Why does transparent energy efficiency begin with the production cell and not with the machine?

Energy efficiency remains one of the central investment criteria in injection moulding. In addition, sustainability (CO₂ footprint) is becoming increasingly important due to cost reduction and regulatory requests.

Anyone evaluating a machine or cell needs reliable values that not only look good on paper but also reflect real-world operation. This can be achieved by focusing clearly on transparency and a holistic view of the energy system required for production.

So how can energy efficiency in injection moulding production be meaningfully evaluated today? Which reference value is decisive, and which standards deliver comparable results? And how can digital assistance systems contribute to optimization in permanent operations?

We explore these questions fully in the following blog article:

• Why is the total production cell the decisive reference value for energy efficiency?

• What is the difference between EUROMAP 60.1 and 60.2? And why does EUROMAP 60.2 count for practical comparison?

• How do digital solutions from ENGEL help to reduce energy consumption and cycle times during operation?

In injection moulding, energy is not consumed in isolation in one area of the machine. Energy consumption arises from the interaction between the injection and clamping unit sides of an injection moulding machine and all process-relevant components.

The decisive factors are:

• the complete machine (injection and clamping unit sides),

• all process-relevant settings in the cell,

• the material used

ENGEL therefore consistently evaluates the energy system holistically. This creates the basis for reliable, economically relevant statements regarding energy efficiency in production, whether for cost accounting or sustainability goals.

EUROMAP 60.1 is a standardised, machine-specific basis value for calculating energy efficiency.

EUROMAP 60.2 calculates product-specific values under production conditions and makes energy efficiency truly comparable.

EUROMAP 60.1 (EM 60.1) describes a machine-specific energy calculation with a standardised process. This is important in order to have a neutral starting point.

EUROMAP 60.2 (EM 60.2) provides the decisive sharpness for practical comparisons because it measures on a product-specific basis.

Real parameters are included in the evaluation, including:

• Specific material for component manufacturing

• Shot weight

• Cycle times

• Component wall thickness

Initial situation

• Material: PP

• Cycle time: 25 s

• Shot weight: 355 g

Result

• Machine-specific after EM 60.1: 0.34 kWh/kg

• Product-specific (actual) after EM 60.2: 0.30 kWh/kg

EM 60.2 thus provides a precise answer to the question that injection moulders really ask themselves: How energy-efficient is my production cell for my specific product?

Comparability creates trust, leads to better decisions and forms the basis for accurate CO₂ calculations. A theoretical value is not sufficient for investment decisions.

Only product-specific calculations and/or transparent measurements provide:

• fair benchmarks between plants,

• reliable energy cost models,

• a consistent basis for CO₂ calculations and reporting.

This is relevant from a regulatory perspective and also offers a clear economic advantage, because only comparable energy data can create planning security and support a competitive production strategy.

With digital assistance systems and energy monitoring directly at the control unit, energy efficiency in production becomes visible and actively controllable, in real time and with concrete optimisation steps. ENGEL not only supports standard-compliant energy efficiency assessment, but also permanent efficiency design.

Digital tools in production enable:

• Real time transparency by means of energy monitoring in the control system,

• Energy-optimised processes at the touch of a button

• Systematic improvement of cycle time and energy consumption.

The process checklist integrated into the control unit standard guides the operator step by step towards energy efficiency.

Examples of further digital solutions from the ENGEL portfolio include:

• iQ weight control (compensate for viscosity fluctuations)

  • Less waste

  • Less material

  • Result: Less energy per good part

• iQ clamp control (optimization of clamping force)

  • Low clamping force

  • Fast cycle

  • Result: Less energy requirement

• iQ hold control (optimisation of the sealing point)

  • Optimised holding pressure time

  • Shorter cycle

  • Result: Energy reduction

• iQ flow control (intelligent temperature control)

  • Only necessary cooling capacity

  • Reduction in water consumption

  • Result: Energy saving in production and processing

Read more about how digital solutions can be used to optimize production processes and control and increase energy efficiency in the blog article Digitalisation as the key to skills shortages and energy efficiency.