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Looking for New Injection Molding Equipment? ROI Factors You Should Know Before You Buy

Let’s be real: when you’re looking at a quote for a new injection molding machine, that bottom-line number can be a bit intimidating. It’s easy to get “sticker shock” and start wondering if you should just keep patching up that old hydraulic “workhorse” in the corner.

But here’s the straight talk: the purchase price is only a fraction of what that machine will cost: or save: you over the next ten years. In the plastics industry, the real winners aren’t the ones who buy the cheapest equipment; they’re the ones who understand Return on Investment (ROI).

At Hirate America, we don’t just sell machines; we partner with you to build a business that actually makes money. Whether you’re a seasoned pro or building your first facility from the ground up, understanding these 10 ROI factors will help you see past the price tag and focus on the profit.

1. Energy Consumption: The Silent Profit Killer

Energy is typically 30% to 45% of your total operating costs. If you’re still running standard hydraulic machines, you’re essentially leaving a “lights-on” bill equivalent to a small stadium every month.

Switching to a Servo-hybrid (LSG-H) or All-Electric (LSG-E) machine can slash your energy consumption by 50% to 60%. Those savings go directly back into your pocket. Over a 12-to-18-month period, the energy savings alone often pay for the price difference between a cheap machine and a high-efficiency one.

The LSG-E series all-electric injection molding machine, designed for maximum energy efficiency and precision.

2. Shaving Seconds: The Power of Cycle Time Reduction

In high-volume manufacturing, time isn’t just money: it’s everything. If we can shave just 2 seconds off a 20-second cycle, that’s a 10% increase in production without adding a single hour of labor.

Modern machines, like our LSG series, use faster, more dynamic movements and overlapping functions (like charging while the mold opens). When you calculate your ROI, don’t just look at the machine; look at the extra parts per year those saved seconds produce.

3. Maintenance Costs (and the Peace of Mind Factor)

Old machines leak. They have outdated piping, proprietary parts that take weeks to ship, and hydraulic systems that require constant cooling.

Modern equipment uses high-quality, standardized components and simplified piping layouts. Less heat in the system means longer life for your seals and oil. When you choose a machine with world-class components, your maintenance crew spends more time on preventive tasks and less time “putting out fires.”

4. Labor Costs: Let the Robots Do the Heavy Lifting

If your operators are manually picking parts or trimming gates, you’re wasting human potential. We believe in integrating automation from day one.

By setting up a “plug and play” automation cell, one operator can manage multiple machines instead of just one. Reducing the “labor per part” is one of the fastest ways to see a massive ROI, especially as labor markets get tighter.

An advanced high-performance injection molding cell featuring integrated robotics for labor reduction and high-speed production.

5. Utility Costs: Water and Air Matter

It’s not just about electricity. Inefficient machines require massive amounts of cooling water and compressed air.

High-efficiency chillers and precision-controlled compressors (like the ones we integrate into our turn-key solutions) ensure you aren’t overworking your facility’s infrastructure. Saving on water treatment and compressed air maintenance adds up to thousands of dollars over the machine’s life.

6. Maximizing Your Floor Space

Floor space is expensive. If you can fit three machines in the space where two used to sit, you’ve just increased your facility’s potential revenue by 50%.

The LSG-H series features a compact, two-platen design that significantly reduces the machine’s footprint compared to traditional toggle designs. This “Small Footprint, Big Power” approach is a game-changer for shops looking to scale within their existing walls.

The LSG-H series hybrid machine, showcasing a compact design that saves valuable floor space without sacrificing clamping force.

7. Training & Ease of Use (The KEBA Advantage)

A machine is only as good as the person running it. If the controller is confusing, your operators will make mistakes, and mistakes cost money.

We use industry-standard KEBA controllers with intuitive, touchscreen interfaces. They are easy to learn, easy to navigate, and reduce the “human error” factor. When your team feels confident using the equipment, your uptime goes up and your stress levels go down.

A modern KEBA digital touchscreen control panel, designed for ease of use and precision process monitoring.

8. The Hirate America “Partner Advantage”

This is the big one. Anyone can ship you a crate with a machine inside. But will they help you calculate your specific ROI? Will they walk you through the process of setting up your facility to minimize labor?

We specialize in Turn-key Solutions. We help you with product design, mold sourcing, and machinery integration. Our goal is to make sure your ROI hits that sweet spot of 12 to 18 months. We guide you through the technical jargon and provide the “peace of mind” that comes from working with experts who actually care about your bottom line.

Ready to see the numbers for yourself?

Buying new equipment is a big step, but you don’t have to take it alone. Whether you’re looking to replace one aging press or build an entire new production line, we’re here to help you do the math.

Don’t hesitate to reach out! Get in touch with our team today, and let’s talk about how we can increase your efficiency, reduce your costs, and get you the ROI you deserve!

Contact Hirate America Today!

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The ‘Hidden’ Electricity Bill: How Much Your Hydraulic Machines Are Actually Costing You

More Than Just Electricity: The Hidden Maintenance Costs

While the power bill is the most visible “hidden” cost, legacy hydraulics carry other burdens that eat away at your profitability. Maintenance on a 20-year-old machine is a constant uphill battle for your crew.

1. Hydraulic Oil and Filtration:
Older machines require hundreds of gallons of hydraulic oil. Not only is the oil expensive, but you also have to deal with disposal costs and the labor required for frequent filter changes. With the LSG-E (All-Electric), these costs are eliminated entirely. With the LSG-H (Hybrid), the oil lasts longer because it isn’t being constantly overheated by inefficient pumping.

