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EXTERNAL GAS ASSISTED MOULDING SAVES 15% ENERGY
04 October 2004 - Rapra Technology Limited
| A programme of energy consumption trials has concluded that significant savings of up to 15% in energy consumption are possible using external gas assisted moulding instead of standard moulding. |
A programme of energy consumption trials has concluded that significant savings of up to 15% in energy consumption are possible using external gas assisted moulding instead of standard moulding. The study also found that significant cycle time and part weight savings are achieveable from both internal and external gas-assisted moulding. The research work was undertaken by independent consultants at Bradford University working at Cinpres Gas Injection (CGI) Middlewich. The production basis consisted of a Sandretto 3000kN locking force moulding machine Series 7) together with a Cheetah control box housing tool, producing a 'frisbee' mould from high impact polystyrene. In addition to the energy savings noted during the gas injection trials, Bradford University concluded that 'the savings generated by cycle time reduction and part weight reduction may outweigh the savings made by the energy consumption reduction.' The Bradford consultants also noted that the clamp tonnage forces when using gas-assisted moulding could generate energy savings but that the energy savings for toggle-lock moulding machines was likely to be small. Moulding machines using the direct lock system were more likely to save more energy. Faraday Plastics Director Richard Simpson said: 'Faraday Plastics is delighted to be helping to map out factual data of this kind - in order that moulders in the industry may be able to make informed and reliable choices about cost effective moulding options. Low energy processing is a key part of the Faraday Plastics mission and these findings in relation to gas injection technology will help in creating a more effective processing sector of the future.' Terry Pearson of CGI (Cinpres Gas Injection) said: 'Certainly our experience with many customers confirms that by using gas assisted moulding, internal and external, in mould pressures are reduced by up to 50%. Therefore power consumption must be reduced in many cases when the size of moulding machine (lock force) is reduced. The reduction in weight of plastic processed by up to 40% in thick section moudings must also produce a pro-rata heating cost saving.' Pearson added: 'We are very encouraged by the contributions being made by Faraday and Bradford in bringing this increasingly important aspect of injection moulding to the notice of a hard pressed industry.' Bradford University is an academic affiliate of the Faraday Plastics partnership, as are most recognised polymer-based University departments in the UK. Dame Prof Julia Higgins, Chemical Engineering, Imperial College, and EPSRC Chair, and Prof Tom McLeish, Director of the Polymer Interdisciplinary Research Centre (IRC) at Leeds have recently become Faraday plastics affiliates. Richard Simpson, Faraday Plastics Director, said that UK Universities have a clear mission to bring their polmeric know-how and scientific skills into the marketplace of industrial and commercial communities. Both parties can only benefit from contact and interaction with each other. 'We in the UK have world class resources in both research and commercial exploitation. Our role at Faraday Plastics is to enhance both activities by bringing them closer together.' Simpson urges other leading UK academics to apply to join the FP affiliate scheme, which is currently free of charge. Benefits for academe include:
* Collaboration with companies to form research teams.
* Support in the preparation of research bids.
* Help in identifying funding sources.
* Opportunities to exploit research outputs. The purpose of the Faraday Plastics affiliate scheme is to link both industry and academe in meeting the critical technological challenges of the plastics sector.
Benefits in the new nano-technology-based polymers, low-energy processing techniques, and environmental polymers are now being shared through the Faraday Plastics network.
Faraday Plastics will publish an edited version of the study and its finding on its web site.
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About: Rapra Technology Limited
Rapra Technology is Europe’s leading independent plastics and rubber consultancy. Rapra provides comprehensive consultancy, technology and information services for the polymer industry and industries using plastics and rubber in any component, product or production process.
Company Statistics: Formerly the Rubber and Plastics Research Association (RAPRA)
Established 1919
5,000 clients worldwide per annum
2,000 technical projects each year
World class Information Centre
2 sites in the UK
130 staff Working for industry. Rapra provides specialist plastics and rubber technical, information and commercial services for the polymer industry and end-user industries including the automotive, construction, electrical, medical, offshore, packaging and polyurethane sectors. Rapra has a unique mix of on-site expertise and facilities enabling the application of an integrated approach to problem solving. Its capabilities lie in the skills and experience of its people, many of whom are recognised as leading experts in their field. Clients can commission individual services,specialist consultancy or participate in multi-client research projects, funded by EC and UK government and/or industry, to progress research and development of polymer technology and applications. Testing, analysis and calibration services. Rapra’s physical testing, analytical and chemical laboratories are UKAS accredited to provide UKAS certification and test to a range of national and international standards. Numerous physical tests assess material properties such as abrasion, fatigue, impact and stress and their performance in products in particular conditions. Rapra’s analytical and chemical laboratories undertake materials identification and characterisation etc. using a range of advanced chromatographic, spectroscopic and thermal techniques. Information services. Rapra’s technical facilities are complemented by an extensive polymer Information Centre. The Polymer Library is the world’s most comprehensive plastics and rubber information database in the public domain. Available either in hardcopy, on CD-ROM or via the internet, it contains over 850,000 references which are updated every two weeks. Rapra produces a range of publications including Journals, Industrial Analysis Reports, Review Reports and global Directories, detailed in a Publications Catalogue. Technology services. Rapra’s plastics and rubber technical services can prevent, identify or solve problems and improve on or ensure continuing quality. Supported by comprehensive testing, analysis and information facilities, technologists can tackle most polymer related projects. Whilst details of specialist services are available, the following represents Rapra’s core technical expertise: Materials selection & application support
Product design & development
Manufacturing process development
Prototyping & small scale production
Engineering & tooling
Fault & failure diagnosis
Testing & Analysis
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Rapra brings together leading academics and industrialists in an annual programme of national and international conferences. Renowned for their quality coverage of polymer topics, Rapra conferences are of interest to polymer processors and industry-wide users. Technology Training Courses
Rapra runs an extensive programme of short technology-based training courses covering materials, product design, processing techniques and environmental considerations. Recognised by the Institute of Materials Continuing Professional Development scheme, they aim to enhance in-house skills, help in identifying problems and to recognise potential opportunities. |
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