Injection Molding Machine Case Study: Energy Savings from All Electric Conversion

In the evolving manufacturing industry, energy efficiency has become a crucial consideration for companies seeking to optimize production, minimize costs, and mitigate environmental impact. For many companies that rely on injection molding machine to produce plastic parts, the energy consumption of hydraulic systems has historically been a significant operating expense. However, with the growing demand for sustainability and reduced energy consumption, many manufacturers are turning to all-electric injection molding machines as a solution to these challenges.

Differences Between Hydraulic and All-Electric Injection Molding Machines

The core difference between hydraulic and all electric injection molding machines lies in their power sources and mechanisms. Hydraulic injection molding machines rely on fluid pressure to drive key actions in the molding process, including injection, clamping, and ejection. While these machines are powerful and efficient in many applications, the constant energy consumption required for hydraulic pumps, motors, and valves compromises their energy efficiency.

All electric injection molding machines, on the other hand, are driven by electric motors that control every step of the molding cycle. These machines are designed to deliver high precision and energy efficiency, using only the energy required for each specific action. Electric drive systems enable more controlled motion, faster response times, and greater accuracy. Because the machines eliminate the need for hydraulic pumps and fluids, they require significantly less energy, offering a clear energy advantage over hydraulic presses.

Transitioning to All Electricity: Identifying the Need for Energy Savings

For many companies, energy costs are one of their most significant operating expenses. In industries like automotive, electronics, and consumer goods, the constant operation of injection molding machines quickly leads to substantial energy consumption, especially when hydraulic systems are used. The need to reduce energy consumption is driving manufacturers to explore more efficient technologies.

The transition to all electric injection molding machines addresses this need by providing a direct solution for reducing energy consumption. According to industry reports, all electric injection molding machines can reduce energy consumption by up to 50% compared to hydraulic presses, depending on the machine size and application. This reduced energy consumption not only lowers electricity bills but also contributes to a company’s sustainability by reducing its carbon footprint.

Case Study Overview: Transitioning to All-Electricity

To better understand the real-world impact of this transition, we worked with a mid-sized manufacturer that produces consumer goods using injection molding technology. They had been operating a fleet of hydraulic injection molding machines for years, but rising energy costs were threatening their profitability. After evaluating various options for reducing energy consumption, the company decided to convert its injection molding machines to all-electric machines.

The transition began with the installation of two all electric injection molding machines, which were expected to replace two aging hydraulic systems. Initially, they focused on achieving significant energy savings while maintaining the same production efficiency and quality levels. The results of this pilot project provided extensive data demonstrating how all electric injection molding machines positively impact energy use and overall operating costs.

Achieved Energy Savings

Once they installed and operated the all electric machines, the machines began closely monitoring their energy consumption and comparing it to that of the hydraulic systems. Within the first six months, the company reduced overall energy consumption by 25%. A variety of factors, including the precision of the electric drive system and the absence of energy losses associated with hydraulic fluid and pumps, attributed to this reduction.

Furthermore, they require less maintenance than hydraulic equipment, further reducing operating costs. With fewer parts subject to wear, such as hydraulic pumps and seals, the machines experience fewer breakdowns and unplanned downtime. This results in higher overall uptime and productivity, ultimately contributing to cost savings.

Environmental Impact and Sustainability Benefits

In addition to financial and operational benefits, transitioning to electric injection molding machines also offers significant environmental benefits. Lower greenhouse gas emissions, especially for manufacturers that rely on non-renewable energy sources, directly result from reduced energy consumption. By reducing energy consumption, they reduce their carbon footprint, align with global sustainability goals, and enhance their reputation as environmentally friendly companies.

Furthermore, eliminating hydraulic fluid not only reduces energy consumption but also helps them avoid the environmental impact of handling and replacing hydraulic fluid. This move not only improves their environmental profile but also reduces the need for hazardous materials management at their facility.

Why All-Electric Is the Future of Injection Molding

This company’s case study clearly demonstrates the significant energy savings and operational benefits of converting to all-electric injection molding machines. By reducing energy consumption, lowering maintenance costs, and improving sustainability, companies can achieve greater efficiency while reducing their environmental impact. With rising energy costs and increasing pressure to adopt more sustainable production methods, transitioning to all-electric injection molding machines is an investment that pays off in both the short and long term.