How Temperature Control Can Save Up To 70% In Energy Savings In Injection Moulding

Phil Black - PII Editor 18/08/2014

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ICS Cool Energy has worked alongside many plastics companies to supply reliable temperatures for both heating plastic pellets and cooling injected moulds to create perfectly formed products. In addition to reliable temperatures, ICS Cool Energy has successfully achieved savings for its customers with energy efficient and free cooling solutions.

Free Cooling – injection moulding case history 1

There are few solutions more economical than Free Cooling.

Richard Metcalfe, Sales Director at ICS Cool Energy explains, “With Free Cooling activated, companies can see potential reductions in energy costs of up to 70%.

“For example, our engineers have recently developed a solution for a Leicestershire-based plastics manufacturer who needed to upgrade its ageing systems to embrace new technologies, enabling it to become increasingly ethical and environmentally aware. We combined the use of an Aptus air cooled chiller with an independent Free Cooling coil which had the ability to extract 220kW thermal load at the company’s optimal conditions. Some of the benefits in selecting the Aptus chiller were the use of effective rotary scroll compressors and two independent refrigerant circuits containing R410a which provided the company one of the most efficient air cooled water chillers available on the market.”

By adding the independent free cooling coil the customer was able to further enhance its systems cooling circuit efficiencies. Not only does it use the cooler ambient air temperatures to pre-cool or completely cool the process fluid, a free cooling coil’s own energy consumption should take into account the use of inverter fan speed control.

Injection moulding case history 2

Metcalfe continues, “Another example of a company benefiting from Free Cooling is a customer renowned for its manufacture of plastics plumbing, heating and drainage systems. The team has modified its three 250kW dry air coolers and modified them to become independent Free Cooling coils. What we did – we modified the system from stage control to systems that operated on inverter fan speed control. In order for the coolers to avoid heat generation in summer months the systems design philosophy had to incorporate a three way diverting valve.”

After the retrofit of the unit’s controls and full integration of the system, the solution was commissioned by ICS Cool Energy’s service division. Metcalfe continued, “By taking this consultative approach to a solution ICS Cool Energy was able to reduce the customers initial capital investment whilst maximising energy efficiency and achieving a return on investment within 12 months.”

Efficient product range

Yet Free Cooling is not the only solution for gaining better efficiencies on site. ICS Cool Energy has recently launched the fourth generation of their extremely popular and well recognised industrial chiller the i-Chillers to coincide with its 25th year in business.

Metcalfe continues, “Our new range of chillers promises to offer vastly improve system efficiencies through its cost-effective, low power operation hermetic scroll compressors, saving energy throughout. It has been specifically designed for use in industrial applications through its core utilisation of R410A refrigerant, and also ensures that companies are fully compliant with EU legislation and primed for the phase out of R22.”

Injection moulding case history 3

ICS Cool Energy has recently worked with a plastics manufacturing firm in the UK that has 14 machines producing over 230 different parts every 1.25 seconds – approximately 95,000 parts per day. Without efficient temperature control equipment, the injection moulding procedure would falter.

“The company made contact with us when it was looking to expand its capacity to a 10 acre site,” Metcalfe says, “yet it also needed to improve its processes and adopt ‘smarter’ practices and of course move away from the R22 refrigerant.”

Rental solutions

The i-Chiller range provides customers with high standards of energy efficiency, is good for the environment and ultimately good for a sustainable industry. It is also available from ICS Cool Energy’s Hire Division so that companies don’t need to invest in the capital to see the benefits.

Injection moulding case history 4 – rented option

With over 30 years’ experience, one of the UK’s most reputable plastics companies has developed and grown to become a leading force in the plastics market. Perfecting the art of design and manufacture of injection moulding, the company has an enviable record of success. Yet with great success comes the need to expand the factory.

Metcalfe comments, “Increasing production to a new 50,000 sq ft facility just outside of London was a major change for the business, which needed to ensure that production quality was not compromised. Yet with capital outlays hovering around the £50,000 price tag, we offered a temporary solution to support the company financially with a five-year rental package that included all maintenance and support.

“Since the initial installation, our engineers have added a further six, 6kW water heaters to support the injection moulding machines on another comprehensive five-year deal, to support future expansion.”