Eight ways to reduce the cost of injection molding

First, the production workshop
The layout of the production workshop is mainly considered from two aspects: to meet the production needs, optimize the layout according to the production process, and meet the requirements of flexible energy use under specific production conditions.

1, the power supply, in order to meet the stable production of power required at the same time with an appropriate margin, not too much surplus caused by excessive non-functional consumption.

2. Build efficient cooling water circulation facilities, and equip the cooling water system with effective insulation and insulation system.

3, optimize the overall production layout of the workshop. Many production processes have the coordination, reasonable coordination can reduce the time required for turnover and energy consumption, improve production efficiency.

4, lighting and other plant equipment as far as possible to consider the most effective small unit control.

5, the workshop equipment to do regular maintenance, to avoid damage to public facilities, affecting the normal operation of production, resulting in increased energy consumption.

Second, injection molding machine

Injection molding machine is a large energy consumer in the injection molding workshop, and the energy consumption is mainly two parts: motor and heating.

1, choose the right injection molding machine according to the characteristics of the product. "Big horse car" type injection molding often means a lot of energy waste.

2, the selection of all-electric injection molding machine and hybrid injection molding machine, with excellent energy saving effect, can save 20-80%.

3, the use of new heating technology, such as electromagnetic induction heating, infrared heating, etc., can achieve 20-70% heating energy saving.

4, for heating and cooling system using effective insulation measures to reduce heat and cold losses.

5, keep the equipment transmission parts good lubrication, reduce the increase in energy consumption due to increased friction or unstable equipment operation.

6, the selection of low compression hydraulic oil, reduce the hydraulic system work energy waste.

7, the use of parallel action, multi-cavity injection molding, multi-component injection molding and other processing technology can significantly save energy.

8, the traditional mechanical hydraulic injection molding machine also has a variety of energy-saving drive systems, instead of the traditional quantitative pump mechanical hydraulic injection molding machine energy-saving effect is significant.

9. Regular maintenance of heating and cooling pipes to ensure that no impurities, scale blockage and other phenomena occur inside the pipes to achieve the designed heating and cooling efficiency.

10. Ensure that the injection molding machine is in good working condition. Unstable processing can lead to defective products and increase energy consumption.

11, ensure that the equipment used is suitable for the processed products, such as PVC processing often need to use special screws.

Third, injection mold
Mold structure and mold condition often have a significant impact on injection molding cycle and processing energy consumption.

1, reasonable Mold Design, including runner design, gate form, cavity number, heating and cooling water channels, etc., all help to reduce energy consumption.

2, the use of hot runner mold, not only can save materials, reduce material recovery energy consumption, the molding process itself also has significant energy saving effect.

3, copying fast cooling fast hot mold can significantly save processing energy consumption, and achieve better surface quality.

4, to ensure that the cavity balanced filling, help shorten the molding cycle, to ensure product quality uniformity, has excellent energy saving effect.

5. The use of CAE-assisted design technology for mold design, mold flow analysis and simulation can reduce the energy consumption of mold debugging and multiple mold repairs.

6, under the premise of ensuring product quality, the use of lower clamping force molding, help to extend the life of the mold, conducive to the rapid filling of the mold, help save energy.

7, do mold maintenance work to ensure effective heating and cooling water channel conditions.

Fourth, peripheral equipment
1, choose the appropriate ability of the auxiliary equipment, both to meet the requirements of the work, but not too rich.

2, do equipment maintenance, to ensure that the equipment is in normal working condition. Auxiliary equipment that is not working normally will cause instability in production and even poor quality of parts, resulting in increased energy consumption.

3, optimize the cooperation and operation sequence of the host and peripheral equipment.

4. Optimize the mutual position of peripheral equipment and production equipment, and make peripheral equipment as close to the host as possible without affecting the operating conditions.

5, many auxiliary equipment manufacturers provide on-demand energy supply systems, can achieve significant energy savings.

6, the use of rapid mold change equipment to reduce the waiting time required to switch products in production.

fifth,Materials
The energy consumption of different materials is different, and the poor management of materials or the improper management of recycled materials will lead to increased production energy consumption.

1, under the premise of meeting the performance of the product, the material with lower processing energy consumption should be preferred.

2, under the condition of satisfying the performance and cost optimization, give priority to the selection of high-fluidity materials.

3, note that different suppliers of materials may have different process conditions.

4, material drying treatment, it is best to use with drying, to avoid material moisture waste energy after drying.

5, do a good job of material preservation, to prevent materials mixed with impurities or foreign bodies, ultimately resulting in poor products.

6. Some products are allowed to add certain recycled materials, but attention should be paid to the preservation and cleanliness of recycled materials to avoid bad parts due to unclean materials.

Six, processing technology
1, under the premise of meeting the performance of the product, the shortest molding cycle is used.

2, if there is no special factors, as far as possible to use the supplier recommended processing technology for processing.

3, for specific products and molds, all stable equipment and process parameters are saved to shorten the next replacement production time.

4, optimize the process, using low clamping force, short cooling time and pressure holding time.

Seventh,Adopt new technologies
1, the use of auxiliary molding technology, such as gas assisted, liquid assisted, steam assisted, micro-foam injection molding technology.

2, the use of unit molding scheme to reduce intermediate links.

3. Adopt new technologies such as in-mold welding, in-mold spraying, in-mold assembly and in-mold decoration.

4, the use of new low pressure molding technology, shorten the molding cycle, while reducing the melt temperature.

5. Energy regeneration system is adopted.

Eighth, Production management
1, one-time production of high-quality products, reducing the defective rate is the largest energy saving.

2, the maintenance of the entire production system is closely related to energy consumption. This not only involves the main machine, but also surrounding and factory equipment, for example, if the workshop die changing crane fails, manpower is needed to change the mold, which is bound to extend the waiting time of the equipment, resulting in increased energy consumption of the equipment.

3, equipped with workshop energy consumption monitoring system, easy for enterprises to purposefully implement energy analysis and improvement.

4, when the equipment is shut down for maintenance, not only check the maintenance content and projects of the equipment itself, but also pay attention to the status of the connection between the equipment and other systems, and whether the working performance is reliable.

5, regularly compare with industry benchmarks to see if there is room for further improvement.

6, the establishment of reliable contracts and cooperative relations with suppliers is beneficial to the energy conservation management of enterprises.