High-performance hydraulic fluids save energy in injection molding equipment
DYNAVIS® stands for greater efficiency
DYNAVIS® technology from Evonik optimizes the viscometry of hydraulic fluids. Here’s how: like most oils, hydraulic oils lose viscosity at high temperatures. In this state, the hydraulic fluid transfers less hydraulic energy through the hydraulic fluid system, because it has become hot and thin-bodied; “internal” leakage within the system increases and efficiency drops in the desired direction of flow.
In contrast, using a fluid formulated with DYNAVIS® technology results in less internal leakage and the hydraulic fluid system retains its efficiency, even at high temperatures. At the other end of the temperature scale, in extreme cold, oils become increasingly viscous and more and more difficult to pump. As a result, the hydraulic system consumes more energy, primarily through its pump drive. Here too, fluids formulated with DYNAVIS® technology reduce the pump’s energy consumption.
Evonik’s DYNAVIS® team has carried out comprehensive tests on injection molding equipment, using a range of different hydraulic fluids, and has now assessed the results. The focus of the tests was on how the selection of hydraulic fluid affects the injection molding machine’s efficiency; the key question being, “Does the choice of hydraulic fluid significantly reduce energy consumption?”
The DYNAVIS® team started by taking comprehensive measurements on their own hydraulic injection molding machines at different pressure levels and temperatures, using different fluids. The results of these tests were then shared with equipment manufacturers.
Tests convince Dr. BOY GmbH to adopt DYNAVIS® technology
The injection molding machine selected by equipment manufacturer Dr. Boy for its series of DYNAVIS® tests, a BOY 35 E, came already equipped with Boy’s “Econ-Plast”, concept, a patent-pending, more cost-effective method of plasticizing, which already made for a high degree of efficiency. Impressively, the change-out of the hydraulic fluid to a DYNAVIS®-formulated fluid only served to amplify the equipment’s “built-in” level of efficiency.
“The fluids used in most injection molding machines are formulated to ISO 46”, explains DYNAVIS® After-market Support Manager Rolf Fianke. “In the test, the ISO 32 fluid formulated with DYNAVIS® technology turned in an energy-saving performance superior to that of the ISO 46 fluid. And at its best, the efficiency gain with DYNAVIS® technology attained a two-digit percentage improvement,” he smiles.
Fianke goes on to explain that the reduction in energy consumption came primarily from the optimization of the hydraulic fluid’s viscosity. The fluid formulated with DYNAVIS® technology reduced hydraulic power erosion within the hydraulic system due to overheating and a phenomenon called “internal leakage”. For example, internal leakage in a hydraulic vane pump occurs when overheated and “thin” hydraulic fluid slips backward through the pump vanes, sapping the pump’s power and producing additional heat. The ability of DYNAVIS® technology to reduce or eliminate internal leakage means less heat is produced in the hydraulic system, and less energy needs to be dissipated via the cooling cycle.
DYNAVIS® technology for optimizing the viscosity of hydraulic fluids is currently being used by five DYNAVIS® technology licensees globally, and you’ll find the DYNAVIS® insignia clearly marked on their product containers. In addition, a significant number of high brand-recognition lubricant marketers use DYNAVIS® technology to formulate their premium hydraulic fluids. However, they do not benefit from the extensive marketing support that Evonik offers free of charge to its licensees.
Could experience with mobile construction equipment hydraulic fluid systems be transferred to injection molding machines?
Evonik’s DYNAVIS® team ran its first tests with excavators. The data gathered from these tests indicated that fuel savings of up to 30 percent could be achieved simply by changing from a conventional hydraulic fluid to one formulated with DYNAVIS® technology. The hydraulic systems worked better and were more agile and responsive.
“All these findings suggested that positive results could also be achieved in the hydraulic systems of injection molding machines”, explains Rolf Fianke. “But our team wondered how significant would energy savings be in the controlled indoor environment and 24/7 operations of plastics production? Would any other benefits be observed?”
The DYNAVIS® team will present the test data gathered and test development experience gained at Fakuma. They will also demonstrate an energy savings calculator tool that is used to determine the savings potential for injection molding machines. The calculator is being presented for the first time at Fakuma.
“All plastics equipment manufacturers who would like to test the DYNAVIS® effect on their own machines are very welcome to visit us at the Evonik stand,” adds Rolf Fianke. “The Evonik stand at Fakuma is located in Hall A4, location 4117. Visit with us at Fakuma, or contact us at +49 6151 18-4107.”
The DYNAVIS® technology calculator determines savings potential in injection molding equipment simply by switching over to a viscosity-optimized hydraulic fluid.
A measurable increase in efficiency was achieved by switching from a conventional hydraulic fluid to one formulated with DYNAVIS® technology on a BOY injection molding machine.
About Evonik”s Resource Efficiency Segment
The Resource Efficiency segment, of which Oil Additives is a key business, brings together Evonik’s activities in specialty chemicals for industrial applications. The Resource Efficiency segment supplies high performance materials for environmentally friendly as well as energy-efficient systems to the automotive, paints & coatings, adhesives, construction, and many other industries. This segment employed about 7,800 employees, and generated sales of around €4 billion in 2014.
As a leading provider of oil additives, Evonik develops technologies to improve fuel and energy efficiency, as well as productivity, with its DRIVON™ and NUFLUX™ technologies in engine oils, driveline fluids and ge
In so far as forecasts or expectations are expressed in this press release or where our statements concern the future, these forecasts, expectations or statements may involve known or unknown risks and uncertainties. Actual results or developments may vary, depending on changes in the operating environment. Neither Evonik Industries AG nor its group companies assume an obligation to update the forecasts, expectations or statements contained in this release.