2. Cooling System Strain:
Legacy hydraulics are essentially giant heaters. The energy they waste is converted into heat, which your central chilling system has to work overtime to remove. When you switch to a Servo-Hybrid or All-Electric machine, you often find that your chillers and cooling towers don’t have to work nearly as hard, extending their lifespan and saving even more on your utility bill.

3. Floor Space and Cleanliness:
Leaks are a fact of life with old hydraulics. They create safety hazards and require constant cleaning. Modern machines like the LSG-E are “plug and play” and keep your facility looking world-class: which is a huge advantage when you’re showing off your shop to potential high-value customers.

Your Personal Partner in the Process

Transitioning from legacy equipment to modern, high-efficiency machinery can feel overwhelming. You might be wondering: “Which tonnage is right for my new mold?” or “How do I calculate the utility rebates in my state?”

This is where Hirate America steps in as your personal partner. We don’t just sell you a machine and walk away. We are here to guide you through the entire process, from the initial energy audit to the final installation.

We call it our Turn-key Solution. We can manage everything, including:

Our goal is simple: to help you build a facility that is so efficient and so automated that you can focus on growing your business while the machines take care of the rest.

Let’s Find Your Savings Together!

The “hidden” electricity bill doesn’t have to be a permanent part of your business model. Whether you’re looking to upgrade a single old press or you’re planning to build a new facility from the ground up, we have the technical knowledge and the “Personal Partner” approach to ensure you succeed.

Don’t wait for the next utility rate hike to take action. Every day you run those old hydraulics is a day you’re leaving money on the table.

Get in touch with the Hirate America team today! We’d love to walk you through our latest LSG models, help you run the math on your potential savings, and give you the peace of mind that comes from working with industry experts who truly care about your success.

Contact us here to start your energy audit!

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All-Electric Vs Hybrid Injection Molding Machines: Which Is Better For Your Bottom Line?

If you are a plant manager or a business owner in the plastics industry, you know that the “utility bill” isn’t just a monthly expense: it’s a direct hit to your competitiveness. Every kilowatt-hour saved and every scrap part eliminated is money that goes straight back into your pocket.

When it comes time to upgrade your facility or build a new line from the ground up, you’re faced with the ultimate industry debate: All-Electric vs. Hybrid Injection Molding Machines.

At Hirate America, we don’t just sell you a machine; we act as your personal partner to walk you through the process of selecting the right technology. Whether you’re looking to slash cycle times or move into high-precision medical molding, understanding the ROI of these two technologies is the first step to scaling your success.

Let’s break down which machine is truly better for your bottom line.

The Energy Efficiency Face-Off: 70% vs. 60%

In the old days, hydraulic machines were the only game in town. They were powerful, but they were energy hogs, constantly pumping oil even when the machine was idling. Today, that’s ancient history.

The All-Electric LSG-E Advantage

The LSG-E Series (30–1430 tons) is the gold standard for energy efficiency. Because these machines use servo motors for every single movement: clamping, injection, and recovery: they only consume power when they are actually moving.

  • The Bottom Line: All-electric machines can reduce your energy consumption by up to 70% compared to traditional hydraulics.

The Hybrid LSG-H “Workhorse”& LSG-HP “High Performance”

Our LSG-H (100 – 4950 tons) and LSG-HP series (500 – 4950 tons) utilize advanced servo-hybrid technology. These machines use servo motors to drive the hydraulic pumps, giving you the best of both worlds: the raw power of hydraulics with the efficiency of electric controls.

  • The Bottom Line: Hybrid machines can still save you up to 60% in energy costs. While it’s slightly less than all-electric, the “power-per-dollar” on larger tonnage parts is often more favorable for hybrids.

LSG-E All-Electric Injection Molding Machine
The LSG-E All-Electric series offers maximum energy savings and high-precision repeatable results.

Precision vs. Power: Where Does Your Part Fit?

Choosing between these two isn’t just about the electric bill; it’s about what you’re actually making.

Precision & Repeatability (All-Electric)

If you are molding thin-walled packaging, micro-electronics, or medical devices, the LSG-E is your best friend. Electric motors are inherently more precise than hydraulic valves. You get sub-millimeter accuracy and high-speed repeatability that ensures your scrap rate stays near zero.

  • ROI Tip: Lower scrap rates mean you aren’t just saving on plastic; you’re saving on the labor and machine time it took to make those bad parts!

Raw Strength & Versatility (Hybrid)

When you get into larger parts: think automotive bumpers, large crates, or heavy industrial components: you need “muscle.” The LSG-H and premium LSG-HP series provide the massive clamping forces (up to 4950 US tons!) needed for heavy molds.

  • Hybrid Versatility: Hybrids are often better at handling complex molds with multiple “core pulls” (the moving parts inside a mold) because they have built-in hydraulic systems to power them.

LSG-H Servo Hybrid Injection Molding Machine
The LSG-H Servo Hybrid is a heavy-duty workhorse designed for large-scale production and durability.

Maintenance and “Peace of Mind”

No one likes downtime. When a machine goes down, you aren’t just losing production; you’re paying people to stand around.

The All-Electric “Clean” Benefit:
The LSG-E series is virtually oil-free. This means:

  1. Lower Maintenance: No oil changes, no filters to swap, and no leaks to clean up.
  2. Cleanroom Ready: If you want to get into medical or food-grade molding, a clean, oil-free environment is often a requirement.

The Hybrid “Robust” Benefit:
While hybrids still use oil, the modern design of the LSG-HP has eliminated 100% of welding pipes. By using the latest piping technology and galvanized pipes, we’ve minimized the risk of leaks and kept the hydraulic purity at world-class levels. It’s a robust system designed for 24/7 “set it and forget it” operation.

