Process optimization

Energy-efficient machine settings

Even the best injection molding machine only works as well as its settings permit. This is true for the quality of the molded parts, the cycle time and energy consumption. Our SELOGICA control system offers numerous options for process optimization, monitoring and documentation.

The cycle time diagram and integrated energy measurement enable you to carry out detailed analysis and coordination of production sequences. as well as their energy consumption. As a rule, achieving shorter cycle times is the primary objective in terms of both cost and energy efficiency. You should always establish whether the maximum values are actually necessary for a stable, reliable process, because the higher the setting value, the more energy is required. Nevertheless, maximum values do make sense whenever they enable significantly shorter cycle times.

What you should do

  • Do not to use excessively small molds on machines that are too big for them
  • Aim for short cycle times: ensure optimum machine utilization and increase material throughput
  • Movements should be performed simultaneously or synchronized where possible, e.g. ejector or robotic system already start during the mold opening movement
  • Individually adapt simultaneous movements with travel or pressure dependent start conditions: ideal production sequence freely configurable without special programs
  • Increase the speed of the mold movement appropriately: Very fast mold movements are only of benefit where they effectively reduce the cycle time – particularly on large machines
  • The mold should only be opened as far as is necessary
  • Adjust the clamping and nozzle contact force to the application: wherever possible, these forces should be reduced in stages during the residual cooling time
  • Utilize the complete cooling time for dosage: reduce the screw rotation speed as much as possible during melt preparation – the higher the speed, the greater the energy consumption and material load
  • Dosage can be performed even beyond the cooling time using servo-electric direct drives
  • Reduce the maximum melt temperature: save heating energy, reach demolding temperature faster
  • Make use of the SELOGICA options for quality and process control, e.g. through monitoring of extreme values and signal characteristics
  • Evaluate any signals via individual alarm inputs: control the injection molding process as a function of e.g. granulate feed, compressed air or water supply, or automation components
  • Detailed further training: regularly take advantage of ARBURG training courses