Why does transparent energy efficiency in production start with the component – not with the machine?

Energy efficiency remains a key investment criterion in injection molding. In addition, sustainability (CO₂-footprint) is becoming increasingly important due to costs pressures and regulatory requirements.

Anyone evaluating a machine needs reliable data that not only looks good on paper but also reflect real-world operating conditions. This required a clear focus on transparency and a holistic view of the energy system required for production.

So how can energy efficiency in injection molding production be meaningfully evaluated today? Which reference values are relevant, and which standards enable practical comparisons? And how can digital assistance systems contribute to continuous optimization?

These are the key questions explored in this blog article:

• Why is the entire injection molding process the decisive reference value for energy efficiency?

• What is the difference between EUROMAP 60.1 and 60.2, and why is EUROMAP 60.2 more relevant for practical comparison?

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

In injection molding, energy is not consumed in isolation within a single machine component. Instead, total energy consumption results from the interaction between the injection unit, clamping unit, and all process-relevant components.

The key factors are:

• the complete machine (injection and clamping unit sides)

• all process-relevant settings for component production of a component

• the material used

ENGEL therefore consistently evaluates the energy system holistically. This approach provides a reliable and practical basis for assessing energy efficiency in production, whether for cost analysis or sustainability objectives.

EUROMAP 60.1 provides a standardized, machine-specific reference value for evaluating energy efficiency.

EUROMAP 60.2 by contrast, calculates product-specific values under real production conditions, and making energy efficiency truly comparable.

EUROMAP 60.1 (EM 60.1) defines a machine-specific energy evaluation based on a standardized process. This provides a neutral baseline for comparison.

EUROMAP 60.2 (EM 60.2) enables accurate comparisons in real production environments by measuring energy consumption on a product-specific basis.

Key parameters included in the evaluation are:

• material used for component production

• shot weight

• cycle time

• component wall thickness

Initial conditions:

• 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 therefore provides a precise answer to the question injection molders actually ask: How energy-efficient is my production for my specific product?

Comparable data builds trust, supports better decision-making, and forms the basis for accurate CO₂ calculations. A purely theoretical value is not sufficient for investment decisions.

Only product-specific calculations and transparent measurements provide:

• fair benchmarks across production sites

• reliable energy cost models

• a consistent basis for CO₂ calculations and reporting

This is relevant not only from a regulatory perspective but also offers clear economic advantages, as comparable energy data enables better planning and supports a competitive production strategy.

With digital assistance systems and energy monitoring directly at the control unit, energy efficiency in production becomes visible and controllable in real time, enabling targeted optimization. ENGEL supports not only standard-compliant energy efficiency assessments, but also continuous efficiency improvement.

Digital tools in production enable:

• Real-time transparency through energy monitoring at the control unit,

• Energy-optimized processes at the push of a button

• Systematic improvement of cycle time and energy consumption.

The process checklist integrated into the control unit guides operators step by step toward greater energy efficiency.

Examples of additional digital solutions from the ENGEL portfolio include:

• iQ weight control (compensate for viscosity fluctuations):

  • Reduced scraps

  • Lower material consumption

  • Result: less energy per good part

• iQ clamp control (optimization of clamping force):

  • Reduced clamping force

  • Shorter cycle times

  • Result: lower energy requirement

• iQ hold control (optimization of holding pressure):

  • Optimized holding pressure time

  • Shorter cycle time

  • Result: reduced energy consumption

• iQ flow control (intelligent temperature control):

  • Cooling capacity applied only where needed

  • Reduced water consumption

  • Result: energy savings in production and processing

Learn more about how digital solutions can optimize production processes and improve energy efficiency in our blog article Digitalization: a solution for skilled labor shortages & energy efficiency.