The “Brain” of the Operation: CSI 4.0 Smart Solutions

Regardless of whether you go Electric or Hybrid, your bottom line is only as good as your data. At Hirate America, we integrate LS Mtron’s CSI 4.0 (Connected Smart Injection) into our solutions.

  • Smart Monitoring: You can check the status of your machines from your phone or office.
  • Smart Peripheral Control: You can control your Dri-Air Dryers, Thermal Care Chillers, and Motan Conveying Systems directly from the machine’s control screen.
  • Smart Mold Recognition: The machine automatically recognizes the mold and retrieves the correct settings, reducing setup time and human error.

Reducing “human error” is one of the fastest ways to improve your ROI. When the machine knows exactly how to run the part, your labor costs go down and your efficiency goes up!

Precision Gear Assembly in LS Mtron Machine
Precision engineering in every component ensures long-term reliability and reduced maintenance costs.

Calculating Your ROI: 12 to 18 Months?

We know what you’re thinking: “All-electric sounds great, but it costs more upfront.”

You’re right. Typically, an all-electric machine has a higher initial purchase price (often 10–25% more) than a hybrid. However, when you factor in:

  1. The 70% Energy Savings
  2. Reduced Scrap Rates
  3. Lower Annual Maintenance Costs

Many of our clients see a Return on Investment (ROI) in as little as 12 to 18 months. After that period, the machine is essentially “paying you” in the form of lower operating costs for the next 15–20 years.

If you are looking for a more cost-effective entry point but still want modern efficiency, the Hybrid LSG-H offers an incredible middle ground, delivering most of the energy benefits with a lower upfront capital expenditure.

Which One Should You Choose?

  • Choose All-Electric (LSG-E) if: You prioritize precision, have high energy costs, need a cleanroom environment, or are molding small-to-medium parts with fast cycle times.
  • Choose Hybrid (LSG-H/HP) if: You need high clamping forces (500+ tons), work with large or heavy molds, or want a versatile “all-rounder” that balances cost and efficiency.

Modern LS Mtron Production Floor
A high-tech production floor featuring integrated robotics and LS Mtron machinery.

Let’s Build Your Future Together

Choosing the right equipment is a big decision, but you don’t have to make it alone. At Hirate America, we specialize in Turn-key Solutions. We help you design the product, select the molds, and pick the perfect machines to ensure your facility is as efficient as possible from Day 1.

Whether you need a single machine or a complete recycling system to handle your regrind, our team is here to guide you.

Ready to see the numbers for your specific project?

Don’t hesitate to reach out! We’d love to help you calculate your potential energy savings and find the machine that will best serve your bottom line.

Contact Hirate America Today!

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The Ultimate Guide to Turn-Key Plastics Manufacturing: Everything You Need to Start From Scratch

Starting a plastics manufacturing business can feel like trying to solve a 10,000-piece puzzle where the pieces are made of high-grade polymers and steel. You have a brilliant product idea, but then the questions start piling up: What kind of machine do I need? How do I design a mold that won’t fail? How do I keep my utility bills from skyrocketing?

At Hirate America, we believe that building a manufacturing facility shouldn’t be a source of stress: it should be a source of growth. That’s why we specialize in turn-key plastics manufacturing. We don’t just sell you a machine and wish you luck; we walk beside you from the very first napkin sketch to the moment your finished products roll off the line.

In this guide, we’re breaking down the entire process of starting from scratch, showing you how the right partnership can help you save money, reduce labor, and slash your cycle times.

1. The Design Phase: Turning Ideas into “Moldable” Reality

Every great plastic product starts with a design, but not every design is ready for a machine. This is where many new manufacturers hit their first roadblock. A design that looks beautiful in CAD might be a nightmare to actually produce, leading to high scrap rates and long cycle times.

As your personal partner, we start by looking at your product design through the lens of Design for Manufacturing (DFM). We help you evaluate:

  • Wall Thickness: Ensuring uniform thickness to prevent warpage.
  • Draft Angles: Adding the necessary slopes so your parts pop out of the mold effortlessly.
  • Material Selection: Choosing the right resin (PP, PE, ABS, or PC) for your specific application.

By catching these issues early, we ensure that when it’s time to cut steel for your molds, you’re investing in a tool that is optimized for efficiency from day one.

2. Choosing Your Powerhouse: Injection vs. Blow Molding

Once your design is ready, you need the right “engine” to drive production. Depending on your product, you’ll likely need one of two primary technologies.

Injection Molding Machines

If you are creating complex, high-precision 3D parts like automotive components, medical devices, or electronics housings, an injection molding machine is your go-to. Hirate America offers a broad range of LS Mtron solutions so you can match the right machine to your part geometry, output goals, floor space, and labor requirements.

Here’s a closer look at the LS Mtron lineup:

1. LSG-HP Series
The LSG-HP is a high-performance servo hydraulic machine (500 to 4,950 tons) optimized for reduced cycle times and maximum productivity.

LSG-HP Series

2. LSG-H Series
The LSG-H is a robust servo hybrid workhorse (100 to 4,950 tons) designed for high-efficiency, cost-effective plastic manufacturing.

LSG-H Series

3. LSG-E Series
This all-electric series (35 to 1,430 tons) delivers high-precision performance and significant energy savings for demanding production environments.

LSG-E Series

4. LSG-V Series
The LSG-V is a high-efficiency vertical machine (40 to 660 tons) built for precision insert molding with a compact footprint.

