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\u00a0<\/strong>Plastic is one of the most essential products in today’s world. As such, it is among the more commonly produced materials. Like most modern day products, its production relies heavily on compressed air, which is vital across all corners of the plastics industry. In everything from blow molding to injection molding, air compressors help operators manufacture plastics with utmost efficiency.<\/p>\n When it comes to plastic molding, compressed air makes it possible to achieve numerous tasks in seconds that would otherwise take minutes or even hours by hand, including:<\/p>\n Before a mass\u2013produced set of plastics \u2014 be it bottles or containers \u2014 are filled with products for over\u2013the\u2013counter consumption, compressed air is often used to blow the insides clean for sanitation purposes.<\/p>\n <\/p>\n Contact Us<\/a> Learn More<\/a> Find a Dealer Near You<\/a><\/p>\n <\/p>\n A 2005 study, conducted by the Society of the Plastics Industry, Inc. in coordination with the U.S. Department of Energy, found that improvements in compressed air management resulted in an estimated annual savings of $27,143<\/a> at plastics plants. The figure was based on the combined benefits of 29 recommended improvements \u2014 such as stopping leaks and buying smaller or more efficient compressors \u2014 in the maintenance of air compressors.<\/p>\n Essentially, the plastics industry can reduce overhead and boost profit margins by implementing many of the same efficiency measures use in other industries when it comes to air compressors. The benefits of these measures include:<\/p>\n The savings that plastics companies can gain by taking these steps results in numerous benefits across all corners of the process. Not only do operations become more profitable, but also products ultimately improve in quality, which leads to a better profile in the marketplace.<\/p>\n In the majority of plants that employ blow molding methods, air compressors are used to expand the parison, which is the tube\u2013shaped initial form of heated plastics used in the process. Thanks to the power of compressed air technology, blow methods can be very lucrative for the plastics industry<\/a> in terms of production. In PET bottle blowing, for example, rotary machines that run at high speeds can produce as many as 20,000 bottles per hour with 600\u2013psig<\/a> air compressors.<\/p>\n When you think about the productivity level that figure represents, and what it means when multiplied across 8\u201410-hour working days, across 5\u20146-day workweeks, across roughly 40 weeks of operation annually, the numbers are staggering. Theoretically, a large plastics plant could turn out products at the following rate when powered by an efficient system:<\/p>\n Modern day productions are capable of yielding the most staggering numbers, and much of this is due to the remarkable power of compressed air technology.<\/p>\n However, high productivity could negatively affect compressed air efficiency opportunities in the plastics industry, unless companies take steps to reduce pressure drop inside the molding machines.\u00a0Pressure drop stems from the amount of air power that a system ends up consuming during high\u2013level productions. For example, a blow system might use as much as 3,200 scfm in the time it takes to produce 24,000 bottles<\/a>.<\/p>\n Pressure drop is bad for numerous reasons, because it undermines the purpose of compressed air technology. For instance, when drastic pressure drop occurs between the compressor and point of use, applications suffer in the following ways:<\/p>\n Consequently, pressure drop can put plants behind schedule and severely cut into profit margins, because materials have to then be repurchased for do\u2013over productions.<\/p>\n For obvious reasons, plastics industry compressed air efficiency is most effective when molding machine pressure drop is drastically minimized. Typically, this necessitates either the removal or higher\u2013capacity upgrade of certain pneumatic attachments. Determining the actual level of pressure drop over the course of operations can be difficult, even with the use of transducers and electronic reading devices. Therefore, it’s most advisable to hire a compressed air specialist when performing efficiency upgrades to a plastics molding system.<\/p>\n The plastics industry is responsible for roughly 4% of all energy use around the world. In 2012 alone, global plastic production accounted for 288 million tons of product. Two\u2013thirds of this productivity occurred in China, Europe and North America. The industry’s energy consumption is generally split into the following four categories:<\/p>\n While manufacturers use numerous processes for production in each of the four categories, the most frequently utilized are the extrusion and injection\/blow molding methods.<\/p>\n Extrusion is an ongoing method in the manufacturing of equipment like tubes, cable covers, films and profiles. While differences exist between production assemblies in the actual mold designs and extrusion parts put to use, the general methods are pretty much the same.<\/p>\n The extruder is first filled with plastic pellets, which are then heated in a screw\u2013driven barrel. The heat ultimately melts the pellets into liquid plastic. The heating process itself is aided by oils that are temperature\u2013set, usually by electronic means. The melted plastic is then molded into shape and cooled to a hardened state, using either liquid or compressed air. Further modifications, such as trimming, are then made as needed.<\/p>\n The extrusion method can be broken down as follows:<\/p>\n The whole process is direct and simple, yet none of it would be possible without the types of high\u2013tech pressing arsenals employed at today’s facilities, where compressed air plays a vital role.<\/p>\n Throughout the whole process of extrusion, heaters, coolers and compressors consume the most energy. Pressing plants think of the consumption of energy in much the same way as the \u2018time is money\u2019 principle. This way, it’s easiest to harness compressed air efficiency opportunities in the plastics industry, because consumption is correlated to productivity. The concept goes as follows:<\/p>\n In order to conserve energy throughout the process of extrusion, it’s crucial to select the proper extruder. If disparities are present in the screw and mold components, energy goes to waste during the process. The extruder must also be able to run at sufficient speeds and placed in an area with proper insulation. Companies should melt pellets at low temperatures and cool them with air compressors of maximum efficiency. Moreover, the cooling process works best in settings where the ambient air is relatively cool.<\/p>\n Essentially, the company must maintain the following standards in the plastics industry to ensure efficiency during extrusion molding:<\/p>\n With air compressors, consistent and proper time maintenance ensure reliable operations.\u00a0Avoiding maintenance\u00a0can lead to insufficient air pressure that can hamper the process of plastics molding.