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

2. 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

3. 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.

4. 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

5. 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

6. 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.

7. 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.

8. 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.

9. 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

10. Productivity Improvements - Energy

11. 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.

12. 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

13. 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

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

15. 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

16. 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

17. 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

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

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

20. 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.