LSG-V Series

With this range of LS Mtron machines, you can build an injection molding operation that is tailored to your product, labor goals, and long-term growth strategy.

Blow Molding Machines

Are you looking to produce hollow containers like bottles, jugs, or industrial tanks? That’s where blow molding machines shine. For high-efficiency and sustainable production, we offer the all-electric Bekum EBLOW series.

The new EBLOW 8 Series (including the 808 and 1208 models) sets the industry standard for energy efficiency—reducing consumption by up to 20% to 50% compared to traditional hydraulic systems. These machines are engineered for the demanding requirements of the packaging, pharma, and medical industries.

Key advantages of the EBLOW series include:

  • Precision and Reliability: The C-frame clamping unit ensures high plate parallelism and uniform force distribution.
  • Intuitive Control: Equipped with the Bekum Control 8.0, providing Industry 4.0-ready touch controls for easy monitoring and setup.
  • Sustainability: Features like the direct-drive IE5 motor help minimize your carbon footprint while maximizing output.
  • Modular Design: Fast setup times and an open structure for easy maintenance and automated part take-out.

Whether you’re producing 1-liter bottles or large canisters, the EBLOW series provides a future-ready solution that saves you money on utilities while delivering consistent, high-quality products.

The Bekum EBLOW series: All-electric extrusion blow molding machines designed for high-efficiency and sustainable plastics production

3. The “Silent Heroes”: Integrating Plastic Process Equipment

The molding machine is the heart of your plant, but the plastic process equipment (auxiliaries) is the circulatory system. Without proper cooling, drying, and material handling, even the best machine will underperform.

To achieve the “peace of mind” we promise our clients, we integrate high-performance auxiliary systems that automate the heavy lifting:

  • Cooling Systems: We partner with Thermal Care to provide precision chillers. Proper cooling can reduce your cycle times by up to 20%: which directly translates to more parts out the door every hour!
  • Drying and Conveying: Systems from Dri-Air and Motan ensure your resin is moisture-free and delivered to the machine automatically, reducing manual labor and material contamination.
  • Mold Protection: Using Sigmax Vision Systems, we can detect short shots or improper part ejections in milliseconds, preventing “mold crush” and saving you thousands in repair costs and downtime.

4. Closing the Loop: Recycling Systems

In today’s market, being “green” isn’t just about the environment: it’s about your bottom line. Why pay for expensive virgin resin when you can recycle your own scrap?

We integrate recycling systems directly into your turn-key setup. With partners like NGR (Next Generation Recycling), we provide “dump and run” shredder-feeder-extruder combinations. This allows you to turn production waste, sprues, and runners back into high-quality pellets that can be fed right back into your machines.

NGR S Gran pelletizer shredder extruder all in one system

5. The ROI: Why “Turn-Key” Wins Every Time

When you try to piece together a factory yourself, you often end up with “Frankenstein’s Monster”: machines that don’t talk to each other, inconsistent quality, and hidden costs.

When you work with Hirate America as your technical expert, we focus on three KPIs:

  1. Reduced Cycle Times: Every second saved is pure profit.
  2. Lower Labor Costs: With automated conveying and robotics from brands like Sailor Automation and MAC Automation, you need fewer people on the floor to do more work.
  3. Minimized Scrap: Precision controls from Sigmax ensure that every part made is a good part.

Typical ROI for our turn-key solutions ranges between 12 to 18 months. By investing in the right setup from the start, the equipment literally pays for itself through efficiency gains and material savings!

Ready to Start Your Journey?

Whether you are a seasoned manufacturer looking to expand or an entrepreneur with a brand-new idea, we are here to walk you through the process. We don’t just provide equipment; we provide a partnership built on a decade of technical expertise and a commitment to your success.

Don’t hesitate to reach out! Let’s talk about your project and show you how easy it can be to go from “scratch” to “full-scale production.”

Contact the Hirate America team today!

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2020 Guide To All Electric Injection Molding Machine

All electric injection molding machines have been on the market for decades now, and there are many benefits in utilizing all electric injection molding machines.  Although there are still applications for standard hydraulic and hybrid injection molding machines, many of the major injection molding machine manufacturers are primarily focused on manufacturing all electric molding machines.  This is especially so as technology is constantly advancing and the previously too expensive to build larger tonnage all electric molding machines are becoming more and more common. It is clear that the future of the industry is in all electric injection molding machines.

What is the difference between an all electric injection molding machine and hydraulic injection molding machine? 

Electric injection molding machines consume energy only when required for a given action, and motor output is matched to meet requirements, unlike traditional hydraulic injection molding machines which use continuously consume energy even while idle.

Instead of being driven by a hydraulic system, electric injection molding machines are digitally controlled with high-speed and highly-efficient servo motors to drive the whole process. Each axis is controlled by an independent motor for injection, extrusion, clamping and ejection.

The outcome brings about a faster, cleaner, more repeatable and energy efficient injection molding process. Energy consumption for electric injection molding machines can be reduced by 50 to 75% compared to a hydraulic type.

Due to a recent rise in electricity bills in the industry, all electric injection molding machines have become more popular to save electricity costs ultimately leading to overall operational cost reduction.

What are the best applications for an all electric injection molding machine? 

All electric injection molding machines are currently being applied to various industries such as automobile parts, medical supplies, medical equipment, electronic parts, household appliances, lens molding, and daily necessities.

If your products require high product quality, precision and high repeatability then all electric would be the way to go. 

