The future is the time after...

The will to save energy and the necessary system solutions are available. Now it's all about consistent implementation. One thing is certain: energy-saving successes sustainably improve the future prospects of the plastics processor, which is particularly important if there is to be another crash.

In the past, energy costs were only of limited importance... but they have gained considerably in importance due to the price increases in recent years and will be at the top of the list of priorities in the future due to dwindling energy resources. Future-oriented companies have long recognized the importance of energy costs. In difficult times it is difficult to implement, but in the current peak phase these companies are intensifying their efforts to identify optimisation potentials and implement energy-saving measures in order to be prepared for the future.

However, this also requires innovative system solutions that enable plastics processors to successfully implement the energy-saving targets they have set themselves from an economic point of view. Since its foundation, our company has specialized in the development and implementation of particularly energy-saving systems and plants that contribute to strengthening the competitiveness of our customers and sustainably improving their market opportunities.

In phases 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 has shaken many people up and led to some things being viewed more critically and sorted differently in terms of value. The topic of energy optimisation was certainly one of them, because it had once again become clear that energy costs have a significant influence on the competitiveness of the company today and in the future. So the time of crisis had a positive facet after all. They recognized the compelling necessity of having to be more careful with energy in the future if they want to survive in the market.

Many companies have therefore - due to the situation - dealt much more intensively with issues such as process or energy optimisation. For example, we have sat down with our experts to develop holistic concepts which, implemented step by step, lead to a sustainable improvement of the energy cost situation in the companies. A large number of plastics processors are using the current peak phase to consistently implement the planned energy-saving concepts. What was previously spent unnecessarily on energy is now being saved and used for other activities.


Savings yes... only where and how much?

Experience shows that especially in energy-intensive companies in the plastics industry, enormous savings potential can be leveraged. A free energy savings check quickly provides information on where and which savings effects can be achieved.

In the final analysis, the aim is to locate so-called "energy guzzlers", eliminate unnecessary energy consumption and use energy that is absolutely necessary several times at the same time. In a further step, after a detailed evaluation, statements can then be made about the economic effects of the respective measure. There are enough starting points for a successful search for energy saving potentials, especially for plastics processors. Starting with the optimization of the injection moulding machine drive power, cooling system technology, compressed air supply up to the use of free waste heat for heating purposes, the "energy saving" is abundantly covered. Realizable energy saving rates of 30 to 80 percent in the individual areas are nothing out of the ordinary and astonish one or the other plant operator time and again.

A so-called winter relief drastically reduces the electricity costs of a refrigerating machine. In the transition and winter months, the fresh air available free of charge is used to keep the cooling water at the necessary temperature level. With this technology, up to 75 percent of the annual electricity costs can be saved.

With a machine optimization system, the "energy hunger" of hydraulic injection molding machines can be significantly reduced by a short distance. At the heart of EtaControl technology is a controlled oil flow management system that automatically adapts to the energy requirements of the machine in the cycle sequence and the respective molded part. On average, the machines previously equipped with this technology achieved an energy saving rate of 36 percent - while maintaining the same cycle time and product quality. A special advantage of EtaControl technology is that the full power spectrum of the injection moulding machine can be called up at any time.

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