Energy Efficiency

The topic of energy costs is gaining importance for injection-molding production. Apart from raw material, which can account for up to 70% of the manufacturing costs of an injection molded part for packaging applications, the 10% share for energy also represents a significant expense.

Conserving energy has been an important part of Milacron philosophy from the beginning, expressed not only in the performance data of our all-electric machinery, but also in the many details of the entire machine program.

This unified approach is consolidated in an energy-saving package called GreenLine and consists of related elements:

• Detailed consulting including the selection of suitable machinery
• Optimal hardware and software packages
• Identification and documentation of an optimal working point with the accompanying training measures

These three elements act like links of a chain to strengthen each other and produce an ideal result.

How does it work? The answer is easy. Depending on the product and required output, we apply our technical knowledge and current energy measurements to propose the most favorable machine configuration from an energetic perspective. For example, all-electric machinery has become synonymous with energy-efficient injection molding, with an energy-saving potential of up to 70% per application. Another example is the electric drive of the plasticizing unit, one of the most important hardware components for reducing energy consumption in a hydraulic high-performance machine. Measurements show that energy savings of up to 30% are possible. Intelligent hydraulic management can also contribute to energy conservation. The primary objective is to operate the hydraulic system with the greatest possible efficiency. Special electronics control the pump motor to run in the maximum speed range that is energetically optimal.

Proprietary software provides an intelligent charging strategy for the hydraulic accumulators of the injection-molding machine, ensuring that the pressure level in the accumulator is always adapted to the actual requirements of the injection-molding process. The energy used is always used efficiently. A second software element takes an empirical approach to avoid expensive energy peaks. Furthermore, all machine functions are activated sequentially if possible, eliminating all but the absolutely necessary parallel functions.

The GreenLine energy saving package also includes a module that records expended energy. The module’s software shows the energy consumption of each process step for reliable quantification. From an energetic point of view, relevant parameters can be monitored and issued in the form of a report. Processes can in turn be classified based on these reports, giving the user a permanent self-appraisal of the entire process.

We are using all our energy to save you energy. Our application engineers will gladly advise you on all aspects of energy-efficient injection molding.