use of 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, which can replace traditional quantitative pump mechanical hydraulic injection molding machine with significant energy-saving effect.
9. Regularly maintain heating and cooling pipelines to ensure that there are no impurities, scale blockages and other phenomena inside pipelines, so as to achieve designed heating and cooling efficiency.
10. Make sure injection molding machine is in good working order. An unstable process can lead to defective products and increased energy consumption.
11. Make sure that equipment used is suitable for product being processed. For example, PVC processing often requires a special screw.

 

Mold structure and mold condition 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 not only saves materials and reduces energy consumption for material recycling, but also has significant energy-saving effects in molding process itself.
3. Profiling quick-cooling and quick-heating mold can significantly save processing energy consumption and achieve better surface quality.
4. To ensure balanced filling of each cavity, it will help to shorten molding cycle, ensure uniformity of product quality, and have excellent energy-saving effect.
5. 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 repairs.
6. On the premise of ensuring product quality, using lower clamping force for molding will help prolong life of mold, facilitate rapid filling of mold, 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 suitable for ability, which not only meets work requirements, but also will not be too rich.
2. Do a good job in equipment maintenance to ensure that equipment is in normal working condition. Auxiliary equipment that does not work properly will cause unstable production or even poor quality of parts, resulting in increased energy consumption.
3. Optimize cooperation and operation sequence of host and peripheral devices.
4. Optimize mutual position of peripheral equipment and production equipment, and keep peripheral equipment as close as possible to the host without affecting operating conditions.
5. Many auxiliary equipment manufacturers provide energy-on-demand systems that can achieve significant energy savings.
6. Use quick mold change equipment to reduce waiting time required to switch products in production

Energy consumption of different materials processing is different, and at the same time, poor management of materials or improper management of recycled materials will result in increased production energy consumption.
1. On the premise of satisfying performance of product, materials with lower processing energy consumption should be preferred.
2. Under condition that performance and cost are optimized, high-fluidity materials are preferred.
3. Note that materials from different suppliers may have different process conditions.
4. Material drying, it is best to use it with drying, to avoid waste of energy when material returns to moisture after drying.
5. Do a good job of material preservation to prevent material from being mixed with impurities or foreign matter, which will eventually cause defective products.
6. Some products are allowed to add certain recycled materials, but attention should be paid to preservation and cleanliness of recycled materials to avoid defective parts due to unclean materials.

1. On the premise of satisfying performance of product, use the shortest molding cycle.
2. If not affected by special factors, use processing technology recommended by supplier as much as possible for processing.
3. For specific products and molds, save all stable equipment and process parameters to shorten adjustment time for next production replacement.
4. Optimize process, adopt lower clamping force, shorter cooling time and pressure holding time.

1. Adopt auxiliary molding technology, such as gas-assisted, liquid-assisted, steam-assisted, micro-foaming injection molding technology, etc.
2. Adopt unitized molding scheme to reduce intermediate links.
3. Adopt new technologies such as in-mold welding, in-mold spraying, in-mold assembly and in-mold decoration.
4. Adopt new low pressure molding technology to shorten molding cycle and reduce melt temperature at the same time.
5. Adopt energy regeneration system.

1. One-time production of high-quality products, reducing defect rate is the greatest energy saving.
2. Maintenance of the entire production system is closely related to energy consumption. This not only involves host, but also surrounding and factory equipment. For example, if mold changing crane in workshop fails, manual mold replacement is required, which will inevitably prolong waiting time of equipment and increase energy consumption of equipment.
3. Equipped with workshop energy consumption monitoring system, which is convenient for enterprises to implement energy analysis and improvement purposefully.
4. When equipment is shut down for maintenance, not only check maintenance content and items of equipment itself, but also pay attention to condition of connection between equipment and other systems, and whether working performance is reliable.
5. Regularly compare with industry benchmarks to see if there is room for further improvement.
6. Establish reliable contracts and cooperative relations with suppliers, which are beneficial and harmless to enterprise energy conservation management.