<\/p>\n Injection molding is a method for making plastic parts, and it’s carried out in cycles. The method consists of plastic fluid injections into a shape maker, which can all be accomplished and repeated in quick succession. Due to this efficiency, the method is often favored in the manufacturing sector.<\/p>\n The entire process works as follows: hard plastic is melted into fluid, which is then injected through a nozzle that leads to a pre\u2013shaped molding compartment that forms each new injection into a uniform shape. The shape\u2013maker consists of mirrored halves joined together for the molding stage, and then parted to release the newly formed plastic object. Once free, the object moves along the assembly for further modifications, such as cutting and labeling.<\/p>\n Essentially, the process of injection molding can be broken into the following steps:<\/p>\n Objects such as plastic cups are given perfect symmetry by the mirrored halves that join during the molding stage of the injection method.<\/p>\n The types of plastic products regularly produced through the method of injection molding run the gamut in terms of uses. Examples of everyday parts and accessories brought into existence through this method include the following:<\/p>\n A great number of tools and accessories we depend on daily for purposes like grooming, cooking, doing paperwork and engaging in leisurely fun are products of plastics plants.<\/p>\n The usage of energy during the process of injection molding can easily be split into two parts. During the first part, high amounts of energy are used \u2014 from the time that the fluid is injected and until the shape\u2013maker opens to reveal the newly formed plastic object. As the object cools into its permanent solidity, less energy is consumed. The reasons for this energy consumption are as follows:<\/p>\n The lion’s share of energy is divided between the system motors and heating components, while smaller amounts are used by accessories in the whole process. Therefore, plastics industry efficiency is often easiest to harness through the fine-tuning of processes during the crucial shape\u2013making stage of injection molding.<\/p>\n In order for the process of injection molding to be as efficient as possible, mechanics should constantly check the parts in use during the shape\u2013making stage for optimal performance capabilities \u2014 this would entail the periodic cleaning of molding components. Additionally, make sure that the pressure settings are most suitable for the production in question. The maintenance steps that help ensure efficiency during injection molding are as follows:<\/p>\n As far as compressed air efficiency is concerned, units equipped with variable speed drives are generally most optimal for the process of injection molding. The process is most efficient when you give equal consideration to the cleanliness of machine parts and the speed at which each object can be completed.<\/p>\n Blow molding is the process that forms many of the plastic objects that are seen on the shelves at supermarkets, such as food containers and liquid bottles. The process centers around air compressors, which are used to blow preheated plastics into shape. As with other methods of shape making, it all begins with the extraction of hot plastic in fluid form. In fact, blow molding can be divided into two categories: extrusion blow molding and injection blow molding.<\/p>\n In order for the plastics industry to achieve compressed air efficiency through blow molding, they should enact the same principles that apply to other methods. Professionals must periodically clean the equipment used in the shape\u2013making stages to ensure that proper formation occurs. Additionally, air compressors used in plastic making should be lubricated and drained regularly to prevent condensation and the aerosolization of harmful oils in the process.<\/p>\n Nearly a hundred years have passed since two of the greatest developments of the Industrial Revolution: the plastics boom and the\u00a0development of air compressors. From the moment these developments first began, Quincy Compressor has been among the world’s leading innovators in compressed air technology. In the United States, Canada and overseas, our machines have been used in the manufacturing of plastics for everything from food and drink containers to medicine bottles. With our vast range of compressors, tools and accessories, plastics plants turn to\u00a0us for equipment and service.<\/p>\n Over the past few decades, advances in technology have made the Quincy brand of air compressors<\/a> more powerful and efficient than ever. For all these reasons and more, our products have been a\u00a0vital tool for plastics industry compressed air efficiency. When it comes to boosted productivity with minimal power consumption, Quincy\u00a0air compressors make it possible for a variety of sized operations to realize inefficiencies. Likewise, our compressors make it easier for plants to expand their\u00a0supply for greater productivity, and at the same time enjoy healthier profit margins.<\/p>\n As nations move to cut down on emissions and develop more eco\u2013friendly means of production, there are more compressed air efficiency opportunities in the plastics industry than ever before. From quicker blow molding to easier injection molding, plastic pressing plants are boosting productivity and conserving power in the process. Best of all, air compressors allow factories to reduce on\u2013the\u2013floor personnel and render hard tasks easy.<\/p>\n At Quincy, we understand that\u00a0production machinery is easiest to maintain and maximize to its fullest when\u00a0controls are easy to operate and the components are accessible for routine maintenance. Those are just some of the reasons why Quincy air compressors are preferred at factories around the world. To learn more about the many things that Quincy air compressors can do for your factory operations, click on over right now to our sales and service locator page<\/a>.\n
The Monetary Benefits of Plastics Industry Compressed Air Efficiency<\/strong><\/h2>\n
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Productivity in the Plastics Industry With Compressed Air Efficiency<\/strong><\/h2>\n
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Problems That Can Hinder Compressed Air Efficiency in the Plastics Industry<\/strong><\/h2>\n
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Methods of Compressed Air Molding Used in the Plastics Industry<\/strong><\/h2>\n
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The Extrusion Method of Plastic Molding<\/strong><\/h2>\n
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Energy Savings With Extrusion Molding<\/strong><\/h2>\n
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Injection Molding in the Plastics Industry<\/strong><\/h2>\n
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Energy Efficiency With Injection Molding<\/strong><\/h2>\n
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Blow Molding in Mass Plastic Production<\/strong><\/h2>\n
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Quincy Compressors Boost Plastics Industry Efficiency<\/strong><\/h2>\n
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