Case Study and Results (I) Hong Kong-invested Plastics Manufacturers

Customer Name

  • Hong Kong-owned plastics manufacturers

Time

  • To be put into operation in June 2024

Project Background

  • The company’s injection molding department currently has about 72 injection molding machines (total power 674KW) and 2 chillers (total power 90KW) for injection molding production. Due to long-term 24-hour operation, a cooling circulating water system with a cooling water tower is required to continuously dissipate heat for the injection molding machines and chillers to ensure that there will be no shutdown problems due to over-high temperatures. However, due to the large amount of volatilization of cooling water in the water tower, a large amount of scale is generated, which has a long-term impact on the heat exchange efficiency of the injection molding machine and the chiller, resulting in increased electricity consumption, increased shutdown times and a large amount of equipment maintenance requirements. The factory needs to use anti-scaling and sterilization chemicals for a long time to deal with mineral scale and bacteria problems. In addition to increasing costs, it also causes pipeline corrosion and rust problems.

Renovation Plan

  • The power consumption of the electromagnetic wave water treatment system is 35w, 4 sets are installed in the cooling water system of the injection molding machine, and 2 sets are installed in the cooling water system of the chiller, a total of 6 sets are installed;

Test Method

  • By installing electric meters to monitor the power consumption of the injection molding machine and chiller, and collecting the amount of injection molding plastic material used (equivalent to output), the unit energy consumption of injection molding production before and after the transformation (kWh/kg) was calculated and compared:
    • The energy saving rate of the injection molding machine is 48%, saving 152,529 kwh of electricity per year, and saving RMB129,650 in electricity bills per year;
    • The energy saving rate of the chiller is 09%, saving 78,876kwh of electricity per year and RMB67,045 in electricity bills per year;

Results

  • Annual savings on related pharmaceutical and maintenance costs: ¥50,000;
  • Total savings: ¥245,131, payback period: approximately 1.6 years

Real Case Scene Pictures