+86 17727725162 jqj014950@topstarltd.com

Home / How to compare injection molding machines based on energy consumption and efficiency?

How to compare injection molding machines based on energy consumption and efficiency?

2025/09/08 By le zhan

energy consumption and efficiency 1

When selecting an injection molding machine for your injection molding plant, focus on energy consumption and efficiency. The energy efficiency of injection molding machines directly impacts your overall production costs and operational sustainability. Key features that influence an injection molding machine’s energy consumption and efficiency include its design, drive system, cycle time, and maintenance practices. Therefore, a clear understanding of these features when purchasing an injection molding machine can help reduce energy consumption, lower operating costs, and increase productivity.

Factors Affecting Injection Molding Machines Energy Consumption and Efficiency

Primarily, injection molding energy consumption is influenced mainly by the drive system type, the machine’s clamping force, cycle time, and the material being processed. An efficient injection molding machine minimizes energy consumption while maintaining optimal performance throughout the entire production process. Injection molding machines with hydraulic drive systems tend to be less energy efficient because they require a continuous supply of hydraulic fluid even when the machine is idle. In contrast, all-electric injection moulding machines are more energy-efficient because they consume energy only when needed and utilise electric motors for injection, clamping, and ejection, thereby significantly reducing energy waste and improving precision. Hybrid injection molding machines, which combine hydraulic and electric systems, are gaining popularity for their balance of energy efficiency and flexibility.

Injection Molding Machine 9-3

The Role of the Drive System in Energy Efficiency

The drive system is a key factor in determining the energy consumption of an injection molding machine. Hydraulic injection molding machines have historically been a core component of the injection molding industry. Still, due to their hydraulic pumps and fluid dynamics, they tend to consume significant amounts of energy. Consequently, these machines are generally inefficient, and their hydraulic systems operate continuously, regardless of the machine’s load, resulting in excessive energy consumption.

On the other hand, all electric injection molding machines offer significantly higher energy efficiency. They utilize electric motors at every stage of the injection, clamping, and ejection process. Because the motors operate only when needed, these machines consume less energy, making them ideal for manufacturers seeking to reduce operating costs, particularly in regions such as India and Pakistan. Furthermore, electric injection moulding machines offer greater precision, resulting in shorter moulding cycles and reduced material waste, which further saves energy. For manufacturers seeking to optimize energy consumption, all electric or hybrid injection molding machines offer significant advantages over traditional hydraulic models.

All Electric Injection Molding Machines (9)

How Injection Molding Machine Size and Clamping Force Affect Energy Consumption

The size of the injection moulding machine and the required clamping force are two other key factors that affect energy consumption. Larger machines, especially those used to mold larger parts, typically require more energy to operate. The clamping force needed for a given molding process directly impacts the machine’s energy consumption. Higher clamping forces require more energy to maintain constant pressure during the injection cycle. For example, a larger machine requiring higher clamping forces consumes more energy than a smaller one. However, optimizing clamping force to match the size of the part being molded helps reduce unnecessary energy consumption. Furthermore, all-electric machines often offer better control over clamping force and other variables, leading to more efficient energy use.

Cycle Time and Energy Efficiency

Cycle time is another key factor in energy consumption. Machines with shorter cycle times can reduce energy consumption, especially when the machine is idle. Shorter cycle times also increase productivity, further reducing energy costs per unit of production.

One way to reduce cycle times is to optimise the heating and cooling phases, which consume a significant amount of energy during the injection moulding process. All electric injection moulding machines can precisely control heating and cooling rates, thereby shortening cycle times and minimising energy consumption during these phases. Faster injection moulding cycles also result in less idle time for the machine, thereby reducing overall energy consumption during production. To ensure optimal efficiency, energy consumption during idle periods should be analysed, as the energy consumed while waiting for the following cycle results in unnecessary power consumption. Therefore, choosing an injection molding machine that minimizes idle time and optimizes cycle efficiency can reduce energy consumption and improve production efficiency.

Energy Management Systems and Data Tracking

Under the influence of smart manufacturing, energy management systems (EMS) are increasingly being integrated into injection molding operations to track and optimize energy usage during production. These systems monitor energy consumption in real time, providing valuable insights into which stages of the injection molding process consume the most energy. Through data analysis, manufacturers can identify inefficiencies and make adjustments to reduce energy consumption. Many injection molding machines today come with digital monitoring systems that track energy consumption, cycle time, and other key performance indicators (KPIs). With this data, manufacturers can make informed decisions about equipment settings, production schedules, and maintenance needs to optimize energy efficiency. Furthermore, injection molding machines equipped with innovative energy-saving features can automatically adjust settings to maximize energy efficiency, thereby reducing the need for manual intervention. This allows for maximum energy efficiency while maintaining high production standards.

injection molding machine manufacturer 90-2

Prioritize Energy Efficiency

For manufacturers looking to optimize production processes and reduce costs, they can compare energy consumption and efficiency based on drive systems, cycle times, and machine size. Overall, all-electric injection molding machines offer superior energy savings and precision, making them the most suitable choice for companies looking to reduce operating costs and environmental impact.

Recommended product: https://www.topstarmachine.com/product/teii-series-all-electric-injection-molding-machine90t-460t/

Prev: How to reduce production costs through efficient plastic molding technology?

Next: The Complete Buyer's Guide to Mold Temperature Controller Specifications and Sizing

TRENDING POSTS

HOT TOPIC

Get A Quick Quote