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Home / Guide to Hybrid Injection Molding Machine: Servo-Hydraulic Synergy for 40% Energy Savings

Guide to Hybrid Injection Molding Machine: Servo-Hydraulic Synergy for 40% Energy Savings

2025/12/17 By le zhan

Hybrid Injection Molding Machine 1-3

For today’s manufacturers, balancing productivity, quality, and sustainability is crucial. Traditional hydraulic injection molding machines, while reliable, consume a significant amount of energy; all-electric injection molding machines solve the energy problem, but have high initial costs and limited flexibility in heavy-duty applications. A hybrid injection molding machine combines the best of both worlds, integrating the powerful force of hydraulic systems with the efficiency of servo technology. Using servo-hydraulic synergy technology, an average of 40% energy can be saved—without compromising speed, precision, or load capacity.

How does servo-hydraulic synergy technology improve the efficiency of a hybrid injection molding machine?

Traditional hydraulic injection molding machines use a constant-speed motor to drive the hydraulic pump, even when the machine is idle (for example, during part cooling or demolding). This “always-on” design wastes up to 60% of energy. All-electric injection molding machines equip each axis with a servo motor, but they fall short when high torque is required. Hybrid injection molding machines solve both problems by combining servo motors with hydraulic systems; they only activate the motor when pressure is needed and use hydraulic power to handle heavy loads.

Specifically, during injection, the servo motor drives the hydraulic pump to deliver precise pressure, perfectly matching the resin flow requirements. When the machine pauses, the servo motor shuts off, thus stopping energy waste. This synergistic effect is not simply “reducing power consumption,” but rather “smarter energy utilization.”

How does servo-hydraulic synergy technology improve the efficiency of a hybrid injection molding machine

Precision and Stability Beyond Energy Savings in a Hybrid Injection Molding Machine

Energy savings are its most significant advantage, but the actual value of hybrid injection molding machines lies in the synergy between the servo-hydraulic system and the precision and defect reduction it enables. The stable pressure control of hybrid injection molding machines eliminates uneven filling, which can lead to warping. Traditional hydraulic injection molding machines, due to their constant motor speed, generate excessive flow and release it through relief valves, resulting in energy waste and system instability. Hybrid injection molding machines avoid this by regulating the pump speed with a servo motor, ensuring that the hydraulic pressure remains within ±0.5 bar of the set value.

This stability is crucial for high-precision parts, such as medical syringes or electronic housings, where even a 0.1 mm deviation can render a part unusable. Topstar’s hybrid injection molding machines, under a unified control system, can monitor melt temperature, injection speed, and clamping force, sending the data to the servo controller for fine-tuning during the production cycle. For a consumer electronics customer manufacturing phone cases, this means consistent wall thickness across all 10,000 phone cases produced per shift—something their previous hydraulic injection molding machines couldn’t achieve.

Suitable for a Wide Range of Injection Molding Applications

A common misconception about hybrid injection molding machines is that they are only suitable for specific materials or part sizes. In fact, the servo-hydraulic synergy makes them one of the most versatile injection molding machines on the market. They can handle a wide range of products, from miniature electrical connectors (using PP resin) to large industrial containers (using HDPE).

The key lies in the adjustable servo-hydraulic curves: operators can set different pressures and speeds for each material—harder resins require higher pressure. In contrast, flexible TPU requires a gentler approach. Additionally, the servo system coordinates the injection of each component with millisecond precision, ensuring perfect bonding. Unlike all-electric injection molding machines, which may struggle to handle the torque required for large molds, hybrid injection molding machines maintain speed and precision across all applications, making them an ideal solution for diverse production needs.

Suitable for a Wide Range of Injection Molding Applications

How to Simplify Your Workflow?

Topstar hybrid injection molding machines feature an intuitive touchscreen interface for easy adjustment of servo-hydraulic parameters. For custom materials, the system allows users to save profiles so they can complete repetitive jobs with a single touch. The system also integrates predictive maintenance alerts: sensors monitor servo motor temperature, hydraulic oil condition, and pump performance, and send notifications before problems occur. It can also connect to factory IoT systems, allowing managers to track energy usage, cycle times, and defect rates in real time. This transparency helps identify inefficiencies—for example, if a shift uses more energy than usual, managers can check whether they have set the servo-hydraulic profile correctly. By combining advanced technology with user-friendly design, hybrid injection molding machines not only save energy but also make your entire production workflow smoother and more reliable.

Sustainability: Better Aligned with Your ESG Goals

Today’s manufacturers are focused not only on costs but also on sustainability and ESG goals. Hybrid injection molding machines help you achieve these goals by reducing energy consumption by 40% (and thus reducing carbon emissions). For a 500-ton injection molding machine operating 24/7, this means a reduction of 126 tons of CO2 emissions per year – equivalent to the carbon emissions of 27 cars. Hybrid injection molding machines also reduce hydraulic oil waste: traditional hydraulic machines lose hydraulic oil through overflow valves and leaks. In contrast, hybrid systems use less total hydraulic oil and have better sealing. Topstar’s hybrid models use biodegradable hydraulic oil, further reducing their environmental impact. At the same time, their energy efficiency meets the requirements for government incentives.

Improved Efficiency and Reduced Energy Consumption

Hybrid injection molding machines combine energy saving, improved quality, simplified operation, and support for sustainable development. Through servo-hydraulic collaborative technology, they achieve 40% energy savings. Whether you produce automotive parts, medical devices, or consumer goods, hybrid injection molding machines can meet your needs, reduce waste, and improve your production profitability.

 

 

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