9781847355966_Front Cover.pdf -- 9781847355966_Content.pdf -- A Practical Guide to Energy Management for Processors -- Contributors -- Contents -- 1 Introduction -- 1.1 The Need for Energy Reduction -- 1.2 The ENERGYWISE Plastics Project -- 1.3 A Practical Guide for Processors -- 1.3.1 Injection Moulding -- 1.3.2 Extrusion -- 1.3.3 Rotational Moulding -- 1.3.4 Compression Moulding -- 1.3.5 Moulds and Tooling -- 2 Injection Moulding -- 2.1 The Injection Moulding Process -- 2.2 Where and How to Save Energy in the Injection Moulding Process -- 2.3 Machine, Mould and Ancillaries Optimisation -- 2.3.1 Barrel Insulation Jackets -- 2.3.2 Hydraulic versus Electric versus Hybrid Machines -- 2.3.3 Conformal Cooling -- 2.3.4 Variable Speed Drives -- 2.3.5 Case Study: Potential Savings when Fitting a Variable Speed Drive -- 2.4 Basic Actions to Reduce Energy Consumption when Injection Moulding -- 2.4.1 Process Stability -- 2.4.2 Parameter Optimisation -- 2.4.3 Cycle Time Optimisation -- 2.4.4 Periodic Assessment of Scrap Levels -- 2.4.5 Periodic Revision of Mould Performance -- 2.4.6 Injection Machine Adaptation -- 2.4.7 Ancillary Equipment -- 2.4.8 Adequate Maintenance of Injection Moulding Machines and Ancillary Equipment -- 2.4.9 Down Time Energy Consumption -- 2.4.10 Cycle Time Reduction with New Technology -- 2.5 Injection Cycle Parameters Optimisation -- 2.5.1 Process Parameters Adjustment: Standard Procedure for Injection Moulding Process Setup -- 2.5.2 General Recommendations -- 2.5.3 Clamping Unit Adjustment -- 2.5.4 Plasticising Unit Adjustment -- 2.5.5 Injection Unit Adjustment -- 2.5.6 Standard Operation Procedure -- 2.5.7 Parameter Optimisation -- 3 Extrusion -- 3.1 The Extrusion Process -- 3.2 Reducing Energy Consumption in the Extrusion Process -- 3.2.1 Flat Film Extrusion -- 3.2.2 Blown Film Extrusion -- 3.2.3 Profile Extrusion.

3.2.4 Motors and Drives -- 3.2.5 Compressed Air -- 3.2.6 Free Cooling -- 3.2.7 10 Tips to Reduce Your Energy Consumption in Extrusion -- 4 Rotational Moulding -- 4.1 The Rotational Moulding Process -- 4.1.1 Background to Rotational Moulding -- 4.1.2 The Rotational Moulding Technology -- 4.1.3 Advantages and Limitations of Rotational Moulding -- 4.1.4 Machinery for Rotational Moulding -- 4.1.5 Moulds for Rotational Moulding -- 4.1.6 Materials for Rotational Moulding -- 4.1.7 Factors Influencing Moulded Part Quality [8] -- 4.2 Reducing Energy Consumption in the Rotational Moulding Process -- 4.2.1 Good Housekeeping -- 4.2.2 Equipment Improvement -- 4.2.3 Process Improvement -- 4.2.4 Materials -- 4.2.5 Action Points for an Energy Efficient Operation -- 5 Compression Moulding -- 5.1 The Compression Moulding Process -- 5.2 Reducing Energy Consumption in Compression Moulding -- 5.2.1 Control Unit -- 5.2.2 Hydraulic Drive -- 5.2.3 Heating and Cooling System -- 5.2.4 Mould Unit -- 5.2.5 Control of the Machine Run-time -- 5.2.6 Setting the Machine Parameters -- 5.2.7 Controlling Process Parameters -- 5.2.8 Insulation of the Mould -- 5.2.9 New Process Design: Longfibre Thermoplastics/In-line Compounding Process -- 5.2.10 Energy Optimised Press Systems -- 5.2.11 Tips for Reducing Energy Consumption -- 5.2.12 Other New Processes in Compression Moulding -- 6 Moulds and Tooling -- 6.1 Introduction -- 6.2 Variable Temperature Control -- 6.3. Thermal Transfer and Injection Moulding Technology -- 6.3.1 Electrical Resistive Heating [4] -- 6.3.2 Rapid Heating Ceramics -- 6.3.3 Thermal Conduction with Heating Elements -- 6.4 Convective Heating -- 6.4.1 Mould Heating by Convection -- 6.4.1.1 Temperature Control with Water, Oil or Steam [5] -- 6.4.1.2 Steam Technologies - The Mitsubishi International and Fuji Seiko Company Process.

6.4.1.3 Pulsed Cooling - The Rhytemper Process -- 6.4.1.4 Rapid Heat Cycle Moulding - RHCM™ Technology -- 6.4.1.5 Pulsed Cooling - Contradictory Reports [7] -- 6.4.1.6 RiTemp Technology - An Evaporative Cooling Approach -- 6.5 Radiant Heating -- 6.5.1 Infrared Radiators Mounted Externally or Integrated into the Mould -- 6.6 Inductive Heating [9] -- 6.6.1 Induction Heating of a Mould Cavity Surface -- 6.6.2 Indumould -- 6.6.3 High Heating Rates with Induction Heating [12] -- 6.7 Conformal Cooling -- 6.7.1 Hipermoulding Project -- 6.7.2 Portuguese Case Study -- 6.8 Anodised Aluminium Moulding -- 6.8.1 Wear and Hardening Issues -- 6.8.2 Cycle Time Reduction -- 6.8.3 Coating Technologies for Aluminium Moulds -- 6.8.4 Titanium Oxide Coating -- 6.9 Conclusions -- 7 Other Processes -- 7.1 Thermoforming -- 7.1.1 Introduction -- 7.1.2 Energy Consumption -- 7.1.3 Energy Reduction -- 7.1.3.1 Heating the Sheet -- 7.1.3.2 Cooling -- 7.1.3.3 Computer Control -- 7.1.3.4 Optimising Cycle Time -- 7.1.3.5 Servo Motors -- 7.1.4 Conclusions -- 7.2 Blow Moulding -- 7.2.1 Introduction -- 7.2.2 Reducing Energy Consumption -- 7.2.2.1 Polymer Melt Temperature -- 7.2.2.2 Parison Control -- 7.2.2.3 Mould Closing -- 7.2.2.4 Compressed Air for Parison Support and Blowing -- 7.2.2.5 Product Cooling -- 7.2.2.6 Product Trimming -- 7.2.2.7 Machine Run-time -- 7.2.2.8 Setting the Machine Parameters -- 7.2.2.9 Air Compressors and Systems -- 7.2.2.10 Moulding Machines -- 7.2.3 Conclusions -- 7.3 Expanded Polystyrene Foaming -- 7.3.1 Introduction -- 7.3.2 Production of Expanded Polystyrene -- 7.3.3 Environmental Impact -- 7.3.4 Energy Management -- 7.3.4.1 Energy Requirements -- 7.3.4.2 Reducing Energy in Production -- 7.3.5 Conclusions -- Chapter Authors -- Abbreviations -- Index -- 9781847355966_Back Cover.pdf.