High Repeatability and Precision (Closed loop controls and linear motions)

 

  • Accuracy
    Of the 3 types of molding machines, all electric injection molding machines have the highest accuracy and repeatability.  This is because of the fact that these machines use electric servo motors with a 0.1mm +/- rotation to actuate their movements.  This type of movement allows the process to completely negate the fluctuations and inaccuracies of movements actuated by hydraulic pressure and their unavoidable pressure curves.
  • Consistency In Production
    Standard hydraulic injection molding machines constantly experience variations in their process throughout the year, and even throughout the day. This is because the weather is always changing and has an effect on your machines temperature and humidity.  As hydraulic oil gets cooler, its viscosity increases, and as hydraulic oil gets warmer, its viscosity decreases. The way hydraulic oil performs also changes as it degrades over time. This means that the way the oil in a machine moves and lubricates will always eventually be totally different than day 1.This also means that your molding machine’s process may need to be adjusted periodically throughout the day.  Standard hydraulic molding machine controls are considered “open loop” because they send signals to valves to adjust pressures, but don’t actually have direct control over the physical movements of the machine, and thus cannot make all of the minor adjustments that an all electric machine can make in real time.  All electric injection molding machines are considered to have “closed loop” controls because they control every movement with physical gear turns of their servo motors, and have the ability to constantly monitor and control their positions and speeds to a very tight tolerance, regardless of the ambient conditions.  This is the difference between “closed loop” and “open loop” controls.

All electric injection molding machines are the perfect fit for manufacturing most complex, difficult, and thin walled parts.  You can inject very accurate shots, while maintaining precise repeatability through the day, night, and seasons.

You Want Low Energy Consumption To Save On Power Costs

Low Energy Consumption
Contrary to its name, electric injection molding machines are extremely energy efficient. If you compare typical hydraulic injection molding machines and electric injection molding machines in terms of the same part and mold, you will see 50% to 70% energy savings in most applications of electric machines.

In a typical hydraulic injection molding machine, a hydraulic pump is constantly on when the machine is running. It has to keep running to circulate oil and is generating heat as long as the machine is running. On the other hand, an electric injection molding machine only consumes electricity as a servo motor turns to actuate movement, so much of the production cycle is spent idling, this is especially so in case of the cooling phase of cycle.

 

 

Electric Servo Motors
Typical hydraulic injection molding machines have one or more pumps that generate hydraulic pressure, and valves that direct pressure to hydraulic mechanisms to build pressure based on the necessary movements. Electric injection molding machines do not have a central electric motor, but use individual electric motors designed for each function that is needed throughout the machine, i.e. mold open/close, injection, recovery, and ejection. This means that the motors can be idle until their specific function is required. This is day/night comparison with a typical hydraulic injection molding machine that has to run its pumps continuously, even when nothing is happening. This is especially apparent during the cooling phase.

 

 

No Hydraulic Cooling Needed
Energy savings don’t end with an injection molding machine. The elimination of hydraulic pump circuit also doesn’t have a need for cooling hydraulics. Since electric injection molding machines don’t have hydraulics, they don’t require machine cooling. The only cooling that you will likely need is for your mold and feed throat. This leads to additional savings as you will not need additional water lines. Chillers also consume large amounts of electricity, and cooling towers consume water and electricity and require frequent maintenance and monthly water treatment plans.

 

Less Equipment Equals Less Maintenance
It is very common for customers who use only electric injection molding machines to only have chillers in their plant. This is because they no longer have a need for the high temperature circuit of cooling (85-95F) for their machines but only require the low temperature circuit of chilling (anything under 80F, usually 55F) for their molds and feed throats. Having fewer pieces of equipment obviously means, less capital invested, less upkeep and maintenance costs, less energy consumed, and lower overhead costs.

Overall Plant Energy Savings
Electric injection molding machines also run significantly cooler because there is no heat being generated by a hydraulic pump. Medical and clean room molding facilities are often climate controlled, which means that an air conditioning system does not have to work as hard to remove the heat from a molding room, if the machine is electric. This is another reason why many medical and clean room manufacturers exclusively use electric injection molding machines.

Think Long Term Savings
Based on all of the above points, when comparing a 390-ton typical hydraulic injection molding machine vs. an electric injection molding machine, there is around $17,000 of annual savings on the electric machine. This number represents the savings based on today’s factors, but it is only expected to increase as long as energy costs all across the U.S and Mexico are constantly on the rise. With proper maintenance and care, quality injection molding machines should last 20+ years.  This means that when considering a new injection molding machine, you need to think of 10 to even possibly 20 years down the road. Make sure to purchase your new machines from a reputable and established company who manufacturers their own components, such as platens, motors, sensors, breakers, contactors, cables etc. This ensures that you will always have access to replacement parts. LS Mtron is one of the billion dollar companies that manufacture all sorts of major components for their machines in house.

You Want A High Speed Molding Machine

  • Simultaneous Movements
    All electric injection molding machines have multiple electric servo motors.  These motors are coupled to pulleys and belts that work onto ball screw mechanisms that actuate the movements of functions, i.e. platen open and close.  The ability all electric machines have to make compound movements (actuating multiple functions at the same time) is one of the reasons why electric machines often times produce reductions in cycle time vs standard and hybrid injection molding machines.  You can “eject on the fly” or eject your parts before opening the mold completely,and you can start recovering the screw while opening and closing the mold. Hydraulic injection molding machines can only handle one movement at a time, because they typically only have one hydraulic pressure circuit to actuate movements.  This becomes a huge game changer for many molders when they decide to advance to all electric injection molding machines.
  • Instant Torque
    We all know that electric cars get their immense speed from having instant torque from their electric motors, and the same goes for our all electric injection molding machines.  They have instant linear motions from our AC electric servo motors, and can achieve up to 800mm per second injection speeds, and can also have multi-step injection speeds with our high output and high response AC servo motors.With all that instant torque also comes the need for a very rigid and robust toggle clamping mechanism.  LS Mtron utilizes a very rigid 5 pin toggle mechanism to ensure that you will continue to have a fast and reliable machine.  Our platens and toggles have gone through extensive FEA (Finite Element Analysis) to determine where all of the major stress points on the mechanisms are.  We also utilize the highest quality steel and casting technologies via our own inhouse steel forging division. All of this is done to maximize the lifetime of our all electric injection molding machines.
    We also utilize a very robust and precise ball screw mechanism to actuate the clamping motion.   As is with any machine component, the range of performance and quality can range drastically, so it is important to ask what manufacturer’s ball screw the injection molding machine you are looking at uses to fully understand its reliability of performance.

