Energy Efficiency in Manufacturing: Reducing Energy Consumption, Ensuring Productivity
Standards such as DIN EN ISO 50001 are increasing the pressure to continuously improve energy performance. By making energy consumption in production and manufacturing transparent, companies can identify targeted measures, reduce energy costs, and maintain process stability. We help you identify current energy usage in production facilities, prioritize effective solutions, and make the impact of these measures on energy management transparent.
EtaControl® is a technology developed by ONI for the energy-efficient optimization of hydraulic injection molding machines. At its core is controlled oil flow management that automatically adapts to the energy requirements of the cycle and the specific molded part as needed. Provides decision-making confidence for management, engineering, and purchasing: measurable effects, clear technical logic, and clearly specifiable as a package.
Site Overview
- Your benefits
- Save on electricity costs with our expertise
- Energy efficiency as a competitive advantage
- How EtaControl® supports plastics processors
- Why Choose ONI
- Energy-efficient technologies in practice
- ONI Energy and Expertise
- Stably optimizing production processes
- Achieving measurable sustainability
- References
- Contact
- FAQ
EtaControl® is a direct efficiency lever targeting the largest source of power consumption in plastics production: the injection molding machine. The goal is to achieve a demonstrable reduction in energy consumption without compromising cycle time, quality, or production capability.
- Adaptive oil flow management: Automatic, demand-based during the cycle—tailored to the machine and molded part.
- Intelligent control + appropriate hardware: Based on Siemens S7, among other systems, supplemented by components such as frequency converters, soft starters, and filters depending on the machine.
- Significant savings in practice: In field applications, reductions in power consumption of up to 53% have been reported; on average ~36%—while maintaining cycle time and product quality.
- Reduce energy consumption without operators or process managers having to lose sight of their production goals (cycle time/quality/availability).
- In field trials, savings of up to 53% (average ~36%) were achieved—while maintaining cycle time and product quality, ideal for rapid return on investment.
- Confidence for management / engineering / purchasing: Measurable effects, clear technical logic, and a clearly specifiable package instead of “comparing apples to oranges.”
Save on electricity costs with our expertise
EtaControl® is a fast, effective approach to addressing energy cost issues in plastics processing directly at the machine.
- Controlled oil flow management that automatically adapts to the cycle and molded part as needed.
- A clearly defined optimization concept: intelligent control (e.g., Siemens S7-based) plus hardware components tailored to the specific machine.
- Power consumption reductions of up to 53%; on average approx. 36%.
- With consistent cycle times and product quality—focus on savings without compromising the process.
Cost Reduction
In many companies, energy costs are a direct driver of profitability. Improving energy efficiency in machines and production facilities allows companies to reduce energy consumption without sacrificing output. Measures that reduce ancillary consumption and the operation of continuously running equipment—where energy incurs costs “on the side”—are particularly effective.
Regulatory Framework
Legal requirements such as DIN EN ISO 50001 increase the pressure to measurably improve energy-related performance. Energy-efficient production processes create transparency, meet audit and reporting requirements, and reduce regulatory risks—a clear advantage over less prepared competitors.
Supply Chain Requirements
Customers and OEMs are increasingly evaluating suppliers based on energy efficiency and carbon footprint. Energy-optimized production strengthens a company’s position in the supply chain, improves ESG metrics, and is becoming a decisive factor in tenders and long-term partnerships.
Energy Efficiency in Industry: Why ONI’s EtaControl® Technology Supports Plastics Processors
Recooling circuits are often required throughout the year during operating hours—resulting in a significant accumulation of pump power consumption. ONI PowerSave utilizes physical system interactions and a special hydraulic circuit to significantly reduce the power consumption of the system circuit pump in the recooling circuit.
ONI’s EtaControl® technology is the ideal solution for effectively addressing energy cost issues in a timely manner.
An estimate based on market data illustrates the enormous potential for savings. According to a conservative estimate, there are approximately 50,000 injection molding machines in Germany alone with clamping forces ranging from 2,000 to 54,000 kN (average 6,500 kN) that are more than five years old and have an annual operating time of 5,000 hours. Taking into account the power requirement of 60 kW for a 6,500 kN machine, this roughly translates to an annual electricity consumption of 15,000 GWh with a connected load of 3,000 MW. If the EtaControl technology developed by ONI succeeds in reducing the connected load by one-third, a 1,000 MW fossil fuel power plant can be completely shut down, and plastics processors can reduce their energy costs by approximately 550,000,000 euros, assuming an electricity price of 0.11 euros per kWh!
The core of this technology is controlled oil flow management, which automatically adapts to the machine’s energy requirements during the cycle and to the specific molded part as needed.
