Plastic Injection Moulding Components - Tepco India Company

Within the very first test, the quantity of power consumed throughout a 30 minute period was measured with the original plastic injection molding process parameter settings.Cycle time was 18.0 seconds. See table 1 beneath to get a list of all parameters. The electrical energy price per component was calculated to be 2.39 cents. For the 2nd test we chose to double the RPM speed from the plasticizing screw. At the finish of the 30 minute period we could see that this decreased energy consumption by three.5% (without the need of effecting excellent) so the price per part reduced to two.31 cents. Cycle time remained at 18.0 seconds. In test 3 cycle time was decreased by growing the mould opening and closing speeds. Though the power consumption slightly elevated during the 30 minute time interval, the production quantity truly increased from one hundred parts to 120 parts so the price per aspect went down to two.06 cents. Test 4 was to reduce cooling time by 3 seconds from 8.7 to 5.7 seconds as well as the price per aspect decreased once more to 1.85 cents. A 23% reduction in cost in comparison to test 1. Test five involved escalating the fill time from 1.two second to 1.65 seconds and lowering the cooling time in order that the cycle time remained the exact same as test four at 12.0 seconds. The outcome was a rise in cost per component to 1.93 cents.

All these results are in Table 1 below.

RESULTS
TEST NO.	1	2	3	4	5
PROCESS CHANGE	INITIAL SETUP	INCREASED SCREW RPM	SAME AS 2 & REDUCED MOULD OPENING & CLOSING TIMES	SAME AS 3 & CUT COOLING TIME	SAME AS 4 & INCREASED INJECTION TIME
CYCLE TIME seconds	18.0	18.0	15.0	12.0	12.0
INJECTION TIME seconds	1.2	1.2	1.2	1.2	1.65
HOLD TIME seconds	2 stages 0.8 0.2	2 stages 0.8 0.2	2 stages 0.8 0.2	2 stages 0.8 0.2	2 stages 0.8 0.2
HOLD PRESSURE bar	2 stages 504 420	2 stages 504 420	2 stages 504 420	2 stages 504 420	2 stages 504 420
COOLING TIME seconds	8.7	8.7	8.7	5.7	5.25
PLASTICIZING SPEED rpm	125	250	250	250	250
PLASTICIZING TIME seconds	5.0	2.55	2.55	2.55	2.55
BACK PRESSURE bar	4 stages 224 224 224 56	4 stages 224 224 224 56	4 stages 224 224 224 56	4 stages 224 224 224 56	4 stages 224 224 224 56
INJECTION PRESSURE bar	Set to maximum	Set to maximum	Set to maximum	Set to maximum	Set to maximum
MOLD OPEN TIME seconds	1.5	1.5	1.1	1.1	1.1
MOLD OPEN STROKE mm	450	450	250	250	250
MOLD CLOSE TIME seconds	1.3	1.3	1.1	1.1	1.1
EJECTION STROKE mm	70	70	70	70	70
EJECTION TIME seconds	1.0	1.0	1.0	1.0	1.0
BARREL TEMPERATURES ⁰C	235-230-210-205	235-230-210-205	235-230-210-205	235-230-210-205	235-230-210-205
MOLD HOT TIP ⁰C	230	230	230	230	230
ENERGY CONSUMPTION PER 30 MINS kwhr	13.3	12.85	13.75	15.45	16.1
ENERGY CONSUMPTION PER 1 HOUR kwhr	26.6	25.7	27.5	30.9	32.2
TARIFF $ PER kwhr	0.18	0.18	0.18	0.18	0.18
PARTS MADE PER HOUR	200.0	200.0	240.0	300.0	300.0
MATERIAL CONSUMPTION PER HOUR kg/hr	15.2	15.2	18.2	22.8	22.8
ENERGY CONSUMPTION PER Kg kwhr/Kg	1.75	1.69	1.51	1.36	1.41
COST PER HOUR $/hr	4.79	4.63	4.95	5.56	5.80
COST PER PART $/part	0.02394	0.02313	0.02063	0.01854	0.01932
COST PER PART cents/part	2.39	2.31	2.06	1.85	1.93
COST REDUCTION PER PART cents	0.0	0.081	0.332	0.540	0.462
% COST REDUCTION PER PART	ZERO	3%	14%	23%	19%

Results

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The results for this experiment show that for this particular machine producing this part, energy consumption was reduced by up to 23% from the original settings. This translates directly into a 23% saving in electricity costs per part. And this was done just by changing some of the parameters in the plastic injection molding process.