You Don’t Want To Deal With Hydraulic Oil

  • No Oil Equals No Mess
    Injection molding machine types are categorized into hydraulic, hybrid, and electric injection molding machines. Typical hydraulic and hybrid injection molding machines require hydraulic oil to actuate the clamping motion and injection unit of a molding machine. Electric injection molding machines use servo electric motors to actuate all of the machine motions without hydraulic oil.Electric injection molding machines have no risk of oil leaks because they don’t use oil. Your manufacturing site will be free of dirty and slippery oil leaks which are a huge safety hazard during mold changes. Not to mention you will no longer have to replace hydraulic oil after 2 to 5-year lifecycle of oil. The lifecycle of oil depends on whether you run 24/7 and whether you keep oil temperature hot, which accelerates degradation. Using hydraulic oil is significantly different from not using it. You never want to have oil contamination and damage your production site, but this may become a serious problem in the case of food packaging, medical molding or clean room required industries.
  • No Oil Changes Equal Less Maintenance
    The life cycle of the hydraulic oil in a machine depends highly on the hours of use and the quality of the machine itself.  We have seen some instances where the hydraulic oil became extremely contaminated in as little as 6 months of use on a competitors brand new machine.  Imagine having to replace oil every 6 to 12 months, not to mention the cost of the oil which can get relatively expensive with larger machines requiring over 500 gallons of hydraulic oil.  With our hybrid injection molding machines, we have seen some of our customers, who periodically test the quality of their hydraulic oil, get 5 or more years of use out of their hydraulic oil.  However, please note that the manufacturer does recommend that the hydraulic oil be changed every 3 to 4 years depending on the hours of operation.

The clean and quiet working environment that you get with all electric injection molding machines make them the ideal machine to use for food packaging and medical molders.  You won’t have to worry about getting oil contamination when cleaning your facility before a plant audit and sending your customers contaminated parts.

Think of all electric cars not needing any oil and almost no maintenance needed, it’s the same with all electric injection molding machines.

Technology Advancements

  • Extremely Reliable
    All electric injection molding machines are the most reliable of the different types of injection molding machines.  This is because unlike standard hydraulic injection molding machines and hybrid injection molding machines that were designed many decades ago, and are often more geared for a lower price bracket, all electric injection molding machines typically use state of the art technologies available.  All electric injection molding machines are also very quiet while running, and most run at or below 70db. This means that your employees are not required to wear hearing protection while operating the machines.
    You will have no oil, less maintenance, more accuracy, higher repeatability, energy savings, a much quieter work environment and a machine that is easier to maintain to continue running production.
  • Automated Features
    With all electric injection molding machines you will have no sticking valve issues, degrading oil quality issues, ambient temperature process fluctuations and noisy pumps.Many of the all electric injection molding machines have safety features standard, like mold safety to prevent crushing parts and foreign objects in the mold, cold screw rotation prevention to prevent the mistake of accidentally rotating the injection screw when the plastic is still cold and solidified from the machine being idle.Most machines will have a centralized lubrication system or automation lubrication system to automatically pump grease onto the tie bars, toggle links, linear guides and other locations where greasing is necessary.  So as long as the grease reservoir or cartridge is full, the injection molding machine will automatically grease the areas that need lubrication based on the number of full cycles. When the grease levels are low, some machines have sensors to alert that the grease reservoir or cartridge levels are low to remind your maintenance team to refill grease or change the cartridge.

Conclusion

Many of our customers prefer All Electric Injection Molding Machines based on the following:

  • The highest degree of cleanliness
  • Very low energy consumption
  • Very high repeatability and precision
  • High speed molding
  • Technological Advancements and Features

For these reason an all electric molding machines are extremely reliable for long term production runs.

We always recommend LS Mtron’s all electric injection molding machines when customers want to make millions of parts reliably every year.  If it’s a 24/7 operation that is required for maximum production rates, this is the best type of molding machine money can buy. We have customers that run “lights out” without any personnel on-site outside of normal business hours and weekends without any downtime.

Hirate America is partnered with LS Mtron Injection Molding Machines (formerly known as LG Injection Molding Machines) who manufactures all electric injection molding machines in South Korea ranging from 20 to 950 US tons.  We can provide a complete turn key solution including machines, molds, auxiliary and automation equipment. Contact us today to request more information and a proposal for your project.

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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Top 5 Reasons To Get an All Electric Injection Molding Machine

All electric injection molding machines have been on the market for decades now, and there are many benefits in utilizing all electric injection molding machines.  Although there are still applications for standard hydraulic and hybrid injection molding machines, many of the major injection molding machine manufacturers are primarily focused on manufacturing all electric molding machines.  This is especially so as technology is constantly advancing and the previously too expensive to build larger tonnage all electric molding machines are becoming more and more common. It is clear that the future of the industry is in all electric injection molding machines.

