Our Recent News

Eight ways to reduce injection molding processing costs

  1. Production workshop

The layout of the production workshop focuses on two aspects: to meet production needs, to optimize the layout according to the production process, and to meet the requirements for flexible energy use under specific production conditions.

  1. The power supply should have an appropriate margin while meeting the power required for stable production, so as to avoid excessive reactive power consumption caused by excessive margin.
  2. Build efficient cooling water circulation facilities and equip the cooling water system with effective insulation and heat preservation systems.
  3. Optimize the overall production layout of the workshop. Many productions have sequential process coordination. Reasonable coordination can reduce the 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 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.
  1. Injection molding machine

The injection molding machine is a major energy consumer in the injection molding workshop, and the energy consumption is mainly composed of motor and heating.

  1. Select the appropriate injection molding machine according to the characteristics of the 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 the increase in energy consumption caused by increased friction or unstable equipment operation.
  6. Use low-compression hydraulic oil to reduce energy waste in the hydraulic system.
  7. The 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. The energy-saving effect of mechanical hydraulic injection molding machines replacing traditional quantitative pumps is significant.
  9. Regularly maintain the heating and cooling pipelines to ensure that there are no impurities, scale blockage, etc. inside the pipelines to achieve the designed heating and cooling efficiency.
  10. Make sure the injection molding machine is in good working condition. Unstable processing can lead to defective products and increased energy consumption.
  11. Ensure that the equipment used is suitable for the products being processed. For example, PVC processing often requires the use of special screws.
  1. Injection mold

Mold structure and mold conditions often have a significant impact on the 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. The use of hot runner molds can not only save materials and reduce energy consumption in material recycling, but the molding process itself also has significant energy-saving effects.
  3. The profiling quick-cooling and quick-heating mold can significantly save processing energy consumption and achieve better surface quality.
  4. Ensure balanced filling of each cavity, which helps shorten the 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 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 extend the life of the mold, help the 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. Peripheral equipment
  2. Choose auxiliary equipment suitable for your ability, which not only meets the work requirements, but will not be too large.
  3. Do a good job in equipment maintenance to ensure that the 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.
  4. Optimize the cooperation and operation sequence of the host and peripheral equipment.
  5. Optimize the mutual positions of peripheral equipment and production equipment, and keep peripheral equipment as close to the host as possible without affecting operating conditions.
  6. Many auxiliary equipment manufacturers provide on-demand energy supply systems, which can achieve significant energy savings.
  7. Use quick mold changing equipment to reduce the waiting time required to switch products during production.
  1. Materials

The 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 the 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 as they are drying to avoid wasting energy when the 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 the preservation and cleanliness of the recycled materials to avoid defective parts due to unclean materials.
  1. Processing technology
  2. On the premise of meeting product performance, use the shortest molding cycle.
  3. If there are no special factors, use the processing technology recommended by the supplier for processing as much as possible.
  4. For specific products and molds, save all stable equipment and process parameters to shorten the machine adjustment time for the next production change.
  5. Optimize the process and use lower clamping force, shorter cooling time and holding time.
  1. Adopt new technologies
  2. Use auxiliary molding technology, such as gas assist, liquid assist, steam assist, micro-foam injection molding technology, etc.
  3. Adopt a unitized molding solution to reduce intermediate links.
  4. Adopt new technologies such as in-mold welding, in-mold spraying, in-mold assembly, and in-mold decoration.
  5. Use new low-pressure molding technology to shorten the molding cycle and reduce the melt temperature.
  6. Use energy regeneration system
  1. Production management
  2. Producing high-quality products at one time and reducing the defective rate is the greatest energy saving.
  3. The maintenance of the entire production system is closely related to energy consumption. This involves not only the host machine, but also peripheral and factory equipment. For example, if the mold-changing crane in the workshop fails and requires manual mold change, the waiting time for the equipment will inevitably be prolonged and the energy consumption of the equipment will increase.
  4. Equipped with a workshop energy consumption monitoring system to facilitate enterprises to implement energy analysis and improvement in a targeted manner.
  5. When the equipment is shut down for maintenance, not only the maintenance content and items of the equipment itself should be checked, but also the condition of the connection between the equipment and other systems, and whether the working performance is reliable, etc.
  6. Regularly compare with industry benchmarks to see if there is room for further improvement.
  7. Establishing reliable contracts and cooperative relationships with suppliers is beneficial to enterprise energy conservation management.
Scroll to Top