20% energy savings for Atlantic Plastics injection moulders 25 March 2014

Atlantic Plastics is reporting 20% savings on energy costs on one of its large injection moulding machines, following installation of an ABB variable-speed drive.

Gary James, engineering manager for the Bridgend, South Wales, plant, explains that it has 36 plastic injection moulding machines manufacturing fittings and valves for water utilities and water distribution.

"We are trying to become greener and cut energy use and had identified our two 400-ton injection moulding machines as energy intensive," states James.

Having consulted several potential suppliers, he says that ABB partner firm APDS – which recommended an ABB variable-speed drive – gave his team the confidence that they were up for the job.

The injection moulding machines harness hydraulic pumps driven by electric induction motors, chosen for their low cost, efficiency, ruggedness and low maintenance.

However, James explains that the motors ran at fixed speed, direct-on-line, even though for most of the cycle time machine operations did not need all the oil delivered by the pump, so the oil was recirculated.

APDS installed a trial drive to match demand and measured power drawn at 10.5kW, instead of the 25.3kW from the existing direct on line approach.

That was achieved by gradually reducing flow on the on-load and off-load parts of the cycle, with the drive set up to run at two speeds selected automatically according to torque demand, rather than by sensing oil pressure.

James says that payback was about 12 months. "For any investment we make we look for a payback of under two years, so we are very pleased with the results of the project," he states.

"We intend to put similar solutions on the remaining 35 injection moulding machines."

Brian Tinham

Related Companies
ABB Ltd
APDS Ltd

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