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How to reduce the process cost of injection molding machine?

TIME:2021-01-11 Share

How to reduce the process cost of an injection molding machine is a problem that many people in the industry care about. Here, Lisong Machinery will introduce you to 6 methods to reduce the injection process:

1. Production workshop
The layout of the production workshop focuses on two considerations: to meet production requirements, while optimizing the layout according to the production process, it also meets the requirements for flexible energy use under specific production conditions.
1.1. Power supply, while meeting the power required for stable production, has an appropriate margin, so that the excess margin will not cause excessive non-functional consumption.
1.2. Build efficient cooling water circulation facilities, and equip the cooling water system with effective insulation and heat preservation systems.
1.3. Optimize the overall production layout of the workshop. Many productions have sequential process coordination, and reasonable coordination can reduce the time required for turnover and energy consumption, and improve production efficiency.
1.4. Try to consider the most effective small units for separate control of lighting and other plant equipment.
1.5. Perform regular maintenance on workshop equipment to avoid damage to public facilities that affects the normal operation of production and increases energy consumption.

2. Injection molding machine
The injection molding machine is a big energy consumer in the injection molding workshop. The energy consumption is mainly the motor and heating.
2.1. Choose a suitable injection molding machine according to the characteristics of the product. "Big horse-drawn cart" injection molding process often means a lot of energy waste.
2.2. All-electric injection molding machines and hybrid injection molding machines are selected, which have excellent energy-saving effects and can save energy by 20-80%.
2.3. Using new heating technology, such as electromagnetic induction heating, infrared heating, etc., can achieve 20-70% heating energy saving.
2.4. Use effective heat preservation and insulation measures for heating and cooling systems to reduce heat and cold losses.
2.5. Keep the transmission parts of the equipment well lubricated and reduce the increase in energy consumption due to increased friction or unstable equipment operation.
2.6. ​​Use low-compression hydraulic oil to reduce the energy waste of the hydraulic system.
2.7. Using parallel action, multi-cavity injection, multi-component injection and other processing technologies can significantly save energy.
2.8. The traditional mechanical hydraulic injection molding machine also has a variety of energy-saving drive systems, which replace the traditional quantitative pump mechanical hydraulic injection molding machine with a significant energy saving effect.
2.9. Regularly maintain the heating and cooling pipelines to ensure that there are no impurities, scale blockages, etc. inside the pipelines, and to achieve the designed heating and cooling efficiency.
2.10. Ensure that the injection molding machine is in good working condition. Unstable processing may lead to defective products and increase energy consumption.
2.11. Ensure that the equipment used is suitable for the product being processed, such as PVC processing often requires special screws.

plastic injection molding machine
3.injection mold
Mold structure and mold conditions often have a significant impact on the injection molding cycle and processing energy consumption.
3.1. Reasonable mold design, including runner design, gate type, number of cavities, heating and cooling channels, etc., all help reduce energy consumption.
3.2. The use of hot runner molds can not only save materials and reduce the energy consumption of material recovery, but the molding process itself also has a significant energy saving effect.
3.3. Profiling fast cooling and fast heating molds can significantly save processing energy consumption and achieve better surface quality.
3.4. Ensure that each cavity is filled in a balanced manner, which helps to shorten the molding cycle, ensure the uniformity of product quality, and has an excellent energy-saving effect.
3.5. Using CAE-aided design technology for mold design, mold flow analysis and simulation can reduce the energy consumption of mold debugging and multiple mold repairs.
3.6. ​​Under the premise of ensuring product quality, using a lower clamping force for molding can help extend the life of the mold, facilitate the rapid filling of the mold, and help save energy.
3.7. Do a good job in mold maintenance to ensure effective heating and cooling water channels.

4. materials
Different material processing consumes different energy, and at the same time, poor management of materials or improper management of recycled materials will increase production energy consumption.
1. On the premise of meeting product performance, materials with lower processing energy consumption should be selected first.
2. Under the condition of satisfying the performance and cost optimization, preferentially select high-fluidity materials.
3. Note that materials from different suppliers may have different process conditions.
4. The material is dried, it is best to use it as it is dried, so as to avoid the material returning to moisture after drying and wasting energy.
5. Keep the materials well to prevent the materials from being mixed with impurities or foreign bodies, which will eventually cause defective products.
6. ​​Some products allow the addition of certain recycled materials, but attention should be paid to the preservation and cleanliness of recycled materials to avoid defective parts due to unclean materials.

5.processing technology
5.1. Under the premise of meeting product performance, use the shortest molding cycle.
5.2. If there are no special factors, try to use the processing technology recommended by the supplier 5.for processing.
5.3. For specific products and molds, all stable equipment and process parameters are saved to shorten the adjustment time for the next production change.
5.4. Optimize the process, adopt lower clamping force, shorter cooling time and pressure holding time.

6. adopt new technology
6. 1. Adopt auxiliary molding technology, such as gas-assisted, liquid-assisted, steam-assisted, micro-foam injection molding technology, etc.
6. 2. Adopt unitized molding scheme to reduce intermediate links.
6. 3. Adopt new technologies such as in-mold welding, in-mold spraying, in-mold assembly, and in-mold decoration.
6. 4. The use of new low-pressure molding technology shortens the molding cycle and reduces the melt temperature.
6. 5. Adopt energy regeneration system.

The above is the introduction about reducing the process cost of injection molding machine. For more relevant information, please leave us a message and reply you within 24 hours.

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