Saving energy means securing the future

However, this also requires innovative system solutions that enable plastics processors to successfully achieve their energy-saving goals while taking economic factors into account. Since its founding, our company has specialized in the development and implementation of highly energy-efficient systems and equipment that help strengthen our customers’ competitiveness and sustainably improve their market prospects.

During periods of economic success and full order books, the focus in companies is usually not on topics such as process or energy optimization. The recent financial crisis served as a wake-up call for many and led to certain issues being viewed more critically and prioritized differently. Energy optimization was certainly one of these issues, as it had once again become clear that energy costs have a significant impact on a company’s competitiveness, both today and in the future. Thus, the crisis period did have a positive side. Companies recognized the urgent need to use energy more carefully in the future if they want to survive in the market.

As a result of the situation, many companies have therefore engaged much more intensively with topics such as process or energy optimization. For example, they have sat down with our experts to develop holistic concepts that, when implemented step by step, lead to a sustainable improvement in the energy cost situation within the companies. A large number of plastics processors are using the current peak period to consistently implement their planned energy-saving strategies. What was previously spent unnecessarily on energy is now being saved and used for other activities.

Experience shows that there is enormous potential for savings, particularly in energy-intensive companies in the plastics industry. A free energy-saving assessment quickly reveals where savings can be achieved.

Ultimately, the goal is to identify so-called “energy guzzlers,” eliminate unnecessary energy consumption, and reuse essential energy sources multiple times. In a subsequent step, a detailed analysis allows for assessments of the economic benefits of each measure. There are plenty of starting points for a successful search for energy-saving potential, especially for plastics processors. From optimizing injection molding machine drive power, cooling system technology, and compressed air supply to utilizing free waste heat for heating purposes, the “energy-saving table” is generously set. Achievable energy savings of 30 to 80 percent in the individual areas are not uncommon and continue to astonish many plant operators.

So-called “winter load reduction” drastically cuts a chiller’s electricity costs. During the transitional and winter months, the freely available outside air is used to maintain the cooling water at the required temperature level. This technology can save up to 75 percent of annual electricity costs.

A machine optimization system can significantly reduce the “energy consumption” of hydraulic injection molding machines in a straightforward manner. At the heart of EtaControl technology is controlled oil flow management that automatically and dynamically adapts to the machine’s energy requirements during the cycle and to the specific molded part. On average, machines equipped with this technology to date have achieved an electricity savings rate of 36 percent—while maintaining consistent cycle times and product quality. A particular advantage of EtaControl technology is that the full range of the injection molding machine’s performance is available at all times.

The examples described illustrate how the energy cost situation can be successfully improved. Similar to these examples, significant optimization potential can also be realized in other areas.

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