I have need some project on Energy Saving.

Air compressor

Replacement with variable screw will save energy. Variable screw type compressor will generate output on demand. Saving over the type that cycle from high too low. The pressure can all so be dropped to some value just above the maximum need for the equipment it services.

You may all so pick up savings on efficiency in todays new designs.

Thank You Sir,

One point keep in mind, while measuring energy use highest eccuracy of meter, CT etc, and calibrate them at prescribed regulat interval.

Our facility has 24 moulding machines in similar size range to your nominated ENGEL machines.

We have recently (over 1 year) audited all machines and found the largest "first cut" energy saving is through monitoring machine idle time during die changeover and material changeover.

Basically machine state options have different strategies.

Running at load: Check not using excessive clamp forces, injection pressures and so on. This loads the motors and pumps beyond the necessary conditions and uses power that provides no return. Check/add thermal insulation cloaks tot he barrel. We even moved one machine away from a draft that was affecting barrel power usage.

Standby mode: (Machine faults out and goes into standby condition waiting for operator intervention. ) Fit machine alarms (seems you already have this for maintenance)

Idle mode: (Machine shut to idle mode by operator, motors still running, some heaters still operational, usually happens during material or tool changeover.) Focus on "world best practice" for die changeover reductions and such. Also do calculations for a "cold restart" compared to sitting at idle for extended periods. We now have a chart showing for each machine the "breakeven" point (Of power consumption) of when it should be shut down rather than left in idle mode. You will be surprised at how short the time is even for 250T machines. [The same chart also nominates times for breakeven from standby mode so operators know when to shut down if they expect delays in support to restart the machines.]

Off: While the moulding machine is off, check also that material driers, die temperature controllers and ancilliary equipment are also "off", or at least not turned on until really needed.

We showed our operators what each state meant in terms of how much power htese machines use in terms of a typical household power bill. It's frightening!

Other things:

Material driers should be run so that materials are dried JIT (Just In Time) so that they don't continue to burn power maintaining material at elevated temperature for extended periods of time.

Mould tool heating: Check whether there is a net transfer of heat from the tool to the machine platten. Sometimes this is good as it helps the cooling cycle, other times you want to retain heat in the tool. If you want to retain heat, then insert insulating plates between tools and platten. (Will change die close height.) We have a couple of machines with such heat pads on the plattens, rather than fit them to 45 tools for each machine.

Could go on for hours on this stuff.

Hope has been of help.

Good luck