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5 Reasons Why You Want to Upgrade To A Hybrid Injection Molding Machine

Hybrid injection molding machines have been on the market for a couple of decades now, and have proven themselves to be the standard choice in many facilities.
Hybrid injection molding machines are different compared to standard hydraulic injection molding machines in that they use a servo motor coupled to a hydraulic pump to circulate the oil used to provide the hydraulic pressure which actuates the components of the machine. The use of a servo pump allows for continuous adjustments to the actual power requirements, low emissions, less noise, and energy savings.

1. Energy Savings.

Compared to standard hydraulic machines, hybrid injection molding machines typically provide 40% to 60% in energy savings. This is because the servo pump only runs when hydraulic pressure is needed, where as a standard hydraulic machine runs the pump continuously. Because there is no need for movement during the cooling stage of the process, the longer the cooling time, the more energy savings you will see.

Hybrid machines that utilize toggle clamping mechanisms are more energy efficient than the direct ram style clamping units that many manufacturers use. Toggle mechanisms are more energy efficient in creating the clamping tonnage, and locking the mold halves together to maintain pressure.

2. Longer Hydraulic Oil and Machine Life.

Hybrid machines also run the hydraulic oil at a lower temperature because there is less circulation required. This leads to an extended lifespan of the oil, servo pump, and other mechanical components involved. Less maintenance means less downtime and more production with the hybrid injection molding machines.

3. Less Demand for Process Cooling Equipment.

When hydraulic oil runs at a lower temperature, it requires less cooling from your chiller or cooling tower. Today most injection molding machines come equipped with a water saver valve that adjusts the amount of water that flows through the heat exchanger to provide just the right amount of cooling so that you are not wasting money on excessive cooling. There are machines without a water saver valve so make sure your machine manufacturer adds this feature. Using less water from your tower or chiller reduces the heat load on your water system which will end up saving you money in the long run.

4. Faster Response and Closed Loop Process.

Servo motors have a faster response time than standard hydraulic pumps, which leads to faster cycles and decreased cycle times. They also offer more precise controls and a more consistent process due to the encoders that track each turn to the exact rotation position. This means higher quality parts and less scrap..

5. Faster ROI.

Although hybrid injection molding machines are slightly more expensive than standard hydraulic molding machines, all of the above benefits provide a very fast return on investment. Hybrid machines are also typically faster than standard hydraulic machines, so you will be able to make more parts in the same amount of time.

The case study below showcases an old Mitsubishi hydraulic injection molding machine that was retrofitted with a hybrid servo system.

Conclusion

Many of our customers have switched over to hybrid injection molding machines, or replaced their old standard hydraulic machines based on the benefits we talked about above, and all of our customers have noticed significant energy savings and increased production efficiencies. Hirate America is partnered with Hyundai Injection Molding Machines and LS Mtron Injection Molding Machines who manufactures hybrid injection molding machines in South Korea ranging from 80 to 3,300 tons.

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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5 Reasons Why Magnets & Metal Separators Will Provide A Quick ROI

We all want to believe that the resin we buy, whether it be virgin, re-pro, or regrind, will come free of any contaminants/metal, but experience tells us otherwise. Whether it be pieces of metal that broke off from the process of pelletizing, grinding, or just the accidentally dropped bolt, we have all found metal in our material at some point in time.

Before we jump into the 5 reasons why having a magnet or metal separator in your plastic process will absolutely provide a quick ROI, here’s how it works:

The video below showcases Sesotec Sesotec’s Protector metal separator in action, which ensures that your process will be free and clear from any metal contamination.  The metal separators are installed directly at the material inlet of the injection molding machines and we believe it is an important component in the protection of your molding machines and molds.

1. Damage to your Screw and or Barrel.

A piece of metal can cause minor scratches to your screw/barrel, or render it completely useless, which can cost anywhere from $5,000 to $20,000 dollars depending on the damage and size of your injection molding machine.

2. Damage to your mold and or hot runner system.

If you are getting small amounts of metal in your material that doesn’t get caught by your nozzle tip filters, it can clog up your hot runner tips, causing more frequent maintenance to be required, or cause a breakage in the tip/valve which can quickly become an expensive repair.

3. Down time.

Every time you have to clean out a filter, get maintenance done, or send out your equipment for repairs, you lose precious production time, which may cause problems in your production schedule.

4. Cost of Labor.

Whether it gets calculated or not, time spent by employees removing equipment or doing maintenance is an hourly cost, and time spent dealing with avoidable metal problems, is time not spent doing other necessary maintenance/work.

5. The effect on sales.

If the downtime causes a shortage on production, this could lead to problems or even the loss of a customer(s). There is also the level of confidence that any potential customer(s) will have when they see your process has a magnet & metal separator protecting your equipment or their molds.

From our experience, we have seen payback on magnets & metal separators to pay themselves off by catching metal contamination. We recently did a trial of a magnet at a custom molder who was using 100% virgin material, and within the first 3 weeks, they found a nail on the magnet. This saved them thousands of dollars of repairs and down time with just a several hundred dollar investment. They immediately invested in 10 magnets for their machines.

Conclusion

Magnets and metal separators protect your equipment, minimizes downtime, saves you money on repairs/labor, reduces scrap rates, and provides confidence to your customers.

They clearly increase productivity, consistency, and product quality. Magnets and Metal separators typically have a 1 to 6 month return on investment (ROI) because catching 1 piece of metal 1 time will typically pay off the unit by preventing repairs. Sesotec’s “easy-clean” magnets has a removable stainless steel sleeve over the magnet, which instantaneously removes metal from the magnet. There is also a clear glass opening so you can see if any metal is caught on the magnet without having to continuously checking for metal contaminates. Any metal caught will remain on the magnet or in the discharge bin, ready to be presented as evidence.

Having a magnet & metal separator is an insurance policy on your machines. Hirate America is partnered with Sesotec, a German based company (one of the most well-known respected in the industry). They provide many types of magnets, metal separators and optical sorting equipment to provide a solution for every process.

Please contact us if you have any projects you’d like to discuss with us.