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What are the typical energy savings of an all electric injection molding machine?

2024/08/19 By Topstar

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Throughout the injection molding production process, people are concerned about quality efficiency and energy conservation during the molding process. Rising energy costs and growing environmental concerns are prompting manufacturers to pursue more sustainable and cost-effective production methods. The all electric injection molding machine has the best energy-saving effect in injection molding, and they can save significantly more energy than hydraulic injection molding machines.

Energy consumption of all-electric injection molding machines

The key difference between all-electric injection molding machines and traditional hydraulic presses is the use of servo motors, which independently drive all major functions of the machine (such as injection, clamping and ejection) and perform precise control. Unlike hydraulic systems that continuously run pumps to maintain pressure, all-electric machines only consume energy when the motor runs, significantly reducing overall energy consumption. On this basis, Topstar’s TE ll series all-electric injection molding machines use the intelligent drive control mode to reduce the impact of communication delays on the high-speed operation of servo motors, realize real-time control of servo motors, improve the accuracy of position, speed and pressure control, and increase the response speed by 8-16 times.

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You can observe their energy-saving effects at all stages of the production process. For example, the system maintains pressure during the hold phase to ensure the mold is filled correctly. In contrast, a hydraulic press would continue running the pump, consuming much energy. They minimize energy consumption while using servo motors to control and maintain pressure precisely. This results in an energy consumption of 30% to 70% lower than that of a hydraulic press.

Energy savings in high-volume production

The energy savings of all-electric injection molding machines are more intuitive in high-volume production environments, such as home appliances, consumer goods, and the medical industry.

All-electric injection molding machines can operate with high precision and repeatability in high-volume production and consume less energy. Topstar’s TE ll series injection molding machines use an integrated injection seat in the injection unit, which makes control more precise under a highly rigid structure. Throughout the high-speed injection cycle, the servo motor can quickly and efficiently provide the required force, minimizing energy consumption during the injection phase. Once the part is molded, the motor can immediately reduce power consumption during the holding and cooling phases because these two phases require less force.

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In addition, all-electric machines offer energy efficiency beyond just direct power consumption. These machines generally generate less heat during operation, reducing the need for auxiliary cooling systems. This further reduces overall energy usage and forms a more stable and controllable production environment.

The impact of all electric injection molding machine on energy costs

Energy costs have a direct impact on manufacturers’ profits. The power consumption of TE II series injection molding machines ranges from 3.8KWh to 17.9KWh, and the overall energy consumption is generally 30% to 70% lower than that of hydraulic presses. In addition to direct savings on electricity bills, all-electric injection molding machines have other cost-saving advantages. They can reduce the need for cooling systems and auxiliary equipment, reducing energy consumption and related maintenance and operating costs. Their overall mechanical design is simpler, and the non-contact tie rods used do not require lubrication, reducing the strain on the tie rods and reducing maintenance costs and downtime. The low damping brought by the linear guides makes the operation smoother. This stable performance and energy usage enable manufacturers to better control operating expenses, making planning and optimizing production easier.

Environmental benefits from energy saving

The energy-saving effect of all-electric injection molding machines can also bring certain environmental advantages, especially for industries with demanding production environments. They can reduce greenhouse gas emissions associated with energy use. Traditional hydraulic presses have high energy consumption and greater carbon emissions. All-electric machines can reduce energy use by up to 70%, helping to reduce the amount of carbon dioxide and other greenhouse gases emitted into the atmosphere. All-electric machines will not leak oil, etc., and their high net capacity is more suitable for use in industries such as medicine and optics.

Environmental benefits from energy saving(1)

Leverage energy saving to bring you greater profits.

The advantages of all-electric injection molding machines are not limited to energy saving. They have precision, reliability and flexibility, making them ideal for mass production and precision manufacturing applications. As energy costs continue to rise, all-electric injection molding machines have been widely adopted in various industries. With our intelligent integrated injection molding machines and expert support, we can provide you with a comprehensive injection molding solution.

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