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EtaControlReduces Energy Consumption in Injection Molding Machines

ONI’s EtaControl® technology is the culmination of continuously improving the ONI machine optimization system developed approx. 30 years ago. It’s the perfect way to effectively and effi ciently cut high energy costs in the plastics industry.

The EtaControl® electric control unit for an injection molding machine
with a clamping force of 23,000 kN during the fi nal assembly phase.
The EtaControl® electric control unit for an injection molding machine with a clamping force of 23,000 kN during the final assembly phase.

The power consumption of injection molding machines makes up the lion’s share of the electricity bill and accounts for a significant portion of a plastic processing company’s total costs. This explains why machine manufacturers have intensified energy optimization measures for many years. But that’s also why the requirements of customers collide with those of machine manufacturers. The customer wants a cost and energy efficient universal tool capable of producing a variety of products ranging from high-speed presses for yogurt cups all the way to complex technical moldings. While the machine manufacturer delivered a universal tool at a low price, they had to cut corners in optimizing the energy consumption. That’s why the injection molding machines which had been built until about three years ago consumed so much energy. The optimization possibilities were relatively limited depending on the produced products. In addition, plastic processing companies have to also meet the requirements of the DIN EN ISO 50001 “Energy Management System” standard which calls for a continued improvement of the energy performance in order to attain a better energy and environmental balance through increased energy effi ciency (i.e. “CO2 reduction”).

ONI’s EtaControl® technology is the perfect solution to effectively and effi ciently cut high energy costs. The key component of this technology is a controlled oil flow management system which automatically adjusts itself on demand to the energy requirements of the machine during the cycle process and to the respective molding. In addition to an intelligent control system based on the Siemens S7 control technology, such other hardware components as, for example, a frequency converter, soft-start motor, bypass switch, du/dt or sinus filter are individually adjusted to each machine.

In addition to the low-cost EtaControl® LC option, an energy recovery system is available specifi cally with EtaSave which feeds surplus power back into the company’s electrical system and, thus, generates additional power optimization. An optional bypass circuit also increases the operating comfort by switching to grid operation.

During the large-scale field operations at ONI customers who use the most diverse molding and machine types, reductions in power consumption of up to 53 % were realized in injection molding machines! An average energy saving rate of 36 % was achieved at the same cycle time and product quality in the approx. 1,600 machines that have been equipped with this technology so far. A particular benefit of the EtaControl® technology is the fact that the output range of the injection molding machines can be fully utilized at any time.

We’d be happy to advise you in optimizing the energy consumption of your machines!

EtaControl® in a practical application with a power saving rate of approx. 43 %
EtaControl® in a practical application with a power saving rate of approx. 43 %

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ONI-Wärmetrafo GmbH · Niederhabbach 17 · 51789 Lindlar · Tel. + 49 (0) 2266 4748 - 0 · Fax + 49 (0) 2266 3927