Essentra plc, the global manufacturer of essential industrial components, has replaced its 55th hydraulic injection moulding machine with a new electric model as part of a long-term investment programme to upgrade its machine portfolio as it aims to be fully electric by the end of 2031.
The company is working with a small number of key equipment suppliers with global support networks to replace 180 machines that have been operating for 15 years or more — and currently heading towards the end of their working lives. The replacement machines are both all-electric and hybrid electric, and the latter features Vireo servo drive technologies.
The machines, which are now installed at Essentra sites across the UK, the USA, Brazil, Barcelona and China, are delivering a 30% reduction of energy consumed, cycle-to-cycle, and an improved overall equipment effectiveness (OEE) in excess of 85%. Cycle times have been reduced by an average of 15% across the board.
The process and productivity improvements are effectively enabling three electric machines to do the work of four hydraulic models, reducing the overall footprint. The increased capacity is complemented by the guaranteed repeatability that electric machines can deliver, ensuring even greater product quality.
Engineering director Chris Butler said the substantial investment is clearly paying off. He added: “The increased capacity and reduced energy costs are exciting for both our business and customers alike. Electric machines are more reliable and last longer than their hydraulic counterparts, and deliver significantly greater productive hours per annum. With this performance, and greater automation, we are supporting even greater efficiencies for our customers.”
Essentra recently announced the opening of a new manufacturing facility in Monterrey with £1.28 million of investment in eight new machines. In October, the business also opened a new Centre of Excellence at its UK headquarters which included a further £110,000 in a bespoke electric machine.
Mr Butler concluded: “We have plans to replace further hydraulic machinery in 2024, with more than £2.1 million allocated to enable the roll-out of new electric machines. We will focus on replacing our oldest machines first as they reach the end of their useful working lives.”