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Energy Efficiency in Rubber Molding Machines

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  1. Energy Efficiency in Rubber Molding Machines Hsin-Chiao Frank Lin October 25th, 2013

  2. Background • Industrial Rubber Parts are made through Vulcanization – Converting rubber into more durable materials Vulcanization Uncured NR: Sticky, Deforms at Low T; Brittle at High T Vulcanized Rubber: Deforms under Stress, But reverts back to original shape

  3. Background • Vulcanization done through compression molding, under high pressure (~500 ton clamping force) and temperature (~170C) • Done through various molding machines: Rubber Injection Machine VS Rubber Compression Machine High Pressure; High Temperature

  4. Problem • High Pressure, and High Temperature requires Energy • First Rubber has 95 Rubber Molding Machines • High Energy Usage = High Electricity Fee • Electricity Fees become larger part of unit cost

  5. Goal • Reduce Costs by Increasing Molding Machines Thermal Efficiency • Recommend Purchase of Newer Machines • Determine saved energy costs from newer machines • Identify main causes of lower efficiency in older machines

  6. METHOD • Compare Efficiency of Various Rubber Molding Machines • E-Shine Machinery Co., Ltd based in Taiwan • REP Injection Based in France • Other Suppliers from China • Based on current electricity bills, calculate time to return from investment

  7. Method Contact First Rubber Engineers to understand Rubber Molding Machine efficiency Determine Temperature of Machine, Pressure Created on current machines Identify causes of efficiency loss over time