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

Layout of production workshop focuses on two aspects: under conditions of meeting production demand, optimize layout according to production process, and at the same time meet requirements of flexible energy use under specific production conditions.
1. Power supply, while satisfying power required for stable production, has an appropriate margin, so that excess margin will not cause excessive reactive power consumption.
2. Build high-efficiency cooling water circulation facilities and equip cooling water system with an effective insulation system.
3. Optimize overall production layout of workshop. A lot of production has sequential process cooperation, reasonable cooperation can reduce time required for turnover and energy consumption, and improve production efficiency.
4. For plant equipment such as lighting, try to use the most effective small units for separate control.
5. Regularly maintain equipment in workshop to avoid damage to public facilities that affects normal operation of production and increases energy consumption.

 

Injection molding machine is a major energy consumer in injection molding workshop, energy consumption is mainly two parts 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. Use of all-electric injection molding machines and hybrid injection molding machines has excellent energy-saving effects, 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. Adopt effective thermal insulation measures for heating and cooling systems to reduce heat and cold losses.
5. Keep transmission parts of equipment well lubricated, and reduce increase in energy consumption caused by increased friction or unstable operation of equipment.
6. Use low-compression hydraulic oil to reduce energy waste in hydraulic system.
7. Using 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, replacing traditional quantitative pump mechanical hydraulic injection molding machine with remarkable energy-saving effect.
9. Regularly maintain heating and cooling pipelines to ensure that there are no impurities and scale blockages inside pipelines to achieve designed heating and cooling efficiency.
10. Make sure that injection molding machine is in good working condition. Unstable processes 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 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 channels, etc., all help to reduce energy consumption.
2. Use of hot runner molds can not only save materials and reduce energy consumption for material recycling, but molding process itself also has a significant energy-saving effect.
3. Profiling fast cooling and fast heating mold can significantly save processing energy consumption and achieve better surface quality.
4. Ensure that each cavity is filled evenly, which is helpful to shorten molding cycle, ensure uniformity of product quality, and have 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. Under premise of ensuring product quality, using lower clamping force for molding can help prolong life of mold, facilitate quick 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 can not only meet work requirements, but also not have too much wealth.
2. Do a good job in equipment maintenance to ensure that equipment is in normal working condition. Auxiliary equipment that is not working 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 equipment.
4. Optimize mutual position of peripheral equipment and production equipment, make peripheral equipment as close as possible to host machine 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 change equipment to reduce waiting time for switching products during 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 increase energy consumption of production.
1. Under premise of satisfying performance of product, materials with lower processing energy consumption should be selected first.
2. Under condition of satisfying performance and cost optimization, high fluidity materials are given priority.
3. Note that materials from different suppliers may have different process conditions.
4. It is best to use material as it dries, so as to avoid waste of energy 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 some 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 there are no special factors, use processing technology recommended by supplier as much as possible for processing.
3. For specific products and molds, all stable equipment and process parameters are saved to shorten adjustment time for next production replacement.
4. Optimize process, adopt lower clamping force, shorter cooling time and 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. New low-pressure molding technology is adopted 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 involves not only main machine, but also peripheral and factory equipment. For example, if mold changing crane in workshop fails, manpower is required to change mold, which will inevitably prolong waiting time of equipment and increase energy consumption of equipment.
3. Equipped with workshop energy consumption monitoring system, it is convenient for enterprises to carry out 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, whether working performance is reliable, etc.
5. Regularly compare with industry benchmarks to see if there is room for further improvement.
6. Establishing a reliable contract and cooperative relationship with suppliers is beneficial and harmless to energy-saving management of enterprise.