Achieving energy savings and process optimization in plastic injection molding: A design of experiments study

The plastic injection molding process is essential for rapidly producing intricate plastic parts, yet optimizing its energy efficiency without compromising quality remains a challenge. This paper uses the Plackett-Burman method to investigate parameter interactions and identify optimal settings to minimize energy consumption while maintaining quality with the 750-ton hydraulic injection molding machine. Analysis of variance statistically evaluates parameter impacts. Specific energy consumption and cycle time are chosen as response variables, with eight parameters as factors. Results show screw rotation speed significantly impacts Specific energy consumption (84.18%) and mold closing movement affects cycle time (29.27%). The model explains 94.2% of Specific energy consumption variability and 99.34% of cycle time variability. Specifically, the study found that with an optimal configuration of the parameters, the system achieves an average specific energy consumption of 21.7477 kWh/kg and an average cycle time of 38.174 s. Pareto analysis highlights key factors for optimization, guiding efforts to improve energy efficiency. Interaction analysis reveals factors are largely independent. The prediction profiler offers insights into achieving lower energy consumption and cycle time, aiding cost reduction and process optimization. This study provides valuable insights for enhancing efficiency and sustainability in plastic injection molding. It introduces the novel application of the Plackett-Burman design to optimize energy efficiency in plastic injection molding. These crucial insights address complexity in industrial plastics manufacturing, focusing on key factors impacting energy and cycle time.