Akplas, a key actor in plastic injection molding, conducted a field study in cooperation with Petrol Ofisi. According to the results of the field study, it is observed that you can increase energy efficiency up to 68 percent by replacing the hydraulic oil used in injection machines with the Petrol Ofisi Hydro Tech HVI-E series.
Energy is one of the most important expense items of the industry. The oils used in hydraulic systems contribute greatly to energy efficiency. A low viscosity oil can cause problems such as internal and external leakage, inadequate lubrication and compressibility, while a high viscosity oil can cause hydrodynamic friction and churning losses. Therefore, balance and the correct viscosity are highly important factors in hydraulic fluids.
Many manufacturers act very carefully while choosing hydraulic oils in order to reduce their energy consumption and achieve higher efficiency, and constantly work to further increase the level of efficiency. Akplas, a key actor in plastic injection molding, is one of these manufacturers.
Operating in the field of plastic injection molding since 1989, Akplas serves the automotive, white goods, heating and cooling industries. With two plants located in Gebze, Kocaeli, Akplas works with leading companies. It carries out continuous global technological researches specific to the product, makes investments in automation, and cooperates with its stakeholders and universities.
In this context, Akplas carried out a field study on the hydraulic oils used in injection machines in collaboration with Adco Oil Additives and Petrol Ofisi, and investigated the impacts of a special formulated hydraulic oil on energy efficiency.
In this field study, Petrol Ofisi’s specially formulated high viscosity index Hydro Tech HVI-E series was used. The results of the field study were satisfactory for both sides.
ARZU YILDIRIM Technical Field Manager Petrol Ofisi Critical parameters were carefully measured. Energy consumption was evaluated with great precision. Voltage signals of three phases (L1, L2, L3), initial and final values of the pumps used in the operation, temperature of pump discharges, temperature of the hydraulic oil tank, and ambient temperature were recorded in high frequencies (2500 measurements per second). It was observed that physical work per piece is lower with the Petrol Ofisi Hydro Tech HVI-E 32, which has high viscosity index. Accuracy obtained in statistical studies was determined as 98 percent. Accordingly, it was seen that Petrol Ofisi HydroTech HVI-E 32 product lowered the electric consumption of the two pumps by 6-8 percent. Moreover, it was identified that Petrol Ofisi Hydro Tech HVI-E 32 heated less than the previously used 46-viscosity lubricant. In addition to the increased efficiency, unit time per piece was also calculated. In this way, it is estimated that there will be an output growth by 7-10 percent. It is also projected that this efficiency will be balanced both in summer and in winter, and the lubricant’s life will be almost doubled thanks to the high viscosity index and fluidity control of Petrol Ofisi Hydro Tech HVI-E 32. |
HALIL ÖZTÜRK Technical Sales Specialist Adco Petrol Katkıları Petrol Ofisi Hydro HD 46 (current hydraulic oil in use), Petrol Ofisi Hydro HD 46 (reference hydraulic oil changed with the oil in the system) and Petrol Ofisi Hydro Tech HVI-E 32 (high viscosity index hydraulic oil) were measured using energy, temperature and pressure parameters and analyzed under real production conditions in order to compare the energy consumption in Akplas plastic injection plant. The results obtained in the product tests were highly satisfying. It was seen that significant levels of energy saving is possible by changing the current hydraulic oil in use. It is estimated that choosing the right and efficient product will o ffer not only energy conservation but also many other gains in the long term. |
HAKAN YILMAZ Process Development Responsible Akplas As the use of plastic is increasing in almost every field, plastic injection process is preferred more and more every day. As Akplas, we are a corporate firm with a wide product range and customer network in the field of plastic injection molding. We are always searching for and following any improvements that will provide added value to our company, and we try to reflect such developments in our production. Electric consumption is one of the most important expenses of plants and factories, and it is an obligation to carry out various studies to make improvements in this regard. Especially in companies that has manufacturing operations mostly in plastic injection, electric consumption is a priority area for improvement. Therefore, we carried out a joint study with Petrol Ofisi and Adco companies with the aim of facilitating the operation of machine pumps and decreasing our electricity consumption by using a specially formulated hydraulic oil in the injection machines in our plant. When we analyzed the results of this one-week study, we observed that electricity consumption of the pumps decreased by 6 percent and thus, continuity of such studies is important. |