In addition to intelligent control based on Siemens S7 control technology, other hardware components—such as frequency converters, soft starters, bypass switches, and du/dt or sine wave filters—are individually tailored to each machine.
In addition to a low-cost variant, EtaControl® LC, EtaSave is available as an energy recovery system that feeds excess power back into the in-house power grid, thereby ensuring further energy optimization. An optional bypass circuit also enhances ease of use when switching to grid operation.
In a broad-scale field trial among ONI customers, covering a wide range of molded parts and machines, power consumption reductions of up to 53% were achieved on injection molding machines! On average, the approximately 1,600 machines equipped with this technology to date have achieved a power savings rate of 36%...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.
If we have piqued your interest and you would like to learn more about the possibilities for energy optimization on your machines, please feel free to contact us. We would be happy to advise you.
Energy-efficient technologies in practice
Energy-efficient technologies only realize their full potential when system engineering, automation, and media management work in harmony. In recooling circuits in particular, significant gains can be achieved through demand-based pump control, precise pressure and flow control, and stable temperature windows. This provides companies with a stronger foundation for energy management and enables them to transparently reduce energy consumption per machine or process.
This is how energy efficiency in production becomes measurable: less unnecessary energy consumption, more stable operating conditions, and a reduction that is sustained in day-to-day manufacturing operations.
ONI Energy and Expertise
When cooling water loss occurs, cooling capacity decreases and the properties of the fluid in the cooling circuit change—this can increase energy consumption and destabilize processes. Common causes include leaks, evaporation, or pressure loss. A structured procedure is essential: identify the cause, document the refill quantities, and correctly reset the mixing ratio (with concentrate if necessary).
This keeps the system stable during production, prevents energy costs from creeping up, and allows measures to be clearly tracked in energy management.
Stabilizing and optimizing production processes
At low temperatures, antifreeze protects the circuit from shutdown damage—the correct mixing ratio and appropriate water quality (e.g., distilled water, depending on the concept) are crucial. In recirculation cooling circuits, the operational reliability of the hydraulic system at low outdoor temperatures is also important to ensure that minimum water volumes and pressure conditions are reliably maintained.
A well-defined winterization and shutdown plan stabilizes production processes, reduces startup issues, and helps lower energy consumption and operating costs in the long term.
Achieve measurable sustainability
Coolant is a critical resource for production and manufacturing in many companies—it’s not a “fill-and-forget” matter. Over time, concentration and properties change, for example due to refilling, evaporation, or the aging of additives. When the protective effect diminishes, the risk of corrosion increases, deposits can build up, and cooling performance decreases—with direct consequences for the energy efficiency, energy consumption, and energy costs of your systems.
The most effective approach is not to plan change intervals rigidly, but to base them on the condition of the system: If analytics, temperature trends, or the need for refilling reveal anomalies, flushing or changing the coolant is often more cost-effective than accepting a gradual loss of efficiency and availability. This ensures stable processes, reduces unnecessary energy consumption, and makes a measurable contribution to sustainability—supported by clear measures and practical energy management. When it comes to disposal, the type and composition of the coolant (antifreeze, additives, concentrate) are critical; we assist with the assessment and implementation to ensure that operations and costs remain predictable.
Plastics and Electrical Engineering, Inc.
Plastik- und Elektrotechnik GmbH uses refrigeration systems manufactured by Oni-Wärmetrafo GmbH at its production facility in Mönchweiler.
Plastics and Electrical Engineering, Inc.
Plastik- und Elektrotechnik GmbH uses refrigeration systems manufactured by Oni-Wärmetrafo GmbH at its production facility in Mönchweiler.
When cooling performance declines (e.g., due to deposits or an improper mixture), systems often have to “compensate” by running longer, increasing pump capacity, or operating in standby mode more frequently. A stable coolant helps reduce energy consumption and lower energy costs in a predictable manner.
It is not just the quantity that matters, but also the correct mixing ratio (including concentrate, if applicable) and the appropriate water quality—to ensure continued corrosion protection and operational safety. Top-up quantities should be documented, as they provide important clues about leaks or changes in the process.
Energy management is effective when technical conditions and equipment are taken into account. By systematically tracking analytics, refill volumes, and temperature trends, it is possible to identify opportunities for savings, prioritize measures, and sustain energy efficiency in production facilities over the long term.
The key factors are the type of coolant and its composition (e.g., antifreeze, additives, concentrate), as well as operational requirements. We help you determine the appropriate procedure for replacement, flushing, and disposal, ensuring that operational needs, costs, and sustainability are all balanced.
