SyncroSpeed from Plastic Metal USA Ltd. is a retrofit motor speed control system that the company claims can improve the energy efficiency of older hydraulic injection molding machine to nearly that of an all-electric press.
Plastic Metal USA Ltd. of Bayside, NY is the distributor/North American distributor of SyncroSpeed, developed by CCS Technology Ltd. of Coventry, England.
Motor power is reduced by 35 to 55 percent on presses with fixed displacement pumps, or 10-20 percent with variable displacement pumps, according to Robert Knaster, president of Plastic Metal USA.
SyncroSpeed is a combination of hardware and software that matches the speed of the molding press motor to the process. Instead of the motor running while the machine sits idle, the motors run only when needed, and only run as much as needed.
According to Plastic Metal USA, the system provides quick and simple comparison of machine productivity, reduced cooling load and a quieter-running machine.
The machine setup process can operate in the same way as before. SyncoSpeed monitors what the setter has demanded of the machine and reacts to that information.
Automotive molders that run SyncroSpeed have experienced 38 to 45 percent energy savings.
CCS Technology lists some major customers, including Tupperware Brands Corp., Compagnie Plastic Omnium, Xten Industries LLC, Wavin NV, Linpac Group Ltd., Mann+Hummel GmbH and Aliaxis GPS.
Plastic Metal USA released some SyncroSpeed case studies:
• Successful trials by a customer on an Engel press with 500 tons of clamping force led to the company ordering eight additional SyncoSpeeds for other Engel machines in two European molding plants. Within a year, the molder SyncroSpeed at plants in Korea, India and Mexico. The customer has SyncroSpeed on a total of 100 machines from six different press makers – 50 of them were Engels.
• A 1,000-ton HPM injection press, making polyethylene storage boxes on a 42-second cycle, generated a return on investment in 20 months.
• A 1,000-ton Cincinnati Milacron press molding toilet seats from polypropylene on a 105-second cycle had a 16-month ROI.
• A 1,500-ton Farrel press molding an automotive component in glass-filled PP on a 87-second cycle, with a ROI of 17 months.
• A 1,000-ton Sandretto machine molding an ABS automotive glove box at a 32-second cycle had a 20-month ROI.
An 800-ton KraussMaffei molding ABS automotive interior trim generated a 15-month ROI.