Electrified plasticizing unit – Next Level for energy savings and carbon dioxide reduction
Baumüller supplies energy-efficient direct drives for the ZENITH 580 injection molding machine from Hürmak Machinery and thus drives electrification forward
How can energy be saved, and carbon dioxide emissions reduced in injection molding machines? Together with injection molding machine manufacturer Hürmak Machinery, the drive system partner Baumüller has found an answer to this question: „We are working almost ten years together and are successfully using the servo hydraulic solution of Baumüller for five years. Now we are using direct drive technology for the plasticizing unit and are very happy of the precision, faster cycle-times, and the energy savings”, says Burç Angan, Deputy Chair of The Board Hürmak Machinery.
Zenith series is the model line up with innovative two-platen hydraulic clamping system. It consists of seven different models between 110 and 1000 tons of clamping force
Hürmak Machinery is one of the leading and most trusted solution partners in the Turkish plastics industry. Founded in 1969, Hürmak became one of the most experienced and trusted company for injection molding machines in Turkey through its almost half a century life span.
With its machines that are designed, crafted, and produced completely in Turkey, Hürmak enjoys a great appreciation and demand from both local market and international markets. With this demand and realized-growth, Hürmak was awarded already in 2013 as being one of the top 100 fastest growing companies in Turkey.
Sustainability and carbon dioxide emissions
Global warming and the measures introduced by politicians to meet global climate targets are giving the issues of sustainability and the circular economy a considerable boost. The processing of recyclate, the design and use of thin-walled products to reduce the use of material, and, for example, the substitution of heavy metallic materials with plastics in e-mobility are being implemented with continuously increasing consistency. These and other measures should help reduce carbon emissions.
Another major factor is energy consumption in the industry. Energy costs have risen significantly in the recent years and are also an important element for protecting our environment. „Apart from the heater, the plasticizing drive is the most important energy consumer. We have done a calculation for two different machines to show our customer Hürmak Machinery the potential of electrical drive solutions in comparison to hydraulic solutions and the results were amazing”, explains Marcel Möller, Branch Manager Plastics Industry at Baumüller.
Electrified plasticizing unit
“Our goal for the future is creating a lower carbon footprint. This is also very important for example because of the regulatory due to the European Green Deal and other different EU regulations like Corporate Sustainability Reporting Directive (CSRD). We are very happy that the studies together with Baumüller showed a huge energy saving by using synchronous direct drive technology instead of hydro motors.
Efficiency considerations of the plasticizing unit: direct drive solution (92 %) vs. hydraulic solution (58 %)
We evaluated two use cases with a shaft power of 67.6 kW: One with short cycles, for example to produce paint buckets and one with long cycles, for example to produce infrastructural parts. Both machines are running in a permanent manner. We are very happy with the quality and the efficiency of the Baumüller motors. The energy consumption is reduced up to 50 percent. That is great”, says Burç Angan pleased. The trend shows a clear increase in electricity costs. In both use cases the return on investment can be achieved very fast.
The calculation of the energy efficiency for two different machines shows the energy cost savings with direct drive technology which creates a very attractive return of investment (ROI)
Hürmak Machinery is now using a direct drive solution of Baumüller for the plasticizing unit of the new ZENITH 580 injection molding machine. The high energy efficiency and low life cycle costs of Baumüller torque drives save the end users of Hürmak permanently money.
Due to their consistently high efficiency over a wide speed and torque range, synchronous direct drives are ideally suited for use in plasticizing units instead of hydraulic solutions. This is because, where direct drives are used, the energy efficiency increases even more at operating points with a reduced torque requirement. Processing different materials results in different operating points and partial load conditions. This further increases the efficiency, thereby improving the energy balance.
With its DST2 high-torque motors, Baumüller offers direct drives with a wide torque and speed range. Thanks to their good scaling options in shaft height and length allow an optimal design technical as well as economically.
Parallel functions and cycle time reduction
Parallel functions are another benefit by using electric plasticizing drives. These allow a significant reduction of cycle times and a corresponding increase in machine productivity especially in case of short cooling times – This is realized by an economical and performance-optimized design of the system.
These functions allow for example to start tool opening already during the plasticizing operation and thereby significantly reducing the cycle time.
Hürmak Machinery is now using DST2 high-torque motors of Baumüller. The high energy efficiency and low life cycle costs are huge benefits 
Optional cycle time can be reduced in case of short cooling times by using electrical drives and parallel functions
Long esteemed partnership
Burç Angan, Deputy Chair of The Board Hürmak Machinery:
„With Baumüller we have a strong partnership for almost ten years now. Most important for me is a value cooperation and communication in between. The support we get is very valuable for us. Baumüller is the leading brand. Many plastic machine builders are using Baumüller. We and our customers are very satisfied with the drive technology of Baumüller, and it is also adding us brand value”.
The plasticizing unit from Hürmak Machinery is now driven by a DST2 direct drive in combination with a b maXX 5500 servo drive from Baumüller
Conclusion
Manufacturers of plastics machinery are currently facing major challenges. In addition to optimizing productivity and the reliable in cost effective production of high-quality products, the machines must also be energy-efficient in operation because of the increased consideration of total costs of ownership. In the energy-intensive plasticizing process in particular, energy consumption can be significantly reduced by replacing the full hydraulic solution with efficient electrical drive technology. Hürmak Machinery is working with Baumüller together for almost ten years now. The partnership relies on value cooperation and trustful communication. With the electrification of the screw drive the next level of innovative electrical drive solutions is successfully in the books. End users can look forward to an attractive amortization period. Carbon dioxide emissions are reduced, which will bring further benefits for example in terms of EU regulations in the future.
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