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How Much Electricity Does an Injection Molding Machine Use per Hour?

2024/04/10 By Topstar

How Much Electricity Does an Injection Molding Machine Use per Hour

The energy consumption of an injection molding machine depends on the machine itself, the materials used, the mold, and the production cycle. Topstar’s early TS series reference tables show that, depending on the model, hourly electricity consumption ranges from approximately 5 to 20.9 kWh. Of course, these figures are for reference only and do not represent a universal energy consumption range for all injection molding machines.

To estimate production energy consumption, measure the average operating power and multiply it by the operating time. For example, if a machine’s average operating power is 12 kW, its hourly electricity consumption is 12 kWh. When evaluating operational efficiency, it is also necessary to calculate the electricity consumption required to produce each qualified product and clarify whether this energy consumption data includes auxiliary equipment.

Understanding the Hourly Power Consumption of Injection Molding Machines

When estimating power consumption, it is not sufficient to rely solely on the rated power listed on the machine’s nameplate. Installed capacity, actual operating requirements, and cumulative power consumption are distinct metrics. Therefore, you need to understand these differences to grasp why the power consumption of the same machine may vary when performing different production tasks.

Understanding the Hourly Power Consumption of Injection Molding Machines 1

Why Does the Power Consumption of Injection Molding Machines Vary?

Energy requirements vary across different stages, such as clamping, injection, holding pressure, plastification, cooling, and ejection. Brief peaks that occur during the injection stage do not represent the average energy consumption over the entire production cycle.

The type of material and injection volume affect heating and plastification requirements. Mold design, pressure requirements, and cycle time settings determine the duration and intensity of the machine’s operations. Downtime during production increases standby energy consumption while reducing output.

The machine’s technical configuration also affects power consumption. Traditional hydraulic injection molding machines experience energy losses during pump operation and hydraulic transmission; servo-hydraulic injection molding machines can adjust pump output based on actual demand; and all-electric injection molding machines use electric power to perform primary movements.

Research by the National Institute of Standards and Technology (NIST) in the United States has proposed a method for estimating energy consumption based on the power and duration of each stage of the injection molding process. This method supports evaluations tailored to specific application scenarios, rather than providing a general figure based solely on machine specifications.

When comparing different machines, ensure that the comparison is conducted under the same conditions regarding material, mold, production goals, and quality requirements.

Why Does the Power Consumption of Injection Molding Machines Vary 1

How is the energy consumption of an injection molding machine calculated?

Please ensure that the units used are consistent:

MeasurementUnitMeaning
Installed powerkWRated equipment capacity
Average operating powerkWAverage measured demand during a defined period
Electricity consumptionkWhEnergy used during that period
Energy per acceptable partkWh/partElectricity divided by accepted output

The basic calculation formula is:

Electricity consumption (kWh) = Average actual power (kW) × Operating time (h)

For example, suppose a plastic molding machine has an average power of 12 kW during an 8-hour production shift:

12 × 8 = 96 kWh

If the electricity rate is $0.12/kWh, the energy cost is:

96 × $0.12 = $11.52

This is a sample calculation and not actual data from Topstar. This calculation does not include demand charges, taxes, or other billing items.

For a more accurate result, subtract the starting meter reading from the ending meter reading. If energy consumption during the startup, production, and standby phases significantly impacts the overall production plan, it is recommended to record energy consumption for these phases separately. Before comparing results, clearly define the scope of measurement. Results will differ between measurements taken solely for the plastic molding machine itself and those for the entire production unit, which includes auxiliary equipment such as robots, dryers, mold temperature controllers, and chillers.

Reducing Energy Consumption While Ensuring Quality

After continuously measuring energy consumption, evaluate whether proposed changes can reduce electricity usage while meeting established production volume requirements. If production speed slows or the scrap rate increases, the metric “reduction in hourly electricity consumption” may be misleading. Therefore, when optimizing processes and selecting equipment, energy consumption measurements should be considered in conjunction with cycle time, yield of conforming parts, and product quality.

Reducing Energy Consumption While Ensuring Quality

What Process Adjustments Can Reduce Energy Consumption Per Part?

Energy consumption per part in injection molding can be reduced by eliminating unnecessary cooling and holding times, avoiding excessive pressure, and matching the plasticizing parameters to the material used and the molding cycle. When making these adjustments, it is essential to ensure part quality meets specifications and to maintain (or increase) the output of conforming parts.

Lowering the barrel temperature or slowing the injection speed does not necessarily result in energy savings; these actions may instead increase filling resistance, lengthen the molding cycle, or lead to a higher scrap rate. When making adjustments, validation should be based on the metric “measured power consumption divided by the yield of qualified products.”

Power Consumption Data for the Topstar TS Series

Charts previously released by Topstar provide the following reference values:

Hourly Power Consumption
Please note: The experimental data is for reference only, the actual data is determined by the process parameters of the product.

These historical data reflect differences among various reference machine models. They are not guaranteed energy consumption values for specific molds, nor do they represent current ordering specifications. Note: The charts do not provide sufficient testing details to reproduce the relevant results independently; they are for reference only.

If the average power consumption for a given application during an 8-hour production cycle is 12.3 kW, the total energy consumption would be 98.4 kWh. This estimate assumes that the measured average value is representative.

Please compare the Topstar injection molding machine series with your production requirements. For electric injection molding machines, please refer to our guide on energy consumption for electric injection molding machines.

How Much Electricity Does an Injection Molding Machine Actually Consume?

Based on historical reference data from the Topstar TS series, the hourly electricity consumption of an injection molding machine is approximately 5–20.9 kWh, with the exact figure depending on the machine model and test conditions. Actual energy consumption can vary depending on the material you process, the mold, the molding cycle, and the machine configuration. For example, if the measured average power consumption is 12 kW, this means the machine consumes 12 kWh per hour, for a total of 96 kilowatt-hours over eight hours. Factories can calculate production costs based on actual energy consumption and, by optimizing process parameters such as cooling, holding pressure, and plasticizing—while ensuring product quality—reduce the energy required to produce a single conforming part.

 

 

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