Moulding plant services Manage resources
Providing chilled water for moulds and cooling water for machines consumes between 11-16% of the total energy used in a typical injection moulding plant.
Reduce heat gain Allowing chilled water to gain heat from the plant environment or circulating it through inoperative machines wastes energy. Use insulated piping between chiller and mould and isolate circuits that are not in production.
Increase temperatures Chilled water temperatures should be maximised; raising set temperature by 1°C decreases chiller operating costs by around 3%.
Optimise running costs Cooling towers can be fitted with VSD fans linked to the sump water temperature, which will cut energy use and improve temperature consistency. Where external temperatures allow, use ambient air to provide ‘free’ pre-cooling. Convert distribution pumps from fixed to VSD operation.
Some words about motors
Motors are big energy users; every kW of fully loaded motor will cost you around €900 a year. Cut that cost by turning off motors that are not contributing to production, installing VSDs to match motor speeds to demand, practice good maintenance, and upgrade to new technology when possible.
Control drying
Drying polymers can use up to 15% of total process energy so should only be performed when and as little as necessary.
Dry the right materials Limit drying to the materials that need it: hygroscopic polymers.
Store materials correctly Hygroscopic polymers will
absorb less moisture if stored in a warm and dry environment in a sealed container. Proper storage pays off for non-hygroscopic materials, too, as surface condensation can occur if moved from a cold storage area to a warm moulding shop.
Improve control systems Replace temperature/time or
process air dew point control with systems that monitor material moisture content to save energy and avoid overdrying, which can harm the resin.
Cut drying costs Install insulation and improve sealing. Recover heat and and, where possible, recycle it for space or water heating.
12 An energy saving guide for injection moulders
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