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processing | Energy management

down of the process energy consumption. The system can also optionally be extended to incorporate periph- eral equipment within the same moulding cell. Customers are able to view the energy monitoring in

two different bands: machine energy, which is broken down into barrel heating, drives and system consump- tion; and external energy, which is broken down into mould and hot runner heating, hydraulic pack (core pulling) and peripherals. The totals of these values are calculated to provide energy performance fi gures for the machine and global cell independently. At a machine level, energy consumption can be

Above: The new Energy module in Engel’s e-factory MES solution makes the actual energy require- ment of each consumer transparent

tion of the molten polymer material during production. After each cycle, the system redefi nes the consump- tion limits and priorities. The concept is that the priority of each consumer that received a high amount of power in the previous cycle is reduced and the priority of each consumer that received no or little power is increased. What ecobalance does within a machine or produc-

tion cell is performed on a operation-wide basis by the MES energy module for the entire machine pool. Machines and production cells can be grouped arbitrar- ily to allocate individual consumption limits to different production halls or hall areas. “The more consumers and energy sources that are available to the energy management system, the more effective distribution can be,” Engel says.

Integrated monitoring At French injection equipment supplier Billion, the company’s UK Managing Director Peter Kirkham says the company’s Dixit 3 control system – which is utilised throughout its range of injection moulding machines - is now available with a new integrated energy manage- ment program that provides a comprehensive break-

Below: The integrated energy management system in Billion’s Dixit 3 control monitors machine and auxiliary energy use

analysed by cycle phase to allow the customer to optimise their moulding process for best energy performance. “This type of energy management program not only allows moulders to maximise the benefi t of their modern effi cient machines, but also to have a degree of control when optimising new process cycles,” Kirkham claims. Heinz Gaub, Managing Director Technology & Engineering at Arburg, points to the various energy- saving features built into the company’s Allrounder injection moulding machines, including an energy measurement function in the Selogica control that allows the machine operator to record and analyse both average and periodic power consumption of the running injection moulding process. “This data allows the machine’s power consumption to be optimised, thus reducing the energy consumption per moulded part,” he says.

Identifying potential Arburg customer Hasenthaler Kunststoffverarbeitung, for example, identifi ed potential for reducing energy usage and costs by performing energy measurements on the roughly 30 injection moulding machines it operates. “The primary goal for our holistic approach is to uncover potential for reducing costs and to differenti- ate ourselves from our competitors,” says Hasenthaler Managing Director Stefan Merkert. The company, which is certifi ed to ISO 14001,

introduced an energy management system (ISO 50001) last year. In order to measure actual energy require- ments, an external energy consultant spent four weeks measuring consumption of several dozen consumers, including its 30 injection moulding machines plus cooling, refrigeration and drying plants, as well as lighting systems. “The measurements have shown that you can’t simply compare machine data sheets. The energy requirements of our new electric Allrounder are much lower than those of its hydraulic predecessor [but] moulded part weight, cycle time, material and peripherals

28 INJECTION WORLD | September 2016

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