New or renew? Milacron helps injection and extrusion companies decide

There are so many factors to consider when determining whether to upgrade an older plastics injection molding machine or replace it with a new one. Can you afford the cost of replacement? How about the downtime? How long is an older machine expected to last?

It’s a big decision. And there’s a lot of information available on the pros and cons of both options. But over time, the importance of these factors can change.

Currently, one of processors’ top concerns is finding and keeping qualified employees. Training workers to operate a machine is expensive and time-consuming, especially if they don’t stick around long. And suppose you have machines of varying ages that require employees to adapt to very different controls depending on which machine they’re operating at the time?

Kevin Stanley, Milacron’s Aftermarket Services Manager, recalls one such instance in which retrofitting was the solution.

“One customer comes to mind that purchased several new machines, and then we went in and did a control retrofit on five or six of the older machines. So now their operators can walk from a brand-new machine to a 20-year-old machine and the controls are the same,” Stanley said.

“It does help quite a bit, with the new wave of employees coming and going. For most manufacturers, it’s hard to keep up the training, so the less training you have to do, the better. The new controls are all touch screens, and the old machines … you have to cursor to where you want to make the change. Even how you change menu screens is different.”

Read the Aftermarket Retrofits vs. New Purchase white paper here.

Another growing priority among consumers, and therefore among processors, is the green movement and the responsibilities manufacturers face regarding the environment and sustainability.

“Across all industrial markets, as sustainability becomes a greater business & strategic priority, industries are more cognizant about how they look at capital equipment lifecycles, from cradle to grave. We are starting to see a lot more interest from customers inquiring about retrofits and rebuilds, because sustainability is front and center for their shareholders,” said Niikolas Rautiola, Vice President of Aftermarket at Milacron.

Addressing sustainability can also cut costs and waste by increasing operational efficiency, and give companies a competitive advantage to attract new customers, investors and employees.

Something else that has moved up the priority scale for many manufacturers is making sure their machines are properly cared for. Regular maintenance is critical to keep machines running smoothly.

“A lot of customers have cut back on their maintenance staffs, and they just farm it out to us to come in and do it. Over the past couple of years we’ve really seen that take off,” Stanley said.

“Customers are finding that it’s more economical for them to pay Milacron to come in and go over their machinery on a quarterly or annual basis just to keep it up.”

Following machine manufacturers’ guidelines can help extend the life of a press indefinitely. Stanley said a typical machine might last 10-20 years, but there are Milacron machines from the 1980s, with the same controls, still operating.

Rautiola concurred: “Prioritizing maintenance directly contributes to extending the lifecycle & performance of machines.” There are times, however, when a new machine makes more sense than retrofitting an existing one — for example, when a customer hasn’t purchased a new machine in several years and the existing machines cannot accept updated technology, if end-customer demands require a complete production change, or if physical space savings becomes a priority to fit more new machines with increased production capabilities.

“In some cases, you might be able to take a very large, old machine that took up a lot of space and, thanks to modern engineering enhancements, you can repackage it and put it in a much smaller footprint, with the latest and greatest technology” said Rautiola.

But there will always be a steady need for retrofits.

“Typically, customers will need a software sequence changed, or an additional core pull or valve gate just to be able to run a certain tool — maybe a robot interface they didn’t purchase when the machine was new,” Stanley noted. “As for controls, as technology becomes obsolete and parts are no longer available and they’re repair-only, then they’ll have to upgrade to the newer technology.”

What about the costs?

“With a control retrofit, the price really isn’t that different for a small machine vs. a large machine. But if you’re going to replace that machine, the price difference is huge,” Stanley said.

“So if you’re looking for a technology upgrade to make the machine more reliable and increase its efficiency, then a control retrofit would make sense for a large-tonnage machine.”

For a closer look at the challenges and solutions of retrofits vs. new purchases, read the white paper here.