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Reducing Production Costs: 3 Practical Energy-Saving Transformation Schemes for Mold Temperature Controllers

Reducing Production Costs: 3 Practical Energy-Saving Transformation Schemes for Mold Temperature Controllers

October 24,2025

 

In manufacturing industries such as injection molding, die casting, and extrusion, mold temperature controllers, as core equipment for controlling mold temperature, typically account for 15%-30% of the total production energy consumption. With the continuous rise in energy costs, energy-saving transformation of mold temperature controllers has become an important breakthrough for enterprises to reduce costs and increase efficiency. This article will share 3 practical and verified energy-saving transformation schemes for mold temperature controllers, helping enterprises significantly reduce energy consumption while ensuring production quality.

 

Scheme 1: Replace with High-Efficiency Heating Elements to Reduce Heat Loss

Traditional mold temperature controllers mostly use ordinary metal heating tubes, with a heat conversion efficiency of only 70%-80%, and a large amount of heat is lost through the shell during the heating process. The first step in energy-saving transformation is to replace the heating elements with ceramic heating tubes or electromagnetic heating coils. The heat conversion efficiency of ceramic heating tubes can reach more than 90%, and they have the characteristics of fast heating speed and small thermal inertia; electromagnetic heating makes the metal barrel heat itself through electromagnetic induction, avoiding heat conduction loss, and the thermal efficiency can even reach 95%.
At the same time, adding high-temperature resistant insulation cotton to insulate the heating chamber and pipelines of the mold temperature controller can further reduce heat loss. After replacing ceramic heating tubes and adding insulation transformation, an injection molding enterprise reduced the daily power consumption of a single mold temperature controller from 80 kWh to 55 kWh, saving 750 kWh of electricity per month, with a significant energy-saving effect.

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Scheme 2: Install Waste Heat Recovery System for Secondary Utilization of Waste Heat

During the cooling cycle of the mold temperature controller, a large amount of high-temperature waste heat is generated (such as high-temperature oil after cooling of oil temperature machines and hot water discharged by water temperature machines). If this waste heat is directly discharged, it not only wastes energy but also increases the cooling load of the workshop. Installing a waste heat recovery heat exchanger is an effective way to solve this problem.
Specifically, a plate heat exchanger can be connected in series in the cooling circuit of the mold temperature controller to transfer the waste heat to the cold water in the cold water tank. The preheated cold water then enters the heating chamber of the mold temperature controller, reducing energy consumption during the heating stage; in addition, the recovered waste heat can also be used for workshop heating, preheating of employees' domestic water and other scenarios. After installing a waste heat recovery system, a die-casting enterprise reduced the energy consumption of the mold temperature controller during the heating stage by 18%, and at the same time reduced the workshop heating energy consumption expenditure by about 20,000 yuan per year.

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Scheme 3: Optimize Operating Parameters to Achieve Intelligent Temperature Control

Many enterprises have the problem of "overheating" in their mold temperature controllers - in pursuit of production stability, the temperature set value is higher than the actual process requirements, leading to energy waste. By optimizing temperature parameters in combination with production processes, energy consumption can be reduced without affecting product quality. For example, in injection molding, the mold temperature of some products can be reduced from 120℃ to 100℃, which still ensures the product appearance and dimensional accuracy.
In addition, upgrading the PID intelligent temperature control system of the mold temperature controller is also crucial. The temperature fluctuation of the traditional temperature control system is relatively large (±1-2℃), while the advanced PID system can control the fluctuation within ±0.1℃, avoiding repeated heating caused by temperature fluctuation. At the same time, equipped with an intelligent control system, it can realize automatic start-stop and load adjustment of the mold temperature controller, avoiding energy consumption caused by idle operation of the equipment. An extrusion enterprise reduced the energy consumption of the mold temperature controller by 12% and the product defect rate by 3% through parameter optimization + PID upgrade.

Practical Benefits of Energy-Saving Transformation: Short-Term Investment, Long-Term Return

The investment cost of energy-saving transformation of mold temperature controllers varies according to different schemes. The transformation cost of a single equipment is usually between several thousand yuan and 20,000 yuan, but the payback period is short. Taking a 10KW mold temperature controller as an example, if it operates 10 hours a day and the electricity price is 1 yuan/kWh, after transformation, if the energy is saved by 20%, it can save 7,300 kWh of electricity per year and 7,300 yuan of electricity costs, and the transformation cost can be recovered in less than 1 year.
In conclusion, the energy-saving transformation of mold temperature controllers is not a complicated project. Through the three practical schemes of replacing high-efficiency components, recovering waste heat, and optimizing parameters, enterprises can effectively reduce energy consumption while ensuring production efficiency and product quality, providing strong support for production cost control. For enterprises with large production scales and a large number of mold temperature controllers, the economic benefits brought by energy-saving transformation will be more considerable.
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