1. Production Workshop
The layout of the production workshop should consider two main aspects: meeting production requirements and optimizing layout based on production flow, while ensuring flexible energy use under specific production conditions.

(1) Power Supply: Ensure a stable power supply with a moderate buffer to avoid excessive energy waste from unused capacity.
(2) Efficient Cooling Water Circulation: Build an efficient cooling water circulation system with effective insulation to maintain temperature control.
(3) Optimize Production Layout: Coordinate workflow steps to minimize turnover time and energy consumption, thereby improving production efficiency.
(4) Separate Control for Lighting: Use the most effective small units for separate lighting control to reduce unnecessary energy use.
(5) Regular Maintenance of Workshop Equipment: Conduct routine maintenance to avoid disruptions caused by facility damage, which could increase energy consumption.


2. Injection Molding Machines
Injection molding machines are major energy consumers in a molding workshop, with power usage mainly for motors and heating.

(1) Select the Right Injection Molding Machine: Choose machines that fit product requirements; oversized machines often lead to significant energy waste.
(2) Use All-Electric or Hybrid Injection Machines: These machines offer excellent energy-saving effects, reducing energy consumption by 20-80%.
(3) Adopt Advanced Heating Technology: New heating technologies, such as electromagnetic induction or infrared heating, can save 20-70% in heating energy.
(4) Insulate Heating and Cooling Systems: Effective insulation reduces heat and cold loss, optimizing energy use.
5. Ensure Proper Lubrication: Keep transmission components well-lubricated to reduce energy loss due to increased friction or unstable operation.
6. Use Low-Compression Hydraulic Oil: This minimizes energy waste within the hydraulic system.
7. Implement Parallel Actions and Multi-Cavity/Multi-Component Molding: These techniques can significantly save energy.
8. Energy-Efficient Drive Systems for Traditional Machines: Retrofit traditional hydraulic injection machines with energy-saving drives to replace fixed-pump systems and significantly reduce energy use.
9. Regular Maintenance of Heating and Cooling Pipes: Ensure pipes are free of impurities or scale, maintaining heating and cooling efficiency.
10. Maintain Machines in Optimal Condition: Unstable processing can increase defect rates and energy consumption.
11. Use Appropriate Equipment for Specific Products: For instance, PVC processing often requires specialized screws to maintain efficiency.

3. Injection Molding
The structure and condition of the mold often have a significant impact on the injection molding cycle and processing energy consumption.

1. A well-designed mold—including runner design, gate type, cavity count, and heating and cooling channels—helps reduce energy consumption.
2. Using a hot runner mold can save materials, reduce energy used in material recycling, and improve energy efficiency in the molding process itself.
3. Contour-controlled rapid heating and cooling molds can significantly save processing energy and achieve better surface quality.
4. Ensuring balanced filling in each cavity shortens the molding cycle, ensures uniform product quality, and has excellent energy-saving effects.
5. Using CAE-assisted design technology for mold design, flow analysis, and simulation can reduce energy consumed in mold debugging and repeated modifications.
6. Using lower clamping force while ensuring product quality extends mold life, supports quick mold filling, and contributes to energy savings.
7. Regular mold maintenance ensures effective heating and cooling channels are in optimal condition.


4. Auxiliary Equipment
1. Choose auxiliary equipment with the appropriate capacity that meets operational requirements without excess capacity.
2. Proper maintenance and upkeep of equipment ensure it operates normally. Malfunctioning auxiliary equipment can lead to unstable production, poor product quality, and increased energy consumption.
3. Optimize the coordination and operation sequence of the main machine with auxiliary equipment.
4. Position auxiliary equipment as close to the main machine as possible without compromising operational conditions.
5. Many auxiliary equipment manufacturers offer demand-based energy supply systems, which can achieve significant energy savings.
6. Use quick mold change equipment to reduce waiting time during product changeovers.


5. Materials
Different materials consume different amounts of energy during processing, and poor material management or mishandling of recycled materials can increase production energy consumption.

1. Choose materials with lower processing energy requirements, provided product performance is met.
2. Prioritize high-flow materials if they meet performance and cost optimization requirements.
3. Note that materials from different suppliers may require different process conditions.
4. When drying materials, use them immediately to avoid energy waste from moisture reabsorption.
5. Properly store materials to prevent contamination or mixing with foreign substances, which can lead to defective products.
6. Some products allow for the inclusion of a certain amount of recycled material, but attention should be given to the cleanliness of the recycled material to avoid quality issues.

6. Processing Techniques
1. Use the shortest molding cycle that meets product performance requirements.
2. Unless there are special requirements, use the supplier-recommended processing parameters.
3. For specific products and molds, save stable equipment and process parameters to reduce setup time for future production runs.
4. Optimize processes by using lower clamping force, shorter cooling time, and shorter holding time.


7. Adoption of New Technologies
1. Implement auxiliary molding technologies such as gas-assisted, water-assisted, steam-assisted, and microcellular foam injection molding.
2. Adopt modular molding solutions to reduce intermediate steps.
3. Use in-mold technologies, such as in-mold welding, in-mold coating, in-mold assembly, and in-mold decoration.
4. Apply new low-pressure molding technologies to shorten cycle times and reduce melt temperatures.
5. Utilize energy recovery systems.


8. Production Management
1. Producing high-quality products in a single attempt, minimizing defect rates, is the most effective energy-saving measure.
2. The maintenance of the entire production system is closely related to energy consumption. This includes not only the main machine but also auxiliary and facility equipment. For example, if an overhead crane malfunctions, requiring manual mold changes, equipment wait times will increase, leading to higher energy consumption.
3. Installing an energy consumption monitoring system in the workshop enables targeted energy analysis and improvement efforts.
4. When performing equipment maintenance, not only check the equipment itself but also ensure reliable connections and performance with other systems.
5. Regularly compare energy efficiency with industry benchmarks to identify further improvement opportunities.
6. Establish reliable contracts and partnerships with suppliers to benefit energy management efforts.