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16.Matsui & 'factor 4'

TOP > Environmental Activities > The President's Green Column >
16.Matsui & 'factor 4'

The President's Green Column

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16.Matsui & 'factor 4'

In my previous entry, I wrote about the transition from 'Ownership' to 'Service'. In order to achieve 'factor 4', it is necessary to promote energy and resource saving in machineries and processes, practice the 3Rs and change the mentality of the society from 'owning properties' to 'use of service'.

This time turn, I would like to explain the connection of Matsui with 'factor 4'.

Matsui's Mission

As mentioned in my column previously, amongst the various major global environmental issues, the 'Insufficiency of Resources' and 'World Poverty' are the most critical. Matsui deeply agrees with the ideology of 'factor 4 ? Doubling Wealth & Halving Resource Usage' that is said to resolve the 2 most critical problems mentioned above. Matsui aims to help our users

'Achieve factor 4 in molding factories by 2020'

In order to eliminate the wastage of energy, resins and water in molding factories, Matsui is involved in the R&D of machinery of higher productivity, diagnosis of factories and customized proposals according to diagnosis results. In other words, our job is not just about making and selling dryers, mold temperature controllers and other auxiliary machineries, our main aim would be to improve the resource productivity in molding factories.

At such, we hope to strike a balance between our environment and the benefit of our valued users.

Wastage of resources in the molding factories

In most molding factories, the elimination of wastage are being thoroughly implemented on a daily basis. What are the wastages that still remain in such molding factories?

For example, the minimum energy required for the injection molding of resins. Putting it on extreme terms, only energy to melt the resin and energy to inject the melted resin into the mold is required. Any energy used for other purposes are considered unnecessary. However, when the heat from molded resins is brought outdoors via water or other medium, energy is required to circulate and cool the medium.

Despite so, times of the minimum energy required are being consumed in most cases.
A classic example would be the mentality that heat in molding factories is the norm. The heat in molding factories is the exact proof of radiation from excessive energy usage.

In the case that sprue runners are to be recycled, energy will be consumed to melt it again. Not to mention greater wastage if sprue runners are not being recycled at all.

Wastage is also significant during winter, when water evaporates from cooling towers. The cool weather eliminates the need to cool water. In addition, the heating of excessively cooled water to accommodate to use is also another example of wastage.

Wastage is also significant during winter, when water evaporates from cooling towers. The cool weather eliminates the need to cool water. In addition, the heating of excessively cooled water to accommodate to use is also another example of wastage.

As much as the molding factories appear to be eliminating wastage, when examined in terms of resource productivity, there is still much room for improvement.

How exactly is Matsui trying to achieve 'factor 4' in molding factories?

Matsui hopes to achieve 'factor 4' with the following strategies.

1. The continuous improvement of proposals to increase resource productivity of molding line.

The publishing of the 'Create More from Less' handbook that has all the possible proposals put together. This handbook currently consists of 24 possible proposals, however so, Matsui will continue to work on increasing and improving the proposals.
Please click here to request for the Create More from Less Handbook

2. Diagnosis of molding factories and lines

As part of the preparation to propose energy and resource saving improvements, Matsui will diagnosis the current factory and molding line. Currently, we provide 'Water Diagnosis' of the water-cooling system and 'Energy-saving Diagnosis' that focus more on the energy wastage from drying of materials. From the results, the possible saving of water, electricity and cost are being calculated.

3. Customized proposals according to diagnosis result

Cost savings from energy and resource saved will be compared to the cost involved in the remodeling and addition of new machinery. Proposals will then be proposed to acquire breaking even of cost in the shortest possible time while allowing profit in the long run.

Although the strategies above are yet perfect, we will continue to work on improving them.

In my next entry, I would introduce the proposals to increase resource productivity of the molding line.

15 Jul 2009 Hironobu Matsui

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