Uncovering the Hidden Key to Energy Saving in Injection Molding Workshops

Every manager in an injection molding workshop is constantly brainstorming ways to "reduce costs and increase efficiency." We focus on raw material waste, monitor machine hours, and optimize staff efficiency, but often overlook a "hidden energy guzzler" lurking in the corner of the workshop, silently consuming profits day and night—the workshop's cooling system.

Today, let's uncover this "hidden level" in energy saving and see what significant opportunities lie within.

Level 1: Identify the "Big Three" of Workshop Energy Consumption

To save energy, you first need to know where the electricity is going. The energy consumption in a typical injection molding workshop is mainly distributed across three areas:

1. The Injection Molding Machine Itself: This is the main consumer, responsible for clamping, injection, holding pressure, etc., accounting for about 50%-60% of energy use.
2. The Heating System (Barrel): Responsible for melting the plastic raw material, accounting for about 20%-30% of energy use.
3. The Cooling System: Responsible for cooling the mold, hydraulic oil, and feed throat, accounting for about 20%-30% of energy use.

At first glance, the cooling system seems to rank last. But precisely because it lacks "visibility," it often becomes a blind spot in energy efficiency management and is the area with the most potential for energy savings.

Level 2: Why is the Cooling System a "Hidden Energy Guzzler"?

Many companies still use outdated, inefficient cooling solutions, such as:

Low Refrigeration Efficiency: Chillers used for many years have worn core compressors and scaled heat exchangers, leading to high effort for little result—requiring more electricity to achieve the same cooling effect.
Outdated Control Methods: Traditional fixed-speed chillers are like drivers who only know how to slam the accelerator and brake hard. Once the temperature is reached, the compressor stops; when the temperature rises, it starts at full power. This frequent cycling not only consumes more electricity but also causes impacts on the power grid and the equipment itself.
Mismatch with Production: The cooling capacity is either too large or too small, unable to dynamically match the actual working conditions of the injection molding machine, resulting in energy waste like "using a cannon to kill a mosquito" or "a small horse pulling a heavy cart."

These seemingly minor issues, accumulated over time, translate into a huge amount of extra cost.

Level 3: The Key Solution – Upgrading from "Power Consumption" to "Smart Power"

So, how do we conquer this "hidden level"? The answer lies in replacing old solutions with intelligent, efficient cooling technology. And this is the core value that LESINTOR brings to you.

1. Heart Upgrade: High-Efficiency Compressors and Eco-Friendly Refrigerant

LESINTOR industrial chillers use high-efficiency scroll compressors equivalent to those in international brands, whose operating efficiency is 15%-20% higher than ordinary piston compressors. Combined with optimized refrigerant circuit design and eco-friendly refrigerants, this ensures a higher Coefficient of Performance (COP) from the source, meaning more cooling capacity for every kilowatt-hour of electricity consumed.

2. Brain Upgrade: Inverter Drive (PID Control) TechnologyThis is the ace of energy saving. The LESINTOR inverter chiller is like an experienced "veteran driver," able to automatically adjust the speed of the compressor and pump based on the actual cooling load required by the mold, achieving seamless speed control.

Outputs full power when strong cooling is needed.
Runs smoothly at low speed when maintaining temperature.

This method completely avoids the energy consumption of frequent starts and stops, saving up to 30%-40% more energy compared to fixed-speed chillers under most operating conditions!

3. Bloodline Upgrade: Precise System Matching
Our engineers will accurately calculate and match the cooling capacity and pump head for you based on your injection molding machine's tonnage, product cycle, material characteristics, etc., ensuring the system always operates at its optimal point, eliminating any form of energy waste.

The Emerging Opportunity: Energy Saving is Not a Cost, But Your Highest ROI Investment

Upgrading your cooling system from an "energy guzzler" to an "energy-saving pioneer" might seem like a equipment expense, but it is actually an investment with an extremely high return rate.

Let's do a clear calculation:

Assume a 50T injection molding machine has an associated cooling system that consumes about 15,000 kWh annually. Using a high-efficiency LESINTOR inverter chiller, and conservatively estimating 30% energy savings:

Annual Electricity Saved: 15,000 kWh × 30% = 4,500 kWh
Annual Cost Saved: 4,500 kWh × $0.15/kWh = $675 (Please adjust based on your local electricity rate)

This means the saved electricity costs alone can cover the initial equipment investment within one to two years. Given that a high-quality chiller has a lifespan of 8-10 years, for every subsequent year, you are essentially "profiting" from the amount saved.

Choosing LESINTOR means you are not just buying a chiller; you are initiating a long-term "Workshop Energy Saving Profit Plan." The stable, efficient cooling solution we provide not only lowers your operating costs but also enhances product quality stability through precise temperature control, reducing the reject rate. It's a smart choice that serves multiple purposes.

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Take Action Now, Conquer the Final Level of Energy Saving!
Contact the LESINTOR professional team for a free assessment of your workshop's cooling system energy consumption and a customized energy-saving plan. Let us help you convert hidden costs into visible profits!

LESINTOR - The Path to Intelligent Cooling and High Efficiency.