{"id":89783,"date":"2023-08-29T10:09:47","date_gmt":"2023-08-29T05:39:47","guid":{"rendered":"https:\/\/polymervapooshesh.ir\/?p=89783"},"modified":"2023-09-09T09:35:58","modified_gmt":"2023-09-09T05:05:58","slug":"tm-robotics-guide-to-sustainable-injection-moulding","status":"publish","type":"post","link":"https:\/\/polymervapooshesh.ir\/en\/tm-robotics-guide-to-sustainable-injection-moulding\/","title":{"rendered":"TM Robotics’ guide to sustainable injection moulding"},"content":{"rendered":"

Iranpolymer\/Baspar\u00a0 <\/strong><\/em>According to the\u00a0Journal of Clean Production<\/em>,\u00a0injection moulding may be responsible of up to 90 per cent of the Global Warming Potential (GWP) created by the entire mould lifecycle, mainly caused by energy consumption.<\/p>\n

Here, Dervish Ibrahim, international sales manager at TM Robotics, explains why he believes all-electric\u00a0injection moulding\u00a0machines are the way forward for reducing the process\u2019s environmental impact \u2014 while also helping manufacturers achieve a lower cost-per-part.
\nThe\u00a0Journal of Clean Production\u2019s<\/em>\u00a0findings are wake-up call to manufacturers, particularly as demand for injection moulding processes continue to grow. For example, the market for injection moulded medical devices plastics is expected to see\u00a0booming growth\u00a0between 2023 and 2030.
\nInjection moulding is used to manufacture a huge variety of parts, and has several advantages. They include the ability to mould a wide variety of plastics, good repeatability, consistently high production with low waste and a low-cost-per-part \u2014 the latter is always a priority.
\nMaintaining a low cost-per-part throughout the manufacturing process is vital for reducing costs and delivering a higher product value \u2014 from both the manufacturer\u2019s and the customer\u2019s perspective. While injection moulding can support this, manufacturers\u00a0are also concerned about the energy costs of injection moulding, and how this effects sustainability and the bottom line.
\nIt is claimed that More than 90 per cent of the costs of injection moulding can be attributed to energy use. This mainly applies to the electricity used to power and operate the injection moulding machine. As a result, there has been some debate in industry about the cost and sustainability advantages of hydraulic injection moulding versus all-electric machines.
\nInjection moulding machines powered by a hydraulic motor can produce higher energy levels and higher injection pressures, and the initial cost of the machine is lower. But there are also disadvantages with hydraulic machines. They include the machine\u2019s high consumption of electric energy, because its hydraulic power is connected to an electric power unit that works at maximum capacity during every phase of the moulding process.<\/p>\n

Whole-life cost\u00a0<\/strong><\/p>\n

Although hydraulic injection moulding machines are less expensive initially, it\u2019s important to consider the whole life cost when buying new machines. This was demonstrated by TM Robotics\u2019 customer Lotan, a manufacturer of plastic containers based in Leicestershire, UK. All of the injection moulding machines in Lotan\u2019s production facility are electric, rather than hydraulic.
\nThe company relies on Shibaura Machine\u2019s all-electric\u00a0injection moulding\u00a0machines (IMM) supplied by TM Robotics. The machine is manufactured in-house by Shibaura Machine, formerly known as Toshiba Machine. Performance benefits of the IMM include a range of clamping force from 50 to 2,500 tons, which can be calibrated by a digital direct screw transfer (DST) control for added production flexibility.<\/p>\n

Although all-electric machines are initially more expensive with lower injection pressures, they\u00a0are shown to outperform hydraulic versions in a variety of other ways. Advantages include higher rates and speeds of injection because the all-electric maching relies on toggle clamping rather than direct pressure clamping, which is better for high-speed\u00a0injection moulding.<\/p>\n

Further advantages include improved dry cycle times and the overall stability of the mould itself. Thanks to these benefits, Lotan has ordered several more Shibaura Machine IMMs from TM Robotics, specifically its newest SXIII range of\u00a0injection moulding machines. The SXIII is an enhanced performance model that provides significantly faster injection speeds than traditional moulding equipment.\u00a0As a result, the machine offers a 35 per cent faster cycle time than conventional hydraulic servo IMMs. Lotan also achieved a lower cost-per-mould.<\/p>\n

The bottom line\u00a0<\/strong><\/p>\n

Aside from performance advantages, injection moulding machines must also be easy to use. This guarantees Lotan\u2019s team can stay on-track to meet their key performance indicators (KPIs) by controlling the equipment and keeping it running sustainably. That\u2019s why\u00a0SXIII range of injection moulding machines\u00a0areequipped with Shibaura Machine\u2019s user-friendly controller that connects to Lotan\u2019s programmable logic controller (PLC) for simple, repeatable operations.
\nAll-electric moulding machines also have the edge when it comes to maintenance. With PLC controllability, injection moulding operations can be tie-into the production facilties Internet of Things (IoT) things systems. Data on the IMM\u2019s performance can be collected through sesnors and relaid to the plant\u2019s enterprise resource planning (ERP) or manufacturing execution systems (MES) to support preventive maintance, traceability and quality management.
\nBut, what what about the energy effeciency of all-electric versions hydraulically-powered machines? By using Shibaura Machine\u2019s all-electric IMMs, Lotan has experienced 20 to 40 per cent lower running costs compared with older-fashioned hydraulic machine. Traditional hydraulic injection moulding machines are also less efficient because they consume energy even while idle, whereas all-electric injecting machines only use energy while in action.
\nIndeed, Shibaura Machine\u2019s all-electric IMMs have been found to yield energy savings of 60 per cent compared with European hydraulic servo IMMs. Other performance tests by Shibaura Machine measured its EC650SX-61B IMM, with a clamping force of 650 tons, against a hydraulic servo machine. It delivered a 51 per cent energy reduction.
\nIn another instance, another EC-SX model, the 1,800 ton EC1800SX-155B, was tested against a competing all-electric IMM. Although both machines had the same energy consumption, the Shibaura Machine IMM delivered a faster cycle time, which gave overall energy efficiency savings of 30 per cent.
\nInjection moulding might presently be responsible of up to 90 per cent of the processes GWP. Hower, the performance of all-electric IMMs like Shibaura Machine\u2019s\u00a0\u00a0SXIII and EC-SX show this trend can be reversed, with positive effects on sustainability and also manufacturers\u2019 bottom line.<\/p>\n

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