What are the drawbacks of traditional large-scale injection molding machines?

Injection molding machines

2024/04/08 By Topstar

Traditional large-scale injection molding machines have always been the main plastic manufacturing and production equipment. As everyone’s needs change and the era of Industry 4.0 comes, the shortcomings of traditional large-scale injection molding machines are gradually exposed. In this guide, we will list some of their main core shortcomings and share with you what advantages Topstar’s new injection molding machine can have in breaking through traditional limitations.

High energy consumption

Traditional large-scale injection molding machines usually operate using hydraulic systems, relying on pumps, motors, and valves to control the movement of hydraulic oil. The disadvantage of this method is higher energy consumption. Hydraulic systems also require pumps to run continuously to maintain them, resulting in energy losses through friction, heat generation, and leakage. Although they can operate at high pressure and speed, they also bring increased energy consumption. High-pressure hydraulic systems require more energy to generate and maintain hydraulic pressure, and the rapid movement of machine components results in higher energy requirements for motor operation. In addition, the oversized hydraulic components they are equipped with will also increase energy consumption.

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Limited flexibility and versatility

On the production side, while traditional large injection molding machines can standardize large quantities of parts, they often struggle to accommodate smaller production runs, custom designs, or changes in product specifications. Because they are equipped with fixed molds and tooling to produce specific parts, changes would be very time-consuming and labor-cost-prohibitive. Additionally, they lack the versatility to handle various materials with varying properties and specifications. This may pose limitations for manufacturers looking to use new materials or need to incorporate special additives into the injection molding process. Adjusting the machines when facing different production requirements requires additional setup time, so they lack flexibility and versatility.

Large floor area and space requirements

One of the most obvious shortcomings of traditional large-scale injection molding machines is that they require much floor space. Sufficient floor space is required to accommodate the injection molding machine, auxiliary equipment, and manipulators. This will limit layout flexibility and production capacity. When the floor space and space requirements are large, on the one hand, it will affect operational efficiency, on the other hand, the demand for large space will limit the effective use of other available floor space and limit the layout of other production facilities. And their requirements for production workshops will be higher, requiring a certain area of workshops to accommodate them.

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Advantages of Topstar’s new injection molding machine

Maintaining and repairing traditional large injection molding machines can be complex and time-consuming, requiring specialized skills and expertise. As these machines age, they can experience wear and tear, leading to performance issues, downtime, and increased maintenance costs. Additionally, sourcing replacement parts for older machines can be challenging, especially if the manufacturer has ceased support or is out of business. This reliance on outdated technology can pose significant risks to the company’s operational reliability and competitiveness.

TEII Series All Electric Injection Molding Machine(90T-460T)

Modular design of new injection molding machine

The second major advantage of the new injection molding machine is its modular design, which allows us to adapt to various working conditions.
They comprise interchangeable modules and components that allow manufacturers to adapt according to output material type. At the same time, the modular design allows them to add auxiliary equipment easily, and the injection robot improves overall productivity and efficiency. The modular design also enables easy inspection, repair, or replacement of individual components.

Cleaner motion and smoother operation

They are smaller than traditional large injection molding machines, and Topstar’s new injection molding machines provide cleaner movement and smoother operation through the use of linear rail supports. Reducing vibration, noise, and mechanical interference during operation results in smoother movement. And for industries like medical products, which have higher quality control requirements, they can provide a cleaner production environment. They will not face problems such as oil leakage. In addition, they use special optical screws and good mixing and exhaust to ensure that transparent products do not turn yellow.

Breaking the limitations of traditional injection molding machines

Traditional large-scale injection molding machines have accounted for a large part of the main productivity in the manufacturing industry in the past few decades. However, due to high energy consumption, limited flexibility, and large floor space, they cannot meet the needs of modern manufacturers. Therefore, new injection molding machines have emerged to meet the needs of manufacturers under modern Industry 4.0 for high-precision, high-performance, stable, and reliable injection molding.

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What are the drawbacks of traditional large-scale injection molding machines?