Here are the top 5 reasons why it makes sense to mold with all electric injection molding machines.

1.) Cleanliness (No hydraulic oil, no oil leaks and spills on the floor)

  • No Oil Equals No Mess
    When comparing injection molding machine types, there are standard hydraulic injection molding machines, hybrid injection molding machines and all electric injection molding machines.  Standard hydraulic and hybrid injection molding machines require hydraulic oil to actuate the clamping motion and injection unit of the molding machine. All electric injection molding machines use servo electric motors to actuate all of the machines motions and have no need for hydraulic oil.
    All electric injection molding machines cannot leak oil, because they don’t use oil.  Your manufacturing floor will be free of dirty and slippery oil leaks which is a huge safety hazard during mold changes.  Not to mention you will no longer have to replace the hydraulic oil after the 2 to 5+ year life cycle of the oil. The life cycle of the oil depends on if you run 24/7 and also if you run the oil temperature hot which accelerates degradation.  It’s a big difference having to use and not having to use hydraulic oil.You never want oil contaminating and undermining your production floor, but this becomes a serious problem when you are in the food packaging, medical molding or clean room required industries.
  • No Oil Changes Equal Less Maintenance
    The life cycle of the hydraulic oil in a machine depends highly on the hours of use and the quality of the machine itself.  We have seen some instances where the hydraulic oil became extremely contaminated in as little as 6 months of use on a competitors brand new machine.  Imagine having to replace oil every 6 to 12 months, not to mention the cost of the oil which can get relatively expensive with larger machines requiring over 500 gallons of hydraulic oil.  With our hybrid injection molding machines, we have seen some of our customers, who periodically test the quality of their hydraulic oil, get 5 or more years of use out of their hydraulic oil.  However, please note that the manufacturer does recommend that the hydraulic oil be changed every 3 to 4 years depending on the hours of operation.

The clean and quiet working environment that you get with all electric injection molding machines make them the ideal machine to use for food packaging and medical molders.  You won’t have to worry about getting oil contamination when cleaning your facility before a plant audit and sending your customers contaminated parts.

2.) Low Energy Consumption

Contrary to its name, all electric injection molding machines are extremely energy efficient.  If you compare running the same part and mold in a standard hydraulic injection molding machine vs an all electric injection molding machine, you will see a 50% to 70% energy savings in most applications.

In a standard hydraulic injection molding machine, the hydraulic pump is constantly on when the machine is running.  It has to keep running to circulate oil, and is generating heat as long as the machine is running. On the other hand, because all electric injection molding machines only consume electricity as the servo motors turn to actuate movement, much of the production cycle is spent idling, this is especially so during the cooling phase of your cycle

  • All Electric Servo Motors
    Standard hydraulic injection molding machines have one or more pumps that generate hydraulic pressure, and valves that direct the pressure to the hydraulic mechanisms to build pressure based on the needed movements.  All electric injection molding machines do not have a central electric motor, but use individual electric motors designed for each function that is needed throughout the machine, i.e. mold open/close, injection, recovery, and ejection.  This means that the motors can be idle until their specific function is required. This is a night and day comparison vs a standard hydraulic injection molding machine that has to run its pumps continuously, even when nothing is happening.  This is especially apparent during the cooling phase.
  • No Hydraulic Cooling Needed
    The energy savings don’t end with the injection molding machine.  With the elimination of the hydraulic pump circuit also goes its need for cooling on the hydraulics.  Because all electric injection molding machine don’t have hydraulics, they don’t require machine cooling.  The only cooling that you will likely need is for your mold and feed throat. This leads to additional savings as you will not need the additional water lines and permits to put them up.  Chillers also consume large amounts of electricity, and cooling towers consume water, electricity and require frequent maintenance and monthly water treatment plans.
  • Less Equipment Equals Less Maintenance
    It is very common for customers who use only all electric injection molding machine to only have chillers in their plant.  This is because they no longer have a need for a high temperature circuit of cooling (85-95F) for their machines, and only require the low temperature circuit of chilling (anything under 80F, usually 55F) for their molds and feed throats.  Having fewer pieces of equipment obviously means, less capital invested, less upkeep and maintenance costs, less energy consumed, and lower overhead.

  • Overall Plant Energy Savings
    All electric injection molding machines also run significantly cooler because there is no heat being generated by a hydraulic pump.  Medical and clean room molding facilities are often climate controlled, which means that the air conditioning system does not have to work as hard to remove the heat from the molding room, if the machine is all electric.  This is another reason why medical and clean room manufacturers almost exclusively use all electric injection molding machines.
  • Think Long Term Savings
    Based on all of the above points, when comparing a 390 ton standard hydraulic injection molding machine vs an all electric injection molding machine, there is around $17,000 of annual savings on the all electric machine.  This number represents the savings based on today’s factors, but is only expected to increase as energy costs all across the US and Mexico are constantly on the rise. With proper maintenance and care, quality injection molding machines should last 20+ years.  This means that when considering a new injection molding machine, you need to be thinking of 10 to even possibly 20 years down the road. Make sure to purchase your new machines from a reputable and established company who manufacturers their own components, such as platens, motors, sensors, breakers, contactors, cables etc.  This ensures that you will always have access to replacement parts. LS Mtron is an example of a billion dollar company that manufactures all of the major components in their machines in house. www.lsmtron.com    www.lscns.com    www.lsis.com

3.) High Repeatability and Precision (Closed loop controls and linear motions)

