ENERGY MANAGEMENT | PROCESSING
Injection moulders can consider many options to reduce energy use, from hydraulic oils to temperature controllers and smart processing features. By Peter Mapleston
Oiling the wheels of energy efficiency
Sometimes it’s the simplest things that make the biggest difference. When it comes to improving the energy efficiency of an injection moulding opera- tion, new “smart” technologies certainly play their part, in collecting and interpreting data from equip- ment in new ways – a few of those technologies are described in this article. But maybe the first thing to consider should be the hydraulic oil. Just like with a car, some oils work better than others. Just like with a car, many of us go for the budget option, pour it in, and forget about it until the little red light comes on. Mistake. The role of high-performance lubrication is often
overlooked, “with 55% of manufacturing business- es admitting that lubrication is rarely a priority maintenance task,” says Shahina Kazi, Shell Lubricants UK B2B Marketing Manager. “This is a missed opportunity given advanced lubrication can help to protect hydraulic systems from deposits and wear, therefore increasing energy efficiency.” Kazi cites the case of a Hungarian processor that worked with Shell. By trialling injection moulding
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machines with Shell Tellus S4 ME 46, coupled with the Shell LubeAnalyst oil condition monitoring program, the company achieved an average reduction of electricity consumption of 9.5% over a year. “Oil lifespan also increased five-fold, illustrat- ing how increased productivity can be delivered alongside reduced energy costs,” Kazi says. A major factor in how a lubricant can help
reduce energy consumption is its formulation, Kazi notes. “For instance, choosing a high-performance hydraulic fluid with superior filterability and air release properties can help to ensure a cleaner oil, lower pressure loss in the system and a more efficient operation. “However, in order to get the most from the oil,
product choice must be paired with effective lubrication management. This includes trained maintenance teams ensuring correct storage and handling to avoid contamination and to preserve the product’s key characteristics; the correct frequency of oil change to avoid accelerated equipment wear; and regular monitoring of oil
May 2019 | INJECTION WORLD 33
Main image: Using premium oils in injection moulding machines can lead to energy savings
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