Energy efficiency in plastic injection moulding – 11% lower energy consumption per part

The challenge: Lack of transparency regarding energy consumption and machine status

A manufacturer of plastic packaging was looking for ways to reduce its rapidly rising energy costs. Energy consumption was particularly high in injection moulding production – but it was unclear where exactly the greatest potential for savings lay. Real-time data on temperature profiles, cycle times and idle phases of the machines was missing. This was where in.hub GmbH provided support as a specialist in industrial condition monitoring.

The solution: Capture energy and process data in real-time and analyze it directly at the machine

To create this transparency, twelve injection molding machines were retrofitted with the HUB-EN200. The system captures temperature profiles, cycle times and machine states in real time and analyzes them directly on the machine (locally, without cloud infrastructure or complex IT projects). Based on the data obtained, temperature control and cycle times were optimised in a targeted manner. The integrated dashboards on the in.hub operating system siineos® made the results immediately visible and manageable.

The result: rapid amortization and sustainable process improvements

• 11 percent less energy consumption per component
• 2,640 euros saved per machine per year
• Approximately 32,000 euros in total annual savings

In addition to the cost savings, the company benefits from more stable processes and shorter cycle times.

Profitability

The investment of approximately 7,400 euros for hardware and installation paid for itself after only seven months. This example shows how targeted energy monitoring can deliver measurable results quickly, entirely without a cloud.

Facts at a glance