Injection moulding machinery supplier, Sumitomo (SHI) Demag, is giving UK manufacturers the opportunity to reduce energy consumption through a new testing service.
The service aims to allow moulders to make more educated machinery investment decisions based on credible and impartial hard facts.
Sumitomo (SHI) Demag already conducts more than 300 performance measurements for customers each year, and the organisation recently invested in three new Fluke energy monitoring devices to extend this service. The company carries out the energy tests on-site using a real production scenario by plugging the tool into existing machines such as legacy and competitor moulding systems. By calculating the energy used in kilowatts for each kilogram of raw material converted, the team then provides the customer with a credible comparison if they were to purchase a newer Sumitomo (SHI) Demag machine.
Technical manager Nick Stockton helps perform on-site checks. Stockton explained: “Most of the time customers are looking for the justification to switch from a hydraulic machine to all-electric. But equally, the report can flag to customers changes to the process that they can adopt to reduce energy consumption on their existing injection moulding fleet.”
For one customer - McLaren Plastics, the comparative data was a requisite for successfully securing a local grant to help fund the moulder’s investment in two new IntElect2 50 ton machines. The initial measurement revealed that each legacy machine was consuming 7.2kw per hour. The IntElect2 machines consume less than 2kw per hour.
At the start of December, Sumitomo (SHI) Demag revisited the Midlothian company to test McLaren’s new IntElect’s in situ. The results showed that McLaren is now saving over 58% in energy, moulding the exact same components at the same speed, saving 7.11 kw per hour on these two machines alone.
Stockton emphasised: “For a genuine benchmark, you need to compare apples with apples. This means testing the entire process running the same product before and after new kit is installed, with all ancillary equipment plugged in. It is the only true way to gauge the energy and performance improvements.” Stockton believes the real proof is when energy tests are based on the entire machine set-up and perform a like-for-like comparison.
Sumitomo (SHI) Demag’s tests also examine other factors such as parallel movements and the impact of drive cycle times on output. Energy is often wasted through methods such as using too much clamp force, running at full dosing speed and leaving a pump running when the machine’s not operational.
The results are compiled into a report that presents companies with robust data that can be included in annual CSR reports. Stockton explains: “Company stakeholders aren’t just looking at the bottom line, but also non-financial information. Sustainability now features strongly in these annual reports and shows the direct impact that business decisions have in relation to trust and future governance.”
As a sign of how critical the organisation believes this data is, the UK Sumitomo (SHI) Demag team has committed to conducting an energy check along with a Euromap 6 dry cycle check on every annual assessment, effective January 2020.
The latest report issued by the International Energy Agency (IEA) in November 2019, stated that carbon pollution increased by 1.9 percent in 2018. A similar report issued by the Global Carbon Project indicated a 2.7 percent increase in the same timeframe. These figures and future estimates suggest that the net zero carbon emissions goal is 20 years off the 2050 target. However, managing director, Nigel Flowers, explains how the increasing adoption of clean and renewable energy solutions, especially by the manufacturing community can help.
Currently, the UK injection moulding market is spilt 25% electric/75% hydraulic. Sumitomo (SHI) Demag is continuing to extend its IntElect range to cater to the automotive, electronic and packaging sectors, as well as liquid silicone rubber and multi-component moulding.
Flowers concludes: “Applying the circular economy ideologies to plastic processing requires a systemic shift in attitudes and actions. Many are keen to opt for more energy efficient systems. But until recently, machinery suppliers have struggled to quantify and compare performance data in relation to energy consumption, investment and planned maintenance costs, mould wear, output quality etc.
“Having access to this commercial evidence is a real step change for moulders and stakeholders, providing proof that manufacturers are taking steps to reduce their environmental footprint and contribute to the circular economy.”