Hot Energy Savings

Although energy is a word thrown around a lot these days, taking charge of energy management is serious business when it comes to your molds. It can help you reduce your molds energy requirements and increase savings. Moldmakers need to consider the overall package of each mold program to uncover when its possible to optimize your savings.


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I heard Paul Boettger of Technoject speak about methods for producing energy savings when using hot runner systems. He mentioned these eight considerations:

1. Resin selection and resin processing temperature

2. Shot size

3. Delta T mold temperature

4. Hot runner manifold

5. Hot runner nozzles

6. Rectangular heaters

7. Mold base size

8. Runner reduction

Boettger explained that insulating materials can be used to completely encase hot runner manifold blocks reducing radiation and convection. Also, increased contacting surfaces through metallic bonding and reshaped manifold heaters lead to more efficient heat transfers thus reducing the size of heater wattage. Furthermore, profiled coil heaters can supply heat in areas of demand and lower the heat output in other areas of lesser demand translating into further heat reduction requirements. Lastly, choosing a smaller nozzle for small cavities can significantly reduce the wattage requirements due to smaller hot runner components used. Combining the various efficiencies can translate into savings of up to 35 percent.