ES EN DEKERN IoP | ENERGY: CELL
Measure the electrical demand of the entire injection-moulding cell — circuit by circuit.
Monitor the injection-moulding machine and selected auxiliary equipment simultaneously. Establish which loads account for energy consumption during production, start-up and waiting periods.
Discuss your cell configurationAn injection-moulding cell has several electrical consumers
The injection unit operates alongside material dryers, mould temperature controllers, robots, local cooling equipment and other auxiliaries. Their power demand changes with the product, process settings and operating state. ENERGY: Cell measures selected single-phase and three-phase electrical supplies so that recorded power and energy can be attributed to the corresponding instrumented circuit.
Differentiate the machine from its peripherals
Examine the machine’s active power and accumulated energy separately from dryers, temperature-control units and other connected equipment. Measurement points are selected following a review of the installation’s electrical distribution. Shared services require a defined allocation method when they are relevant to the study.
Investigate specific operating situations
Review how much electricity is consumed during warm-up, mould changes, planned waiting and production. Where operating states and production quantities are available, compare energy intervals with the corresponding process information. Establish a baseline before making changes, document the operating conditions and check the results afterwards.
Build meaningful energy performance indicators
Report kW and kWh for each measured circuit. When synchronized records of output are available, calculate kWh per kilogram or kWh per part using matching measurement periods and a documented system boundary. Compare like-for-like products, machines and operating conditions.
Methodological reference: EUROMAP 60
EUROMAP 60.1 addresses machine-related energy efficiency under defined comparison conditions. EUROMAP 60.2 addresses electricity consumption for a specific machine, product and process, with specified reporting boundaries for optional peripherals. ENERGY: Cell supports operational measurements of the circuits selected for an installation. A formal test following an EUROMAP recommendation requires the applicable test conditions, instrumentation and reporting procedure to be verified separately.
HYPOTHETICAL CALCULATION
Illustrative scenario: preparation across 20 injection-moulding cells
Suppose 20 machines each undergo one mould change per working day. A process-improvement project reduces mould-change time from 2 hours to 30 minutes and start-up/warm-up time from 1 hour to 30 minutes. This releases 2 machine-hours per cell and change, or 880 machine-hours over 22 working days. If the reduction also eliminates an average measured electrical demand of 50 kW throughout each recovered period, the associated energy would be 44,000 kWh. At a hypothetical tariff of COP 600/kWh, its value would be COP 26.4 million per month. Actual net bill savings depend on the measured load profiles, any electricity used during additional productive hours and the tariff structure; faster warm-up alone does not imply the same proportionate reduction in heating energy.
Technical references
Select a measurement scope suited to your electrical installation
Tell us about the injection-moulding machine, dryers, temperature-control units, cooling equipment and other auxiliaries that make up your cell. We will review the appropriate electrical measurement points and opportunities to integrate operating data.
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