InnEEPlas workshop 'Energy efficient peripherals and ancillaries in plastics processing' 19 November 2015 Enrgy savings in the temperature control of moulding processes, HB-Therm AG

1. Energy savings in the temperature
control of moulding processes
Philipp Geisser HB-THERM AG, St. Gallen
Afternoon workshop:
Energy efficient peripherals and ancillaries in
plastics processing
InnEEPlas partners in Gent (B)

2. Energy savings in temperature control of moulding processes
Contents
• Primary energy flow in the injection moulding processes
• Secondary energy flow (e.g. heat loss)
• Saving potentials
• Countermeasures by optimal connection of the temperature control equipment to
the mould

3.  US  hhmQ  
 SE  hhmQ  
Q
Moulded part ϑE
Melt ϑS
Raw material ϑU
Plastification Mould
heat flow
processed quantity per time
h enthalpy
ϑ temperature
..S melt
..U environment
..E demoulding
m
R0222-E 1140
Flow of primary energy in injection moulding

4. Water
Plastification
Material
conveying
Material
drying
Part Sprue
Moulded
part ϑE
Melt ϑS
Raw material ϑU
Air Air Humidity
Air
Air Air
Air
Hot runner
Fan HeatingDrive unit
Drive unit Heating
AirAir
TCU fixed side
Pump HeatingWater
Air
TCU moving side
Pump HeatingWater
Air
Cooling system
Pump
Cooling circuit
Water
Inj. moulding:
- Mould closure
- Core pullers
- Ejector
- Injection/
holding
pressure
ϑKW
ϑKW ϑVL FS ϑVL MS
ϑMSϑFS
ϑMP
ϑMP
Air
Air
Humidity
Mould
R0223-E 1213
Flows of primary and secondary energy in injection moulding

5. R0226-E 1140
Saving potentials in the mould

6. R0228-E 1140
Saving potentials in the temperature control unit (dynamic)

7. R0227-E 1140
Saving potentials in the temperature control unit (static)

8. R0229-E 1140
Saving potentials in the cooling system

9. Pressure drop in bar (water 60 °C)
0,0200,120,401,800,0050,0300,100,45
0,0120,060,201,000,0030,0150,050,25
0,0800,241,207,600,0200,0600,301,90
10864di mm10864di mm
V = 10 L/minV = 5 L/min
Example 2Example 1Pressure drop @ 5 L/min
Total
4 x 0,144 x 0,28ClosureQuick coupling DN 9
5 m x 0,025 m x 0,30Hose
6 x 0,0590°
2 m x 0,30
6 x 0,05
2 m x 0,30 6Cooling channel
 10
open
 6
90°
bar
3,52
1,12
1,50
0,30
0,60
bar
1,56
0,56
0,10
0,30
0,60
 6
R0191-E 1140
Pressure drop in the temperature control circuit

10. Mould with hose
flow rate with Ø 6 mm 5,5 l/min
flow rate with Ø 10 mm 7,8 l/min
flow rate increase 2,3 l/min
power difference 30 W
hours run 6000 h/year
energy 180 kWh
price 0,15 EUR/kWh
saving 27 EUR/year
R0192-E
Influence of the hose on the operating costs

11. Mould with hose (Ø 10)
flow volume with 2M-pump 7,8 L/min
flow volume with 4M-pump 9,5 L/min
flow volume increase 1,7 L/min
power 2M-pump 310 W
power 4M-pump 800 W
power difference 490 W
hours run 6000 h/year
energy 2940 kWh
price 0,15 EUR/kWh
saving 440 EUR/year
R0193-E 1546
Influence of the pump on the operating costs

12. Correct
Hose Nipple Mould
Recommended value: ds = 1,5 × dk
Wrong
ds dk
R0194-E 1213
Design recommendation when connecting to the mould

13. Due to the relatively high pressure drop
they cause, quick-action couplings should
only be used where absolutely necessary.
The cross-section should be as large as
possible.
R0195-E 1140
Quick couplings

14. Characteristics DN 9
Medium water
Flow rate L/min
Pressuredropbar
R0196-E 1140
Pressure drop characteristic of hose couplings (example)

15. Characteristics DN 13
Medium water
Flow rate L/min
Pressuredropbar
R0197-E 1140
Pressure drop of hose couplings (example)

16. Characteristics DN 19
Medium water
Flow rate L/min
Pressuredropbar
R0198-E 1140
Pressure drop of hose couplings (example)

17. R0199-E 1140
Pressure drop of quick couplings in an overview (example)

18. R0203-E 1140
Connecting hose with thermal insulation

19. Ambient temperature 20 °C
R0204-E 1140
Thermal dissipation of hoses with and without thermal insulation

20. Reduction of thermal dissipation of
bundled hoses
Surface temperatures of
hoses
R0205-E 1140
Thermal dissipation of hoses

21. Application case
• two temperature control units, each with 2 circuits (total of 8 lines)
• main line temperature 140 °C
• ambient temperature 20 °C
• nominal diameter DN 13
• hose length 6 m
• operating time 6ʼ000 h/year
• electricity costs 0,15 €/kWh
Results
R0206-E
Thermal dissipation of hoses

22. Summary
• We have learned about the primary and secondary energy flow in the injection
moulding processes.
• The saving potentials can be found basically in the secondary energy flow.
• Besides the efficiency of the equipment, simple countermeasures can be taken by
using suitable components to connect the temperature control equipment to the
mould.
Energy savings in temperature control of moulding processes

23. Thank you very much