How can you pay up to 80% less for electricity?

Energy prices represent a major cost item, which is why manufacturing companies are looking for real and measurable ways to reduce operating costs. In plastics molding plants, customer experience and repeated measurements show that switching to fully electric injection molding machines is one of the most effective solutions.

Although hybrid machines consume less energy than fully hydraulic machines, they still represent a compromise. They do not eliminate the full range of costs associated with hydraulics — especially energy losses, operation of the oil management system and higher service requirements.

Why fully electric machines?

Only fully electric injection molding machines make it possible to:

• eliminate the oil management system,
• remove environmental risks associated with hydraulic oil,
• achieve higher production repeatability,
• reduce service interventions and maintenance costs,
• significantly reduce electricity consumption.

In practice, savings of 50% or more can be achieved, and in some cases even significantly higher.

How is energy consumption measured?

Based on a phone consultation, we will agree a date for a no-obligation energy consumption measurement directly at your production site.

The only cooperation required on your side is the assistance of an electrician, who will help connect the measuring equipment.

The measurement is non-invasive:

• no wires need to be disconnected,
• voltage on phases L1, L2 and L3 is measured using magnetic probes on the terminal block,
• current is measured using current probes based on the Rogowski coil principle — toroidal coils that enable precise measurement of alternating current without any intervention in the cabling.

How long does the measurement take?

If the machines are running stably:

10–15 minutes of measurement on a fully heated machine during production is usually sufficient.

If you switch the machines on frequently:

We recommend also measuring the heating phase — oil + barrel.
With hydraulic machines, you pay for:

• oil heating,
• and then, during production, for oil cooling.

Based on the measured data, it is possible to calculate precisely how much energy you pay for even when the machine is not actually producing anything.

With fully electric injection molding machines, you only pay for barrel heating. The barrel is also perfectly insulated, so energy losses are minimal.

Depending on the size of the machine, heating measurement may take from 30 minutes to 2 hours.

What is the output?

We will prepare a measurement report and calculate:

• average consumption per kg of material — kWh/kg,
• annual energy consumption,
• annual costs,
• return on investment.

The average consumption of fully electric TOYO machines is conservatively around:

0,25 kWh/kg

This value is based on dozens of measurements on machines ranging from 50 to 1,300 tonnes.

Model comparison: 220-tonne hydraulic machine vs. TOYO

Input measurement parameters

Result

• TOYO machine consumption lower by: −83%
• Annual savings: CZK 226,719

And this is calculated at an electricity price of CZK 3/kWh and machine utilisation of 223 days per year.

The real costs of hydraulic and hybrid machines

The total cost must also include:

• purchase, cooling and ecological disposal of oil,
• regular replacement of hoses, seals and other parts,
• machine cooling costs,
• higher scrap rates,
• service costs.

With TOYO machines, long-term service costs are negligible.

Do you want to know your real savings?

Send us your contact details and we will call you.