Plastic Metal USA has evolved from a sales agency for injection presses to a firm that helps molders cut their energy consumption, as a distributor of SyncroSpeed retrofit motor speed control — and the company is spreading its message around the world.
SyncroSpeed is made by CCS Technology Ltd. of Coventry, England. SyncoSpeed has opened sales offices in Brazil, Mexico, Puerto Rico, India and the newest location, in Turkey.
By controlling the proper speed needed to deliver oil movement, you can reduce energy by 30-60 percent on older hydraulic injection presses, according to the company. Once profiled, SyncroSpeed requires no further adjustments, and runs fully automatically, reading the needs of all different tools.
Energy consumption and cost are automatically updated and displayed every three cycles of the injection press.
Mounted on the press, or close to it, SyncoSpeed controls every phase of the cycle is controlled through a vector control inverter and a flexible input/output controller. Remote monitoring is done through Internet access to the SyncroSpeed controller.
The main screen displays essential information such as drive (inverter) status, motor speed and power and average energy savings. The status screen tracks the sequencing of the machine and the status of the inverter. Users can establish benchmarks of energy performance for every job, and machine setup personnel have the information needed to refine the setup, to optimize energy efficiency.
Typically, SyncroSpeed identifies 10 to 20 different states within a cycle, or up to 30 states. Each is commissioned with a unique speed control strategy. Adjustments can be made easily to compensate for changes to the machine, such as deterioration of a hydraulic valve or replacement of a worn pump.
Motors and pumps remain as the original machinery manufacturer installed.
SyncroSpeed is not an off-the-shelf product. Its control software and hardware are specially designed for injection molding.
Robert Knaster, CEO of Plastic Metal USA, said injection molding machines use 60 percent of the total electricity consumed in a plastics factory.
SyncoSpeed customers include Xten Industries LLC, a molder in Kenosha, Wis. Knaster said the company also has implemented SyncroSpeed at Tier 1 automotive molders.
Knaster listed some recent energy savings:
• 1,000-ton Engel press for Tier 1 automotive, energy savings of 53 percent.
• Energy savings of 30 percent on a 1,100-ton Husky with an accumulator and variable displacement pumps.
• Forty-four percent energy savings on a Cincinnati Milacron press molding housewares.
Plastic Metal USA, based in Bayside, N.Y also is selling another product: EcoSmart 100 percent biodegradable additive, which is claimed to be compostable, non-toxic and chemical free. EcoSmart products turn into soil in one to seven years, without the need for oxygen, light, heat, moisture or mechanical stress, said the company, which introduced it at the Plastindia trade show.
Plastic Metal USA also sells an additive in pellet form, called Repellem, for trash bags that repel bugs, rats, raccoons and other pests.
Knaster offers a 29-page third-party report of laboratory tests, plus outdoor results. He said Repellem also is targeted to makers of plastic pallets.
Tel. 914-582-1848, email [email protected].