Plastics Technology

JAN 2018

Plastics Technology - Dedicated to improving Plastics Processing.

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Engineers from EVCO (evcoplastics.com) and ExxonMobil (mobil.com/hydraulics) worked together on controlled testing at EVCO's Innovation Center at DeForest. "It was an ideal situation for controlled testing," says Ruiz. "The molding test area is envi- ronmentally controlled and, most important, the machine's power factor is isolated from other electrical equipment." The week-long test involved a 1996 Van Dorn injection press with a 300-ton toggle clamp. Polypropylene parts were molded on a 1-min cycle. The test demonstrated a 3.2% reduction in electricity demand on that machine. Also participating in the test were engi- neers from Focus on Energy, a program of Wisconsin electrical utilities that provides businesses in the state with information, resources, and financial incentives to implement energy-saving projects (focusonenergy.com). EVCO has worked with Focus on Energy on previous projects such as its upgrades of lighting and air-handling systems. As a result of the test at EVCO, Mobil DTE 10 Excel is believed to be the first hydraulic oil to qualify as an energy- efficient technology under a statewide incentive program. Another result of the test is that EVCO plans to use the more efficient hydraulic oil in additional machines. "We're taking it in stages," says Degenhardt, starting with six new tiebarless, servo-hydraulic Engel victory presses of 55 to 130 tons that will be going into a newly expanded medical molding plant in DeForest. Degenhardt is also eager to test the oil in a larger press with a more complex hydraulic system, where the energy savings could be greater. "I really want to get it into the 2000-ton press, which wasn't avail- able for the earlier test." If that trial is also successful, Degenhardt foresees a gradual program of introducing Mobil DTE 10 Excel in more and more of EVCO's machines, starting with the largest tonnage models. QUICK PAYBACK One obvious reason why plastics molders haven't adopted this more efficient hydraulic oil sooner is that it costs up to twice as much as standard oils. Part of that additional cost can be defrayed by programs such as Wisconsin's Focus on Energy, which, in Ruiz's experi- ence, has paid 26% to 27% of the incremental cost for energy-saving technologies. According to Ruiz, prior experience at another injection molder and a metalworking plant showed payback in 18 to 24 months from energy savings alone. Both Ruiz and Degenhardt agree that molders have to look at much more than energy savings to justify switching to a premium hydraulic oil. "Varnish buildup on valves is a big problem," notes Thermal images of hydraulic pump with different oils shows greater pump efficiency, and therefore less heat generation, with Mobil DTE 10 series. Pump cooling was turned off for this experiment. "Reference Fluid" is a market standard fluid. "Competitive High VI Fluid" is Mobil DTE 20 series. Greatly reduced varnish deposits with zinc-free Mobil DTE 10 series saves costly downtime to clean or change valves. "Market general" oil contains zinc anti-wear additive. QUESTIONS ABOUT INJECTION MOLDING? Visit the Injection Molding Zone. Thermal Imaging Efficiency Demonstration Simply Hydraulic Circuit without Heat Exchanger (No Cooling) Reference Fluid, ISO VG 46 VI 100 Competitive High VI Fluid Mobil DTE 10 Excel 46 End of Test Average Pump Temperatures 97.4 C 23 minutes 96.5 C 24.5 minutes 90.3 C 26.6 minutes "Ultra Clean"Performance — Mobil DTE 10 Excel 46 Mobil Hydraulic Fluid Durability Test Reservoir DTE 10 Excel DTE 10 Excel Market General 1000 Hour 2000 Hour 3000 Hour 3500 Hour 3750 Hour 500 Hour 26 JANUARY 2018 Plastics Technology PTonline.com H Y D R A U L I C O I L Close -Up On Technolog y

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