How to reduce the cost of using an injection molding machine by using high-quality lubricants?

An injection molding machine is a device used to produce parts from thermoplastics by injection molding. Today, more than a third of the world's one-piece products made of polymeric materials are manufactured using injection molding machines. More than half of the equipment used in polymer processing is dedicated to injection molding. The molding technology is ideal for mass production of complex shapes that require a repeatable, accurate size.

What is an injection molding machine?

Traditionally, injection molding machines can be divided into manual injection molding machines, where the operator starts each cycle manually, finally removing each finished copy of the product from the tooling, and controlled injection molding machines, where the processes run automatically. The cycle time in the casting process varies greatly - thin-walled products can be produced in seconds, and castings weighing hundreds of kilograms can be produced in minutes. In general, the injection molding machine has 2 main units: kneading unit, mold clamping unit with subsequent ejection. In some cases, the injection molding machine can be equipped with a variety of additional equipment, such as mold heating, a set of sensors, a CNC unit, separate drives for important assemblies, etc.

Why is proper device maintenance so important?

In the plastics industry, injection molding machines are one of the most valuable assets. Proper lubrication can help keep the machine running 24 hours a day, 7 days a week. Reducing unplanned downtime significantly increases productivity. Using the right lubricant is an essential aspect of effective maintenance of your injection molding equipment. Hydraulic oil is critical to injection molding machines and plays a key role in extending equipment life and achieving top cycle speeds. Effective lubrication can help companies lower their total cost of ownership by lowering maintenance costs, reducing unscheduled downtime and improving productivity. Although the purchase of high-quality hydraulic fluid may not be a top priority for some manufacturing companies because it accounts for only 1-2% of total operating expenses, the long-term savings can be significant. Proper lubrication provides a number of benefits:

• Wear protection - helps reduce wear and corrosion, protecting against injection molding machine failures
• Longer equipment life - greater oil resistance to oxidation allows injection molding machines to run at higher loads for longer
• System energy efficiency - good quality oil maintains its lubricating parameters longer, which translates into lower energy consumption

The total cost of ownership (TCO) of the equipment should be considered when calculating the cost-effectiveness of using better quality lubricants. This calculation takes into account the acquisition and operation costs over the entire service life, taking into account additional production losses caused by downtime due to equipment failure.

Oil condition monitoring

Monitoring the condition of your injection molding machine's lubricating oil and grease will help you estimate the remaining life of your hydraulic oil. Regular monitoring of the condition of the lubricant is essential to know when it needs to be replaced and to prevent costly and unnecessary breakdowns and machine downtime. In fact, poor maintenance of lubricants in injection molding machines can reduce productivity by 5 - 20%. In many plastic injection molding operations, whether producing large car bumpers or small DVD cases, the priorities are the same: high quality production at the highest possible cycle speed. Because machines often run continuously, any unscheduled shutdown due to hardware failure is costly and detrimental to productivity.

Lubrication is critical to these machines, especially when choosing a hydraulic fluid. In addition to protecting moving parts, which helps extend equipment life, it also transmits power mechanically through the hydraulic system. However, not all technical managers are aware of its critical role in operations. In a Shell Lubricants survey, more than half of respondents did not know how their choice of lubricant could affect delayed or lost production, equipment availability or unplanned downtime.

Consider the importance of oils and lubricants

Today's injection molding machines face increasing operational challenges of working harder and longer. Keeping your equipment running at peak performance is critical. Typical application challenges include corrosion, acontamination, leaks, wear and the formation of sludge and varnish, which can lead to problems such as blocked valves, filters and worn pumps. These failures are often attributed to the equipment rather than the hydraulic fluid. However, numerous studies by hydraulic equipment manufacturers and other industry organizations have shown that between 50% and 70% of equipment failures are related to the "improper condition of the hydraulic fluid". It's easy to overlook the importance of hydraulic fluid, after all, it is estimated to account for less than 2% of the total operating cost of an injection molding machine. However, the reality is that high-performance lubrication can deliver significant long-term cost savings for businesses, as enhanced equipment protection helps reduce the risk of equipment failure and associated costs. The hydraulic fluid is the driving force of the hydraulic injection molding machine. In addition to performing its primary task of transmitting mechanical power, it should also serve to extend machine life, reduce downtime, and increase productivity and repeatable accuracy. An example of an oil that significantly increases the efficiency of injection molding machines is Shell Tellus S4 ME which lasts up to 10 times longer compared to standard injection molding oils.

Hydraulic systems are expected to deliver peak performance when operating under high pressures, fluctuating temperatures and often harsh conditions. With such demands on lubricants, it pays to choose products with advanced protective properties and stability. Prioritizing lubrication as part of a balanced maintenance strategy will help lower the total cost of ownership, for example through reduced start-up times, lower energy consumption and optimized cycle times. A fast start-up time is important because it means your plastic injection molding machine reaches optimal operating conditions faster. Tellus hydraulic oilsare products of excellent quality , whose effectiveness in optimizing the operation of injection molding machines has been confirmed by numerous real examples.

Sources:

Optimize today to speed up tomorrow, Shell Lubricants brochure