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How much electricity does an electric injection molding machine use?

2024/05/22 By Topstar

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In recent years, many companies have used electric injection molding machines in their production lines. Its cleaner performance and lower energy consumption make it popular with many plastics manufacturers. When purchasing, these manufacturers will also ask how much electricity is used during work. So, in this guide, we’ll answer how much electricity an electric injection molding machine uses and what the relevant factors are.

Injection molding machine power consumption

An injection molding machine is key equipment in the injection molding production process, using various mechanisms to convert raw materials into finished products. Among them, the type and size of the injection molding machine significantly affect its power consumption. Hydraulic machines that utilize hydraulic systems for mold clamping and injection tend to consume more electricity than fully electric machines. The cycle time during the injection molding process will also directly affect power consumption. Longer cycle times will lead to increased energy consumption when producing each part. In addition, they also consume a certain amount of energy and electricity during the heating and cooling process.

Factors affecting power consumption of electric injection molding machines

The size and configuration of the electric injection molding machine play a very important role in its power consumption. The clamping force range of Topstar’s electric injection molding machine is between 90T-460T. Larger machines with higher clamping force and injection capacity may require more power to operate, with their power consumption ranging from 3.8 kWh to 17.9 kWh. Machines running continuously or with long production runs tend to use less energy per component than machines that start and stop frequently. The efficiency of its servo motors and heating elements also affects energy usage. Proper maintenance and calibration of these components are critical to optimize energy efficiency.

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Please note: The experimental data is for reference only, the actual data is determined by the process parameters of the product.

Calculate energy consumption and electricity usage

Since different stages of the molding process have different energy requirements, measuring the power consumption of an electric injection molding machine can estimate energy usage by monitoring parameters such as motor power rating, cycle time, and operating temperature. They usually have a power consumption rating, which is the amount of electricity the machine requires to perform its operations. It includes the electricity used by motors, heaters, pumps, and other components.

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The cycle time of the injection molding process refers to the time required to complete an injection molding cycle, from mold closing to mold opening. The energy consumption formula is equal to power consumption (kW) × cycle time (hours) × operating time (hours/day). Some modern machines are equipped with energy monitoring systems that provide real-time data on energy consumption, allowing operators to identify areas for improvement.

Energy saving features

Electric injection molding machines utilize electric servo motors for all movements, including injection, mold clamping, and ejection. Unlike hydraulic machines, which rely on energy-intensive pumps and valves, electric motors convert electrical energy directly into mechanical motion, significantly reducing energy losses and increasing efficiency. Electric servo motors can also precisely control the entire injection molding process. This precision allows for more accurate control of injection speed, pressure, and position, as well as shortening cycle times and optimizing energy consumption. Topstar’s electric injection molding machines are equipped with regenerative braking systems that capture and store the kinetic energy generated during the deceleration phase and reuse it in subsequent cycles.

Ways to Save Energy Efficiency

Optimizing the energy efficiency of electric injection molding machines can take a multifaceted approach. Regular maintenance is essential to ensure your machine is running at peak efficiency. They themselves are also different from hydraulic machines, which require a pump to run continuously. Electric injection molding machines can switch off the motor during inactive phases. This feature significantly reduces idle energy consumption, ensuring the machine only uses power when necessary. Over time, significant energy savings can be achieved. Finally, using data from energy monitoring systems to identify patterns and trends can help manufacturers optimize machine settings.

Ultimately

The power consumption of electric injection molding machines ranges from 3.8 kWh to 17.9 kWh. Manufacturers can minimize power consumption by considering factors such as machine utilization, energy-saving features, and maintenance practices while maintaining high productivity and product quality.

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