Plastic Production

Plastic production is one of the most versatile and widespread manufacturing processes and has undoubtedly revolutionized entire industries from packaging to automotive, from construction to electronics. Although all the various stages of the production process require special attention, one aspect that is often underestimated is that of cooling. This includes both the cooling of the machinery that ensures the continuous operation of the production cycle, such as the die, injection molding machine or extruder, and the actual process cooling, which includes various steps for the re-solidification of the plastic material after its transformation.

 

Controlling Polymer Structure

During the plastic production process, raw materials are heated and molded to form the desired shape. Once achieved, it’s crucial to cool the material rapidly and uniformly. This controlled cooling helps in setting the molecular structure of the plastic, determining its final properties. Proper cooling ensures that the polymer chains arrange themselves in a stable and predictable configuration, leading to a material with desirable characteristics like strength, flexibility, and durability.

 

Ensuring consistency and quality

Improper cooling can cause internal stresses and distortions in the plastic. If the cooling process is not uniform, different sections of the plastic can cool at different rates, causing deformation. This can affect the dimensional accuracy and structural integrity of the final product. Efficient and accurate cooling systems help prevent these problems, ensuring that the plastic maintains its intended shape and functionality. Consistency in the cooling phase is also critical to achieve uniformity across batches. A reliable and effective cooling system helps regulate temperature variations, ensuring that each unit produced meets the required quality standards.

 

Enhancing Production Efficiency

Optimized cooling processes contribute to higher production rates and lower cycle times. Effective cooling allows for faster mold release, enabling manufacturers to produce more units in a given time frame. This efficiency not only increases output but also reduces energy consumption per unit produced, contributing to a more sustainable production process.

 

Success Stories

Mitsubishi Electric has already successfully supplied its process cooling solutions to key companies in the plastic industry, proposing its water-cooled chiller units with full inverter technology for cooling in the plastic production. The high yields of these units combined with the flexibility and efficiency guaranteed by inverter technology, both at full and partial loads, allow a single unit to respond to the specific needs of the different production phases of this process. Another successful case is the multi-function units, installed to maintain the operation of plastic recycling plants. In this case, our units ensure continuous and constant heat supply, even at partial loads, recovering waste heat to maximize energy efficiency. By recognizing the importance of cooling, manufacturers can improve their production processes, leading to higher-quality products and a more sustainable future for the plastic industry.

 

Our plastics manufacturing solutions expert

Francesco Pernechele, Customized Project Coordinator, has closely supervised the origin and evolution of several plant cooling projects dedicated to plastic production and recycling.

“The plastic production process is as complex as it is fascinating. To see the material taking or resuming shape, to grasp the importance of each step and the attention to detail at each stage is striking and positively impressive. With the constant and targeted cooling of materials and machinery, we can say we also play a key role in these processes. Our high-efficiency solutions also support companies in the industry in their complex and constant journey toward sustainability”.