Introduction: Why Energy Saving Matters in Extrusion
Electricity cost can account for 30–50% of total operating cost in an extrusion plant.
Small improvements = huge savings:
| Area | Energy Consumption % |
|---|---|
| Heaters (barrel & die) | 35% |
| Motor & gearbox | 30% |
| Cooling system | 15% |
| Vacuum + feeding | 10% |
| Others | 10% |
Reducing energy usage not only cuts bills but also:
Enhances melt quality
Improves barrel/screw life
Maintains stable output
Reduces maintenance load
If your plant runs 24/7, even 5% savings = lakhs per year.
1) Use Energy-Efficient Screw & Barrel Designs
Poor screw design wastes power due to:
Excess shear heat
Back pressure rise
Unstable melt
Upgraded screw flight & compression ratio can reduce load up to 12–18%.
Tip: Ask your screw supplier to customize:
✔ Compression ratio
✔ L/D ratio
✔ Flight geometry
✔ Mixing zone
2) Upgrade to Smart Barrel Heaters
Use Infrared + insulation blankets:
| Heater Type | Energy Saving |
|---|---|
| Standard band | baseline |
| Ceramic band | 15–20% |
| Infrared heater | 25–35% |
| IR + insulation | 40–45% |
3) Install VFD / Inverter Drives for Extruder Motor After 90 Days
Motors without VFD run at fixed speed, wasting power.
VFD benefits:
Reduces motor amp load
Smooth startup (low surge)
Stabilizes RPM = better melt consistency
Savings: 15–25% on main motor energy.
5) Improve Raw Material Drying & Feeding Efficiency
Wet PVC/WPC absorbs more heat → more energy.
✔ Maintain stable feeder RPM
✔ Calibrate feeding each shift
✔ Check moisture <0.5%
Efficient material handling improves melt faster = lower heater load.
6) Use Synthetic Gear Oil & Schedule Lubrication
Friction = wasted power.
Switch to synthetic lubricant for gearbox & bearings:
Energy saving: 4–8%
Gear life improvement: 20–30%
7) Implement Power Monitoring & Operator Training
Track:
kWh per batch
kWh per kg output
Load variation per zone
Motor amp trend
Train operators to adjust:
Hopper load
Screw speed
Barrel heating steps
Die temperature balance
“Skilled operator = 10–15% energy saving machine”
Conclusion:
Energy savings in extrusion is not luck — it is engineering.
Modern plants are shifting to:
Intelligent heating Smart motors Predictive maintenance Precision feeding
If you’re serious about improving plant efficiency Contact Us..
