How Electrification is Driving Productivity in Injection Molding Prepared for Molding 2017

Topics Milacron and electric machines Why electric machines, then and now The rise of servo electric systems How individual industries are benefitting Not just for molding machines

Milacron Customer Focus Milacron is a united global team dedicated to providing you with efficient and high quality world-class plastics machinery and products supported by best-in-class customer focus and attention.

Electric Machine Technology at Milacron First US company to introduce electric machines on a large scale…started in 1990 Currently sell 4 different all-electric products Roboshot Power Line Ferromatik Elektron Have seen demand for all electric technology continue to grow and expand beyond small machines

Why Electric Machines? – 20 Years Ago The Technology at the time Hydraulic machines – most with fixed displacement pumps Leaking machines were common Most machines lacked accuracy and repeatability Most machines did not provide for parallel movements

Why Electric Machines? – 20 Years Ago The Market at the time Electricity was beginning to be seen as a high cost Energy companies were paying rebates to take power off the grid. Market was maturing and plastic parts were becoming more demanding.

Electric Machines Filled this Void Primary reason was seen as low energy costs Machine was sold as premium machine that was more expensive than hydraulic Paid difference with rebates from local utilities Improved accuracy and repeatability allowed for the molding of more advanced parts Was seen primarily as a high technology and/or medical machine Not considered for commodity molding In late 90’s, many expected electric machines to be nearly 100% of the market by 2010.

What About Today? Electric machines make up about 55% of the market and have held steady for the last 10 years. Electric machines have moved down to the commodity level as costs have been reduced Hybrid machines have struck balance for many applications Fast cycling Large tonnage Servo hydraulics offer a good compromise at a lower price point. Electric technology is now driving productivity across all markets.

Servo Hydraulic Machines? Has brought many of the benefits of electric machines at a more affordable price point AC servo motors driving small fixed pumps Pumps only run when needed These machines have improved accuracy and repeatability while reducing complexity These machines offer energy savings of 40% versus full hydraulic machines

Productivity Improvements - Energy

Productivity Improvements - Automotive Margins are being squeezed by large OEM’s and there is a need to drive down costs. Larger machines need to have lower noise. Components are becoming more advanced and need more accurate molding technology. Use of additional injection units is key and fully electric solutions can provide better results.

Productivity Improvements - Automotive Servo hydraulic machines are becoming more popular All-electric rotary tables Servo driven valve gate systems Larger tonnage machines now available in electric

Productivity Improvements - Packaging Use of electric screw drives on machines is now “standard” All-electric machines gaining in this space Add on injection units are now electric

Productivity Improvements - Packaging • Electric • Hydraulic • Toggle, electric Injection Plasticizing Clamp Unit Ejector Carriage Movement

Markets and Applications Medical This has been the longest served market for electric technology Seeing an increase in servo hydraulic machines Electrification of the entire work cell now Mold actions Valve gates Rotary tables

Productivity Improvements - Medical Machines almost exclusively electric today. All functions in the work cell becoming electrified Market demands the lower cost and higher repeatability of this technology. Appearance of cleanliness is also a driver

Markets and Applications Consumer/General Molding Benefiting from servo hydraulic machines Price point of electric technology has been lowered Machines once limited to only “high end” are now available to the custom molder Adding “bolt on” second injection units to provide more options for molding more complicated parts

Productivity Improvements - Consumer Low cost options for electric multi-component units. Lower cost servo hydraulic machines.

Not Just for Injection Molding Valve gated hot runners are going electric Blow molding machines are now becoming fully electric

Summary and Conclusions The injection molding industry has made a significant move to electrify many of the processes. The fully electric machine has captured about 50% of the market, holding steady for the past 10 years. Servo hydraulic machines have allowed many of the benefits of all-electric machines to available in a simpler, less complex design. What was once considered only available for “high end” applications is now available for most of the industry. It is not just injection molding machines that are being electrified…molds, rotary tables, blow molding, etc. are all joining in.