15 Ways to Cut the Power Consumption of Vertical Injection Molding Machines

Injection molding machines are among the largest energy users in a molding plant, and most of that energy goes to the motor and the heating system. Here is where to start.

Equipment

• Size the machine to the part — an oversized machine on a small part wastes a lot of energy.
• Choose a machine with a servo system, which can save 20–70%.
• Use newer heating technologies such as induction or infrared heating, which can cut heating energy by 20–70%.
• Insulate heating and cooling systems to reduce losses.
• Keep drive components well lubricated to avoid energy lost to friction and unstable running.
• Use low-compressibility hydraulic oil to reduce hydraulic losses.
• Use machines that support parallel movements, multi-cavity or multi-component molding — such as two-color rotary machines — for significant savings.
• Replace conventional fixed-pump hydraulic drives with energy-saving drive systems.
• Maintain heating and cooling lines regularly so scale and debris do not reduce their efficiency.
• Keep machines in good condition — an unstable process produces rejects and wastes energy.
• Make sure the equipment suits the product, for example by using a dedicated screw where required.

Process

• Use the shortest cycle that still meets part requirements; high-speed machines suit small, thin parts.
• Unless there is a specific reason not to, follow the machine manufacturer's recommended process settings.
• Save stable machine and process settings for each part and mold to shorten setup time on the next changeover.
• Optimize the process to use lower clamping force and shorter cooling and holding times.