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Home / Digital Platform All Electric Injection Molding Machine: Enhance Efficiency & Parameter Control

Digital Platform All Electric Injection Molding Machine: Enhance Efficiency & Parameter Control

2025/10/27 By le zhan

Digital Platform All Electric Injection Molding Machine

Manufacturers across many regions lose 15% to 20% of their production time due to communication delays and parameter loss in traditional hydraulic or basic electric injection molding machines. For a 24/7 factory, this translates to 1,080 hours of wasted production annually and millions of dollars in lost revenue. Even worse, 4% to 8% of parts are scrapped due to inconsistent pressure, speed, or temperature control, costing each manufacturer tens of thousands of dollars annually. To address this inefficiency, Topstar has implemented digital platform control on all electric injection molding machine. By using digital control to enable rapid data transmission and employing discrete intelligent drive technology for real-time feedback, these machines can reduce injection molding cycle times by 15-25% and reduce scrap rates to below 2%.

Why Digital Platform Control Can Solve the Pain Points of Traditional Injection Molding

Traditional injection molding machines, whether hydraulic or electric, rely on decentralized control systems. Hydraulic machines use fluid pressure to drive movement, resulting in slow response times and imprecise parameter adjustments. While basic electric injection molding machines reduce liquid waste, they lack coordinated control between various units, such as injection, clamping, and ejection, resulting in communication delays exceeding 200 milliseconds during high-speed cycles. These deficiencies create two problems:

Parameter inconsistency: Pressure or speed drifts mid-cycle, resulting in inconsistent part dimensions.

Cycle time bloat: Delays between process steps can add seconds to each cycle, which, when accumulated, can ultimately lead to hours of wasted production time.

Topstar eliminates these problems with a digital platform in its all electric injection molding machines. Each control unit communicates via a high-speed bus, reducing communication delays to 20 milliseconds or less. A medical component manufacturer using our TEll injection molding machines stated, “After implementing Topstar’s digital control, our scrap rate has dropped to 1.1%, resulting in lower costs and higher efficiency.”

All Electric Injection Molding Machine 9-9

Fast Data and Coordinated Control of All Electric Injection Molding Machine

The digital control core of Topstar’s all electric injection molding machines integrates the injection molding process, creating a unified process unit and a digital framework for seamless operation.

Unified Data Transmission: Topstar connects the injection unit, clamping unit, ejection system, and temperature regulator via a unified control system with a communication protocol. This allows real-time data sharing between units, eliminating signal latency.

Coordinated Motion Control: Unlike traditional machines where each unit operates independently, Topstar’s system synchronizes each step. For example, the injection unit begins advancing when the clamp is nearly fully closed, reducing each cycle by 2-3 seconds.

Centralized Parameter Storage: All process parameters (injection speed, pressure, cooling time, clamping force) are stored in a digital library. Operators can call up preset recipes for different parts in seconds, reducing changeover time by 40% compared to manual adjustments on hydraulic presses.

Practically speaking, this means that consumer product molders can now complete a changeover in 10 minutes when switching between three different plastic parts. This not only speeds up production but also reduces human error.

All Electric Injection Molding Machine 21

Reduce Delays and Maximize Precision in An All Electric Injection Molding Machine

To further improve efficiency, Topstar’s all electric injection molding machines utilize discrete intelligent drive control technology. Topstar connects servo motors directly to each process unit, bypassing intermediate components that cause delays. The results are as follows:

No Communication Latency: With other motors, drive signals pass through multiple controllers, increasing latency. Discrete intelligent drives send signals directly to servo motors, ensuring real-time adjustments to position, speed, and pressure (response time ≤ 10ms).

Optimized Motion Profiles: The system uses algorithms to customize speed and pressure profiles based on the material and part design. For example, it reduces injection speed near the end of the mold cavity to prevent burrs and then increases ejection speed to shorten cycle time—all automatically.

Energy Efficiency: Servo motors consume electricity only when in motion, reducing energy consumption by 30% to 40% compared to hydraulic injection molding machines. Discrete intelligent drives enable the injection molding machine to adapt to material variations, monitoring viscosity and adjusting injection pressure in real time.

Precision injection molding product

Precise parameter monitoring improves quality consistency

The digital platform of the Topstar all electric injection molding machine not only controls parameters but also precisely monitors them, ensuring consistency across thousands of parts.

Injection speed and pressure: Monitored in increments of 0.1 mm/s and 0.1 MPa, respectively. This accuracy prevents under-injection and over-filling, both of which are the most common causes of scrap.

Temperature control: The heater zone (barrel, nozzle) is monitored with an accuracy of ±1°C, which is critical for materials like ABS that degrade at high temperatures or have poor flow properties at low temperatures.

All this data is recorded and accessible via the injection molding machine‘s touchscreen or MES system. This traceability supports compliance with quality standards (such as ISO 13485) required by industries like medical and automotive, as well as detailed process documentation.

Case Study

Let’s consider a packaging manufacturer producing 500ml PP plastic bottles (2-cavity mold, 28g per part):
Previous setup: Hydraulic injection molding machine (cycle time: 45 seconds, scrap rate: 6%, energy consumption: 12kWh/hour).
Topstar all electric injection molding machine: Cycle time: 38 seconds (15.5% reduction), scrap rate: 1.2% (80% reduction), energy consumption: 7.2kWh/hour (40% reduction).
Annual savings: 129,600 more parts produced, tens of thousands of dollars saved, and lower material scrap.

The manufacturer’s production manager concluded, “We used to run three shifts to meet demand. With Topstar’s injection molding machines, we can achieve the same output in two shifts, while also saving on labor costs. The digital control and discrete drive systems have transformed our production operations.”

How They Compare to Hydraulic and Other All Electric Injection Molding Machine

Here’s how Topstar’s digital platform all electric injection molding machines compare to other injection molding machines in the industry:

FeatureTopstar Digital Platform All Electric Injection Molding MachineHydraulic Injection Molding MachineOther Electric Injection Molding Machines
Cycle Time Reduction15–25%0%5–10%
Scrap Rate<2%4–8%2–5%
Energy Use30–40% lower than hydraulicHighest (constant pump operation)10–15% lower than hydraulic
Communication Delay≤20ms200+ms100–150ms
Parameter Precision±0.1mm/s (speed), ±0.1MPa (pressure)±1mm/s, ±1MPa±0.5mm/s, ±0.5MPa
The data is for reference only, taking actual production as an example

Digital Control for Future-Producing

For manufacturers tired of wasting time, materials, and energy, Topstar’s digital platform all electric injection molding machines can fundamentally solve these problems. Their integrated digital control eliminates communication delays, their discrete intelligent drives ensure real-time accuracy, and their comprehensive parameter monitoring enhances machine stability, while reducing costs and improving quality.

 

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