All Electric Injection Molding Machines. 8 Great Ways You Can Benefit by Making the. Switch from Hydraulics

Transcription

1 All Electric Injection Molding Machines 8 Great Ways You Can Benefit by Making the Presenter: Andy Stirn, Product Manager Milacron Switch from Hydraulics

2 Why Electrics A Brief History 8 Ways to Benefit Markets Using Electrics Case Studies Return on Investment All Electric Equipment Questions & Answers 2

3 A Brief History of Electrics 1952 Numerical control (NC) of machine tools established by MIT on a Milacron milling machine Electro hydraulic pulse motor (NC controlled hydraulic servomotor) patented by Dr. Eng. Seiuemon Inaba of Fujitsu Fujitsu spins off motor and NC control technology into FANUC (Fuji Automatic Numerical Control) Milacron FANUC partnership introduces all electric injection molding machine at NPE Cincinnati Milacron introduces Elektra in North American market as first and only US manufactured electric machine A second generation electric machine line POWERLINE is developed in Cincinnati up to 1125 tons After years of success, PowerPAK all electric is introduced for packaging applications All electric machines represent over half the market for new injection molding machines. 3

4 Hydraulics and Electrics: What s the Difference? It comes down to mechanical complexity Fewer Steps = Less Energy Loss 4

5 8 Great Ways You Can Benefit 5

6 1. Tight Tolerance Better than hydraulics by ½. Mechanical drives with servo motion control use absolute encoders with capability to detect as low as positioning. Electric machines use no oil so processors eliminate variations in viscosity and flow caused by temperature variations in hydraulic machines. 6

7 2. Unbeatable Repeatability All electrics don t vary over time, because there s no hydraulic fluid to heat up or compress, no hoses that expand, no valves that stick. 7

8 3. Better Part Quality Results: Less Material Use. Less Scrap. Less Energy. More Good Parts. 8

9 4. Less Maintenance More reliable, with fewer parts to change out. Servomotors have failure rates below 0.2% for total parts produced. Milacron all electric average warranty costs less than $135 per machine per year. 9

10 5. Oil Free Operation None of the challenges of hydraulic oil: No disposal No leaks No hoses No slipping hazards 10

11 6. No Cooling Water Needed 55 ton hydraulic Annual bill of $3,800 for cooling water ALONE. Electric IMM Air cooled, with NO COST for cooling water. 11

12 7. A Better Work Environment 2/3 the noise = Less stress Greater flexibility in plant layout 12

13 8. Dramatically Reduced Energy Costs On average, electrics use less than ¼ of the energy used by a hydraulic machine without even accounting for cooling for the hydraulic SOURCE: All Electric Injection Molding Machines: How Much Energy Can You Save? Kunungo, Amit; Swan, Eric. Presented at the Thirtieth Industrial Energy Technology Conference, New Orleans, LA, May 6 9,

14 Where Does the Efficiency Come from? Hydraulics: Use energy even when idle. Electrics: Use energy only when required for a given action by high speed and high efficiency servo motors. 14

15 Markets & Applications Electrics are suitable for all markets and applications, needing: High speed, thin walled parts Weight reduction in any plastics part Tight tolerances required for medical and electronics Lower part contamination and cleanliness Consistent and repeatable manufacturing 15

16 Medical Applications Petri dishes Syringes Vaccutainers Closures FDA compliant/calibration Cleanrooms 16

17 Food & Beverage CSD Flip cap Large cap High speed dairy Cutlery Unscrewing cap 17

18 Packaging Thin wall containers Food Dairy Carry out Lids High volumes 18

19 Industrial Buckets & Pails 1 & 2 cavity 5 gallon 90 mil pails 70 mil pails 1 to 4 gallon containers Co injection pails Large pails (12 gallon) 19

20 Consumer Goods Deodorant barrels Flower pots Cosmetics Spray trigger assemblies Trash cans & totes Pens and markers 20

21 Automotive Body panels Light casings Dashboards Handles Under the hood Wheel covers Electronics 21

22 Case Study Smitty's Supply Machinery: Two all electric injection molding machines one PowerPAK machine and one POWERLINE unit. Opportunity: Reduce costs by producing plastic containers for their products inhouse instead of purchasing them from a supplier. Results: Running 17.5 second cycle times in production faster than their previous outsourcing partner. Saving a minimum 45% on energy vs. what they d spend with hydraulic driven machines. 22

23 Case Study Norton Packaging Machinery: POWERLINE all electric injection molding machines. Challenge: Meet customers increasing demands by achieving better performance and efficiency with injection molding machines. Results: Energy savings ranged from 35% savings compared to hybrids to 50% energy savings compared to all hydraulic machines. 23

24 So How Much Can YOU Save? Although all electric machines cost percent more than conventional hydraulic systems, that additional cost can be quickly made up for in energy savings % less power. 25 % lower connected power requirements. Peak loads requirements reduced by 60 80%. Run two or three all electric injection molding machines on the same total power as one hydraulic machine. 24

25 Energy Cost Comparison 25

26 Payback Analysis INVESTMENT BASIS INVESTMENT RESULT $200,000 ROBOSHOT Payback Analysis ROBOSHOT List Pric $127,500 Cost of Capital 10% Comparison List Price $110,225 Payback Period (yrs 0.9 $150,000 $100,000 Price Difference $17,275 Return on Investmen 108% $50,000 Adjustments Net Present Value $88,835 Utility Rebates $0 Features $0 Net Price Difference $17,275 $0 ($50,000) Yr 0 Yr 1 Yr 2 Yr 3 Yr 4 Yr 5 Yr 6 Yr 7 Yr 8 Yr 9 Yr 10 Operating Savings Yr 0 Yr 1 Yr 2 Yr 3 Yr 4 Yr 5 Yr 6 Yr 7 Yr 8 Yr 9 Yr 10 Energy $7,772 $7,772 $7,772 $7,772 $7,772 $7,772 $7,772 $7,772 $7,772 $7,772 Water Usage $2,701 $2,701 $2,701 $2,701 $2,701 $2,701 $2,701 $2,701 $2,701 $2,701 Preventive Maintenance $483 $483 $483 $483 $483 $483 $483 $483 $483 $483 Reliability (higher uptime) $4,800 $4,800 $4,800 $4,800 $4,800 $4,800 $4,800 $4,800 $4,800 $4,800 M aterial $2,209 $2,209 $2,209 $2,209 $2,209 $2,209 $2,209 $2,209 $2,209 $2,209 Housekeeping $750 $750 $750 $750 $750 $750 $750 $750 $750 $750 Total Operating Savings $18,715 $18,715 $18,715 $18,715 $18,715 $18,715 $18,715 $18,715 $18,715 $18,715 Cash Flow ($17,275) $1,440 $20,154 $38,869 $57,584 $76,299 $95,013 $113,728 $132,443 $151,158 $169,872 ($17,275) $18,715 $18,715 $18,715 $18,715 $18,715 $18,715 $18,715 $18,715 $18,715 $18,715 26

27 Sample Cost Worksheet 27

28 Sample Cost Worksheet 28

29 Sample Cost Worksheet 29

30 Milacron s Line up of All Electrics POWERLINE Series Roboshot Series PowerPAK Series 30

31 Milacron Plastics Machinery Leader and innovator in electric injection molding from the very beginning Questions? 31