Process parameter analysis: energy efficiency and component quality in the processing of recyclates
The processing of post-consumer recyclates enables sustainable production through a circular economy. Targeted optimization of injection moulding parameters such as injection speed, holding pressure and melt temperature reduces energy consumption and CO₂ emissions while maintaining component quality. Current research compares the energy consumption and quality characteristics between virgin and recycled materials.
Initial situation/problem:
The processing of recyclates is increasingly becoming the focus of processors due to new regulations and the establishment of a comprehensive circular economy. An advantage of processing
of recyclates is that no fossil raw material has to be used for new material. Rather, the production and processing of recyclates and, in particular, post-consumer
In the case of recycled materials, packaging waste is used, which means that a product is returned to the material stream at the end of its useful life. In addition to the use of recyclates for sustainable production, the energy consumption of the machine can be reduced by adapting the processing parameters, which can reduce CO2 emissions from electricity generation. To optimize the injection moulding process in terms of energy consumption, it is necessary to analyse the influence of machine parameters such as injection speed and holding pressure on the machine’s energy consumption. In addition to optimizing energy consumption, however, the component quality must continue to meet the specified requirements.
Objective:
The aim of these studies is to analyze the energy consumption during the processing of post-consumer recyclates and the influence of different process settings on energy consumption. In addition, quality parameters such as weight and component dimensions are to be included and compared with virgin material.
Solution:
A fully automated injection molding machine with an integrated measuring cell is used for the investigation. This enables comprehensive recording of process and quality data during
of injection molding. To analyze energy consumption, the total power consumption of the machine and the output of the heating circuit are recorded for each cycle and stored in a database. In addition to the performance data, the component weight is measured via the integrated measuring cell.
(scales) and component dimensions (camera system). To examine the influence of various setting parameters, a test plan is drawn up in which the injection speed, holding pressure, holding pressure time, melt temperature and residual cooling time are varied. The tests are carried out with polypropylene, using virgin material as well as post-consumer recyclate. The investigations focus on the process parameter-dependent energy consumption, taking into account the component quality.
Project data and funding
The underlying research project 033KI101 is funded by the Federal Ministry of Education and Research (BMBF). We would like to thank the BMBF, Project Management Jülich and all partners.
Project duration:
Project partners
