Case studies
Our Energy Covers insulation can solve heat-related molding problems in a variety of plastics applications. These case studies are just three examples of how our equipment insulation can cut energy usage and molding costs.
Problem 1:
A compression molder of thick wall electrical components couldn't maintain uniform heat throughout its molds. Temperatures tended to be at or near set point close to thermocouples and up to 6 degrees lower near the molds' outer surfaces. To compensate, the molder lengthened the "in mold cure time" and raised temperature settings.
Our solution:
We installed Energy Covers mold insulation on both mold halves, reducing the press' overall energy usage by 12%. Temperature uniformity resulted throughout the entire mold cover. "In mold cure time" dropped 35% from 6 minutes 47 seconds to 4 minutes 42 seconds. ROI was within 107 production days.
Problem 2:
A Canadian injection molder of PET pre forms couldn't maintain temperatures at set point in several zones along the barrel. Neither could its HVAC system handle the "load demand" created by three recently installed presses.
Our solution:
Our Energy Covers barrel insulation improved temperature stability with a 28% drop in energy used in the barrel for heating. The HVAC "load demand" also decreased to a manageable level. RIO was within 196 production days. The annual savings on one press exceeded $2,130 Canadian.
Problem 3:
A nylon resin recycler had a problem when steam leaks developed under the rigid calcium silicate insulation on its large steam heated dryers. The recycler removed so much insulation to repair leaks that the drying time for one batch approached 24 hours. Production was down, and drying costs were high.
Our solution:
Our Energy Covers custom removable insulation cut drying time and costs by about 40%. Now, when a leak develops, the recycler unlaces the energy covers, repairs the leak and reinstalls the insulation.