  • Accuracy
    Of the 3 types of molding machines, all electric injection molding machines have the highest accuracy and repeatability.  This is because of the fact that these machines use electric servo motors with a 0.1mm +/- rotation to actuate their movements.  This type of movement allows the process to completely negate the fluctuations and inaccuracies of movements actuated by hydraulic pressure and their unavoidable pressure curves.
  • Consistency In Production
    Standard hydraulic injection molding machines constantly experience variations in their process throughout the year, and even throughout the day. This is because the weather is always changing and has an effect on your machines temperature and humidity.  As hydraulic oil gets cooler, its viscosity increases, and as hydraulic oil gets warmer, its viscosity decreases. The way hydraulic oil performs also changes as it degrades over time. This means that the way the oil in a machine moves and lubricates will always eventually be totally different than day 1.This also means that your molding machine’s process may need to be adjusted periodically throughout the day.  Standard hydraulic molding machine controls are considered “open loop” because they send signals to valves to adjust pressures, but don’t actually have direct control over the physical movements of the machine, and thus cannot make all of the minor adjustments that an all electric machine can make in real time.  All electric injection molding machines are considered to have “closed loop” controls because they control every movement with physical gear turns of their servo motors, and have the ability to constantly monitor and control their positions and speeds to a very tight tolerance, regardless of the ambient conditions.  This is the difference between “closed loop” and “open loop” controls.

All electric injection molding machines are the perfect fit for manufacturing most complex, difficult, and thin walled parts.  You can inject very accurate shots, while maintaining precise repeatability through the day, night, and seasons.

4.) High Speed

  • Simultaneous Movements
    All electric injection molding machines have multiple electric servo motors.  These motors are coupled to pulleys and belts that work onto ball screw mechanisms that actuate the movements of functions, i.e. platen open and close.  The ability all electric machines have to make compound movements (actuating multiple functions at the same time) is one of the reasons why electric machines often times produce reductions in cycle time vs standard and hybrid injection molding machines.  You can “eject on the fly” or eject your parts before opening the mold completely,and you can start recovering the screw while opening and closing the mold. Hydraulic injection molding machines can only handle one movement at a time, because they typically only have one hydraulic pressure circuit to actuate movements.  This becomes a huge game changer for many molders when they decide to advance to all electric injection molding machines.
  • Instant Torque
    We all know that electric cars get their immense speed from having instant torque from their electric motors, and the same goes for our all electric injection molding machines.  They have instant linear motions from our AC electric servo motors, and can achieve up to 800mm per second injection speeds, and can also have multi-step injection speeds with our high output and high response AC servo motors.

    With all that instant torque also comes the need for a very rigid and robust toggle clamping mechanism.  LS Mtron utilizes a very rigid 5 pin toggle mechanism to ensure that you will continue to have a fast and reliable machine.  Our platens and toggles have gone through extensive FEA (Finite Element Analysis) to determine where all of the major stress points on the mechanisms are.  We also utilize the highest quality steel and casting technologies via our own inhouse steel forging division. All of this is done to maximize the lifetime of our all electric injection molding machines.
    We also utilize a very robust and precise ball screw mechanism to actuate the clamping motion.   As is with any machine component, the range of performance and quality can range drastically, so it is important to ask what manufacturer’s ball screw the injection molding machine you are looking at uses to fully understand its reliability of performance.

5.) Technology Advancements

  • Extremely Reliable
    All electric injection molding machines are the most reliable of the different types of injection molding machines.  This is because unlike standard hydraulic injection molding machines and hybrid injection molding machines that were designed many decades ago, and are often more geared for a lower price bracket, all electric injection molding machines typically use state of the art technologies available.  All electric injection molding machines are also very quiet while running, and most run at or below 70db. This means that your employees are not required to wear hearing protection while operating the machines.
    You will have no oil, less maintenance, more accuracy, higher repeatability, energy savings, a much quieter work environment and a machine that is easier to maintain to continue running production.
  • Automated Features
    With all electric injection molding machines you will have no sticking valve issues, degrading oil quality issues, ambient temperature process fluctuations and noisy pumps.Many of the all electric injection molding machines have safety features standard, like mold safety to prevent crushing parts and foreign objects in the mold, cold screw rotation prevention to prevent the mistake of accidentally rotating the injection screw when the plastic is still cold and solidified from the machine being idle.Most machines will have a centralized lubrication system or automation lubrication system to automatically pump grease onto the tie bars, toggle links, linear guides and other locations where greasing is necessary.  So as long as the grease reservoir or cartridge is full, the injection molding machine will automatically grease the areas that need lubrication based on the number of full cycles. When the grease levels are low, some machines have sensors to alert that the grease reservoir or cartridge levels are low to remind your maintenance team to refill grease or change the cartridge.

Conclusion

Many of our customers prefer All Electric Injection Molding Machines based on the following:

  • The highest degree of cleanliness
  • Very low energy consumption
  • Very high repeatability and precision
  • High speed molding
  • Technological Advancements and Features

For these reason an all electric molding machines are extremely reliable for long term production runs.

We always recommend LS Mtron’s all electric injection molding machines when customers want to make millions of parts reliably every year.  If it’s a 24/7 operation that is required for maximum production rates, this is the best type of molding machine money can buy. We have customers that run “lights out” without any personnel on-site outside of normal business hours and weekends without any downtime.

Hirate America is partnered with LS Mtron Injection Molding Machines (formerly known as LG Injection Molding Machines) who manufactures all electric injection molding machines in South Korea ranging from 20 to 950 US tons.  We can provide a complete turn key solution including machines, molds, auxiliary and automation equipment. Contact us today to request more information and a proposal for your project.

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.