1. ffiffiENERGY
MANAGEMENT:
AII-electric
machines
s-E
par
excelfenc€
RisingTeW prics$-i$ srucial
a issus
withtheplastie
pruoessills
ierdu*try. a resurt, necd *onitl,,nJ
As the
reduce to
sn*rgyconsumptinn [eccmrlnor*
rras impcrtant
thanever. hasgiven to n** i***lopments
Ttris rise
thetniectien
moutding ir
indusrry, ;,L;;_d
iid
uffi ;;
mculdingmachines. Jaininalyses enectiven*ss
Avani trre
of thesem*ehines acfrieving
in un*rgr*#*iency.
he cost of energy has
conventionally been between iniection injection
moulding
machinessaid
fltltxilf;t#ffi:'j"t* are to
4 and 5 per cent of the cost
of a moulding, but this is
rh.;;;;.*;;b1v;en two H"itri,l.#_?r'r..ffTfl"
the is
increasing rapidly with rising
the useof servomotors in electric
energ.y moulding machines
injection
on trr. ,.rouang and the machine. ;
prices.To remain competitive, as against the use of
a business pumps in hydraulic
must havean effectivee: injection moulding lhe plus polnts
machines. Rohan Shrikant
process. the
Thus, ffiyf'ff:nT Regional Director - South
Shahani Ail_"t..rrl. machines have several
energ.y efficiency, which has E*t A;i;; .Jrrrrrr.r., over hydraulic machines.
led to Machine Point Consutt*t, ,lih.
popularisation of electric st, ..f, ,.*o motor used in an electric
iniection "Energy consumption
moulding machines. in drfferent inlection ,*"t rrr. only drives ,h. Ji required for
Earlier, hydraulic injection moulding on how the th. *o.r.irrg process,crearing
fflI::tchinestepends
orrvesarepowered'Theproduct a direct
machines ruled the market, but type,size exchangeoi..r"rgy and ensuring
witfr and material can be a large contributor ress
the advancementsin technolog;,,, to enel
new developments now taking
various the
dirf.erence. consumprion.
i,' .,,.,sv A,".i3;'ilyJir"-fi:;J".i:lJl*
are place. conventional hydraulic
Currently, all-electric machines machine ur., orr" the electric machine eriminates
are or more pumps as a central the need
making inroads into the Indian unit to drive for hydraulic
market, the machine' Two ;;;;;;; the need to
with a 4-5 per cent shareoftotal
injection aspectsof a hydrauric
of-the ,""*firr ,lor", airpo.., "ri;
miintain .oor the oir.
-*,
machine are the "rrd
moulding machinerysales. Their demand architecture All-erectric machineseriminate
of the s;ntem and the wasted the need
is expected to increase in . fol cooring the hydraulic system,
the near pump powerwhen besides
future due to their energ.y thereis no demand.In the associatedequipment requirements
efficiency, contrast,all-electric
greater-deanliness, machinesreducelosses and
quick start_up,better
repeatabilityand noiseless
by htsh;;;;;;;
using tod,ive ',1,::::#:t"ir%:
operations. injection moulding processes." -:io,.
Al-elssu'... -"u.',T?"T"i
hydraulicmachines.
All_electricmachines
! *o*"rr: pla**i*e & F*tym*rs
I November
2011

2. WAll-electric machines
produce less noise as it does not have moulding machine is high in other
pumps. The plumbing piping to the countries like Japan where 90 per cent
plant can be greatly reduced for new of the machines are injection moulding
construction. Moreover. these machines machines. As a result, the governments in
are more preciseand good for repetitive these countries have subsidised the price
operations," notes Shahane. of these machines for end-users."
All-electric machines allow machine Adding to this, Shahane says, "In
&$$"*$*m*r$s e$*s
s&e*$Tfi movements to be integrated direcdy with India, people prefer to buy machines
the control system.This greatly improves
*#Ecs*$mm€* f*r ce*$$xrgmachine
€fus ra**d that are less costly and bear the high
set-up, adjustment and process maintenance cost throughout the year.
&$re$eydrm*e$6* fu*s$des control. These machinesuse less water,
*ys€e*w, Although the capital investment in
€fums*e*$e**d
* eqa*$peawert and, depending on the product, water electric injection moulding machine
consumptioncan be reducedby
r*qaxEr'*mea?&s mm{$ sffi*r*f #$*. per cent. Generally,all-electric up to 65 appear to be huge in the beginning, there
machines are no further costs involved with them.
& s$xwr€*r pnwda**t mskes require less maintenanceas comparedto
*yc$m Thus, despite being energy efficient, the
pr*dr**t$vm
*fu***ssftstrffi t8xmm hydraulic machines. Overall, all-electric scope of these machines in the Indian
machines have a relatively lower risk of market seems limited at present." he
tfumfuydrmar$F*Eci*s.
mesfu failure and are easy to maintain than continues, "But with the growth in auto,
conventionalmachines.Thus, all-electric medical and electric & electronic sectors.
RohanShrikantShahane machines can significantly reduce energy the investment in all-electric machines
Regional
Director SouthEastAsia,
-
consumption and production cost for is expected to increase. This growth will
MachinePointConsultants
SL
manymouldings.Thesemachines used are be fuelled by productivity improvement
in applications that requirehigh precision, initiatives due to manpower shortage, wage
eS, engineering and pharmaceutical inflation and higher power availability."
applications.
New technologes greater
for
Demerits efficiencies
Despite the many advantagesof all- With the rising focus on energy
electric machines,these do have certain management, companies are looking
disadvantages,which might hamper beyond electric injection moulding
their demand. Shahane observes."The machines. "For this purpose,
newmachines
market barrier of accepting all-electric like the Canbio VS serieswith electro-
machinesis the cost differential between hydraulic system comprising servo-driven
hydraulic and all-electric machines,which motor andvariabledisplacement pump are
is almost 40 per cent. However, of late, producedby Negri Bossi," saysRamesh.
this price has dedined by 70-20 per cent. Through completedigital control, Canbio
Although all-electric injection mouldings VS provideshigh moulding accuracy and
exhibit superior efficiencyin the plastics improved repeatability of the moulded
manufacturing process,these cannot be parts. The use of digital variable
&* m*rc'xp*rmd
&*$md$m, tfum used in applications that require high displacement pumps with integrated
speedand high damping forces." electronic control of pressureand speed
**r*xmmdm*$"*$e**r$*
f*r
permits higher energysavings.
€m$***&mm
rwmm$dF*rg $ss*
snwsfu Demand scenario "These machinesare closeto electric
FsfuEgtum€fu*r
$m *maxsx*r$es
$$k* The higher cost of electric injection injection moulding machines and can
moulding machines than the conventional save more energJr' other costs. This
$epe*wken* pcn
Sffi *srt* w$ hydraulic systerrx'limits their usage. V
&
gives them an advantage over electric
&fuemc**$s&sB&$
ffitr#
$m$**€$wn Ramesh,Chief Executive Ofiicer, Negri injection moulding machines,which are
xmww*d*rag
swms$x$sles. Bossi SACMI Engineering (India) Pvt expensiveand have certain limitations,"
Ltd, says, "Of the total injection moulding details Ramesh.Thus, in future, energy
V Ramesh machinery market in India, electric management concerns expected rise
are to
ChiefExecutive
Officer,NegriBossiSACMI injection moulding machine constitutes further and machineswith higher output
(lndia)PvtLtd
Engineering only a small percentage. comparedto
As and lower power consumption per unit
India, the demandfor all-electriciniection will lure customersworldwide. ffi
@ ruto*l*rnFia**ios & Fofyru*rs I November
2011