Towards a sustainable molding factory- an era where the environment and business management coexist
An era in which environmental response increases corporate value
In recent years, efforts to achieve carbon neutrality have been accelerating across the entire manufacturing industry. Small and medium-sized enterprises account for 10-20% of Japan's greenhouse gas (GHG) emissions, making reduction of these emissions an essential task. In addition, many large globally operating companies have set reduction targets (SBT) that are in line with the international goal of the 1.5°C level, and there is a growing trend to require emissions reductions throughout the supply chain. As a result, there is strong demand for small and medium-sized enterprises, who are trading partners, to also take on greenhouse gas reduction initiatives and demonstrate their achievements.
Furthermore, financial institutions are increasingly supporting companies that are proactively taking environmental concerns into consideration, and reduction activities lead to increased fundraising and new business. In other words, decarbonization is not only a social responsibility, but also an initiative that brings significant business benefits.
Achieving carbon neutrality requires decarbonization efforts. In recent years, interest in the importance of this has been growing, and the percentage of companies and organizations actually taking action is increasing year by year.
Ministry of Economy, Trade and Industry, Small and Medium Enterprise Agency: 2024 White Paper on Small and Medium Enterprises (Part 1, Chapter 4, Section 5)
The necessity of balancing environmental friendliness and cost reduction
Against the backdrop of rising energy prices worldwide, electricity prices have risen significantly in Japan in recent years.
Such rising electricity costs pose a very serious issue for plastic molding factory. Molding machines and other equipment require large amounts of electricity to operate, and this consumption is directly linked to running costs. In particular, the operation of heat source systems, primarily heaters, consumes a huge amount of electricity, which has a direct impact on factory 's profitability when electricity costs rise. Molding factory operate 24 hours a day and with many machines in operation, so the increased costs caused by rising electricity costs lead to a squeeze on profit margins and a decline in price competitiveness. Electricity costs account for a large proportion of the cost, especially for low-cost mass-produced products, and without countermeasures, management risks increase.
At the same time, there is a need to improve energy efficiency and reduce CO2 emissions in order to achieve carbon neutrality. In other words, molding factory are under double pressure to be environmentally conscious and reduce costs.
That is why it is now essential for factories to have a system that can both save energy and reduce costs. Turning rising electricity rates to our advantage and promoting efficiency and equipment improvements will not only strengthen cost competitiveness, but will also lead to a step towards sustainable factory operations.
Measures that are both environmentally friendly and energy-saving are being introduced at molding sites as well.
The effects of heat on molding sites
Heat insulating boards are a standard measure against heat.
Mold Temperature Controller are essential devices for maintaining molds at a specified temperature. However, did you know that the heat is transferred not only to the mold but also to the molding machine itself? Heat transferred from the mold causes the entire molding machine to "stretch," resulting in a decrease in mold clamping force and an impact on molding accuracy.
*The "automatic mold pressure adjustment" function installed in the molding machine is a mechanism to compensate for the decrease in mold clamping force caused by this stretching.
Therefore, many workplaces use "insulating boards" as a common countermeasure. By placing them between the platen and the mold, they are expected to suppress direct heat conduction. However, the insulating effect varies depending on the material, and the platen and molding machine come into contact widely through the bolt holes provided for attachment, which allows heat to be transferred from there. In other words, although insulating boards are an effective measure, they are by no means sufficient.
Heat transfer that cannot be prevented by insulation boards
The only thing that heat insulation plates can block is heat conduction at the contact surface between the mold and platen. However, heat is also transmitted through parts such as the Fitting bolts and locating ring, and from there spreads throughout the molding machine. Unless these multiple routes are blocked, it is impossible to prevent unnecessary heat dissipation.
① From the mold Fitting plate
②From the Fitting bolt
③ From the locate ring
When heat is transmitted to the molding machine, the iron expands slightly, causing it to stretch on the order of microns. This results in an imbalance in the mold clamping, affecting the dimensions and quality of the product.
Blocks heat from three directions to protect the molding machine from heat
TamaGON is proposed as an effective insulation measure.
TamaGON creates an "air insulating layer" between the platen and the mold, significantly reducing the heat transfer from the mold to the platen.
The ease of heat transfer is generally determined by the following calculation:
TamaGON reduces conductivity by reducing the contact area with the platen and forming an insulating layer of air.
1. Blocks heat from the mold Fitting plate
When the mold is heated, the heat is transferred to the platen through the mold Fitting plate.
TamaGON creates an air gap between the platen and the mold, significantly reducing heat transfer from Fitting plate to the platen. This prevents unnecessary temperature increases in the platen, leading to dimensional stability of the entire molding machine and consistent quality of molded products.
① From the mold Fitting plate
2. Blocks heat from the Fitting bolts
At molding sites, Fitting bolts are essential for firmly fastening the mold and platen. However, metal bolts are highly conductive and act as a heat path, transferring heat from the mold directly to the platen.
Therefore, TamaGON was installed in combination with an air clamp and insulating washer, which significantly reduced heat transfer via the bolts and prevented localized temperature increases on the platen.
②From the Fitting bolt
3. Blocking heat from the locating ring
The locating ring is an important part that determines the mold position, but its thick wall can also be a source of heat.Normal locating rings are in close contact with the platen, which efficiently transfers heat.
Therefore, a special design is used to remove the thick parts, blocking the heat conduction path and minimizing the heat transfer from the locating ring to the platen.
③ From the locate ring
By combining TamaGON with an air clamp and insulating washer, you can insulate the heat transmitted from the bottle.
That's right. By using it in combination with TamaGON, it is possible to prevent localized temperature increases and maintain a stable molding environment.
I see... So, what exactly is different about the shape of the locate ring?
Please see here. The thick parts have been hollowed out, which minimizes heat transfer to the platen compared to conventional models.
Effectiveness examples
When comparing a normal heat insulating plate with "TamaGON + α (air clamp, heat insulating washer, special locating ring)" which takes measures against three heat transfer routes, it was confirmed that the power consumption effect was approximately 60% at the maximum. Furthermore, in addition to energy savings, it also shortens the time it takes for the mold to heat up, and because the required heater capacity is smaller, it also has the advantage of allowing for the downsizing of the temperature controller.
