1. Production workshop
The layout of the production workshop focuses on two aspects: under the condition of meeting the production demand, optimize the layout according to the production process, and meet the requirements of flexible energy consumption under specific production conditions.
(1) The power supply shall have appropriate margin while meeting the power required for stable production, so as not to cause excessive non functional consumption due to excessive surplus.
(2) Build efficient cooling water circulation facilities and equip the cooling water system with effective insulation system.
(3) Optimize the overall production layout of the workshop. Many production processes are coordinated successively. Reasonable coordination can reduce the time and energy consumption required for turnover and improve production efficiency.
(4) The lighting and other plant equipment shall be controlled separately with the most effective small unit as far as possible.
(5) The workshop equipment shall be regularly maintained to avoid the impact of normal production operation due to the damage of public facilities, resulting in increased energy consumption.

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2.  Injection molding machine
Injection molding machine is a large energy consumer in the injection molding workshop. The energy consumption is mainly motor and heating.
(1) Select the appropriate injection molding machine according to the product characteristics.
(2) All electric injection molding machine and hybrid injection molding machine are selected, which has excellent energy-saving effect and can save energy by 20-80%.
(3) New heating technologies, such as electromagnetic induction heating and infrared heating, can achieve 20-70% heating energy saving.
(4) Effective thermal insulation measures shall be taken for heating and cooling systems to reduce heat and cold losses.
(5) Maintain good lubrication of equipment transmission parts and reduce the increase of energy consumption caused by increased friction or unstable equipment operation.
(6) Select low compression hydraulic oil to reduce the waste of working energy of hydraulic system.
(7) Using parallel action, multi cavity injection molding, multi-component injection molding and other processing technologies can significantly save energy.
(8) The traditional mechanical hydraulic injection molding machine also has a variety of energy-saving driving systems, which can replace the traditional quantitative pump, and the mechanical hydraulic injection molding machine has remarkable energy-saving effect.
(9) Regularly maintain the heating and cooling pipeline to ensure that there are no impurities, scale blockage and other phenomena inside the pipeline, so as to realize the designed heating and cooling efficiency.
(10) Ensure that the injection molding machine is in good working condition. Unstable processing may lead to defective products and increase energy consumption.
(11) Ensure that the equipment used is suitable for the processed products, such as PVC processing, which often requires special screws.
3. Injection mold
Mold structure and mold condition often have a significant impact on injection molding cycle and processing energy consumption.
(1) Reasonable mold design, including runner design, gate form, number of cavities, heating and cooling channels, etc., will help to reduce energy consumption.
(2) The use of hot runner mold can not only save materials and reduce material recovery energy consumption, but also has a significant energy-saving effect in the forming process itself.
(3) Profiling rapid cooling and heating die can significantly save processing energy consumption and achieve better surface quality.
(4) Ensuring the balanced filling of each cavity helps to shorten the forming cycle, ensure the uniformity of product quality, and has excellent energy-saving effect.
(5) Using CAE aided design technology for die design, die flow analysis and simulation can reduce the energy consumption of die debugging and multiple die repair.
(6) On the premise of ensuring product quality, the use of low mold locking force is helpful to prolong the service life of the mold, facilitate the rapid filling of the mold and save energy.
(7) Do a good job in mold maintenance to ensure effective heating and cooling water channel conditions
4. Peripheral equipment
(1) Select the auxiliary equipment suitable for the capacity, which can not only meet the work requirements, but also won’t have too much margin.
(2) Maintain the equipment to ensure that the equipment is in normal working condition. Abnormal auxiliary equipment will lead to unstable production and even poor product quality, resulting in increased energy consumption.
(3) Optimize the coordination and operation sequence of host and peripheral equipment.
(4) Optimize the mutual position between peripheral equipment and production equipment, and make the peripheral equipment as close to the host as possible without affecting the operating conditions.
(5) Many auxiliary equipment manufacturers provide on-demand energy supply systems, which can achieve significant energy saving.
(6) Use fast die changing equipment to reduce the waiting time required to switch products in production.

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5. Material
The energy consumption of different materials processing is different, and the improper management of materials or recycled materials will increase the production energy consumption.
(1) On the premise of meeting the product performance, materials with low processing energy consumption shall be preferred.
(2) Under the condition of meeting the optimization of service performance and cost, high liquidity materials are preferred.
(3) Note that materials from different suppliers may have different process conditions.
(4) The drying treatment of materials is better to be used with drying to avoid the waste of energy after drying.
(5) Keep the materials well to prevent impurities or foreign matters from mixing into the materials, resulting in poor products.
(6) Some products are allowed to add recycled materials, but attention shall be paid to the preservation and cleanliness of recycled materials to avoid bad parts due to unclean materials.

6. Processing technology
(1) The shortest molding cycle shall be used on the premise of meeting the product performance.
(2) If there are no special factors, the processing process recommended by the supplier shall be used as far as possible.
(3) Save all stable equipment and process parameters for specific products and molds, so as to shorten the machine adjustment time during the next production replacement.
(4) Optimize the process, adopt lower clamping force, shorter cooling time and pressure holding time.
7.  Adopt new technology
(1) Auxiliary molding technology is adopted, such as gas assisted, liquid assisted, steam assisted, micro foaming injection molding technology, etc.
(2) Unit forming scheme is adopted to reduce intermediate links.
(3) New technologies such as in mold welding, in mold spraying, in mold assembly and in mold decoration are adopted.
(4) New low pressure forming technology is adopted to shorten the forming cycle and reduce the melt temperature at the same time.
(5) Adopt energy regeneration system.

8. Production management
(1) Producing high-quality products at one time and reducing the defect rate is the biggest energy-saving.
(2) The maintenance of the whole production system is closely related to energy consumption. This involves not only the main engine, but also the surrounding and factory equipment. For example, if the workshop mold changing crane fails and needs to change the mold manually, it is bound to prolong the waiting time of the equipment and increase the energy consumption of the equipment.
(3) The workshop energy consumption monitoring system is equipped to facilitate the purposeful implementation of energy analysis and improvement.
(4) When the equipment is shut down for maintenance, not only check the maintenance contents and items of the equipment itself, but also pay attention to the condition of the connection between the equipment and other systems, whether the working performance is reliable, etc.
(5) Regularly compare with the industry benchmark to see if there is room for further improvement.
(6) Establishing reliable contracts and cooperative relationships with suppliers is beneficial and harmless to enterprise energy conservation management.
Qingdao Sainuo Chemical Co.,Ltd. We are manufacturer for PE wax, PP wax, OPE wax, EVA wax, PEMA, EBS,Zinc/Calcium Stearate…. Our products have passed the REACH, ROHS, PAHS, FDA testing. Sainuo rest assured wax, welcome your inquiry! Website：https://www.sanowax.com
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