Yongte successfully optimized the energy consumption of its wood-plastic composite WPC machine.
As a professional manufacturer of WPC production machine, We are well aware that energy consumption accounts for as much as 30%-40% of the production cost of WPC products. Traditional WPC machine also suffers from issues like low heating efficiency and redundant power systems. Over the past two years, our company has implemented energy-saving modifications on WPC extrusion lines, resulting in significant cost savings.
The high energy consumption of WPC equipment is primarily concentrated in the heating and power systems, which were the core areas of our transformation. Previously, the production line used traditional resistance heating coils, which had a heating efficiency of only around 60% and resulted in significant heat loss—the surface temperature of the equipment often reached over 80°C, wasting energy and posing safety risks. After conducting research and comparisons, we replaced the entire heating system with electromagnetic induction heating devices, combined with customized insulation foam, increasing heating efficiency to over 90%. In optimizing the power system, we found that traditional asynchronous motors waste significant energy when production loads fluctuate. For example, when uneven raw material mixing causes varying extrusion loads, the motor maintains its rated speed, creating a "big horse pulling a small cart" situation. To address this, we installed a variable frequency control system on the main extruder motor. This system uses a PLC to collect real-time data on parameters such as screw torque and extrusion speed, dynamically adjusting the motor speed. Furthermore, we replaced the fixed-frequency pump in the cooling system with a variable frequency pump, which automatically adjusts the flow rate based on the cooling water temperature, thereby reducing the pump's energy consumption.
Optimizing energy consumption in wood-plastic composite WPC machine isn't just a simple technical overhaul; it's a systematic project encompassing hardware upgrades, process refinement, and standardized management. Over the past two years, we've not only achieved significant results in optimizing WPC equipment energy consumption, but have also gained a deeper understanding that energy conservation and consumption reduction are not only an inevitable choice for businesses seeking to reduce costs and increase efficiency, but also a responsibility for engineers to implement green manufacturing. In the future, Yongte will continue to explore ways to optimize WPC equipment energy consumption, leveraging data and technology, and contributing to the green development of the industry.
