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Manufacturers are facing pressing demands for their green and smart transformations, and the rubber and plastics industry is no exception. Substantial energy consumption, experience-driven operations, and limited real-time visibility are increasingly hindering both yields and decision making, and therefore have become core priorities for industry competitiveness.
Industry Challenges
The rubber and plastics industry in Taiwan commonly faces several challenges. First, traditional hydraulic injection molding machines typically operate at fixed speeds and continue to consume energy during standby or low-load conditions, causing significant and unnecessary energy waste over time. Second, process control relies heavily on operators’ experience. Variations in temperature, pressure, and flow caused by material differences or environmental changes can easily affect process stability, resulting in yield fluctuations.
In addition, many production lines require integrated real-time monitoring. Energy consumption, utilization rates, and quality data are scattered across different machines and systems, forcing operators to rely on manual inspections and post-analysis. This makes it difficult to respond quickly to anomalies or adjust production plans promptly. As ESG and carbon management requirements become compulsory, manufacturers need traceable and quantifiable data on energy and carbon consumption for disclosure.
Delta's Solution
To address these challenges, Delta’s Smart Injection Molding Solution for the rubber and plastics industry is built on two pillars: energy efficiency and intelligence. By integrating automation, AI-enabled control, and real-time monitoring, the solution effectively supports both green and smart upgrades.
Energy-Efficient Drive Design
A servo-based and energy-saving hydraulic system dynamically adjusts torque output based on actual load demands, eliminating idling energy waste.
AI-Enabled Intelligent Control and Precision Sensing
AI algorithms and high-precision sensing technologies enable rapid barrel heating, significantly reducing thermal lag and preventing nozzle degradation. Intelligent mold locking and hydraulic compensation mechanisms correct process deviations caused by environmental or material variations in real time, minimizing the influence of human and external factors. The system also features a modular design for phased implementation.
Real-Time Monitoring Platform
Delta’s Equipment Automation Program DIAEAP+ collects equipment energy consumption, utilization rates, and quality data to a cloud-based monitoring platform with real-time visualization. Anomalies trigger automatic alerts to enable timely maintenance.
Solution Pack (SP) Services
Delta’s SP provides end-to-end support from energy diagnostics and process analysis before deployment, standard injection programs, and customized development, to remote monitoring and predictive diagnostics, ensuring smooth implementation and satisfactory results.
Proven Benefits
Delta’s Smart Injection Molding Solution has seen years of successful deployments that have delivered measurable results in three key aspects:
Greener Operation Reduces Carbon Emissions
The solution has helped customers reduce electricity usage by 20% to 50%, with even greater savings in heavy-load processing. Additional savings of up to 30% can be achieved by adopting all-electric solutions and energy recovery designs. The system also provides traceable energy and carbon data to support sustainability compliance.
Enhance Process Stability and Yield
With precise mold and temperature control mechanisms, heating time is significantly reduced, thereby minimizing equipment degradation and process variability. Product quality consistency is enhanced. Defect rates and rework are reduced. Customers have achieved yield improvements of approximately 5%.
Data-Driven Management for Rapid and Informed Decisions
Real-time visibility across utilization, downtime, and quality metrics supports more precise production planning and resource optimization. With Delta’s intelligent injection monitoring system, average utilization rates have increased from 68% to 82%.
Starting from energy efficiency and built on data integration, Delta’s Smart Injection Molding Solution enables rubber and plastics manufacturers to reduce energy consumption while also enhancing quality performance. Through its modular architecture and integrated service model, businesses can adopt the solution step by step, minimizing transformation risks while building a solid foundation for smart manufacturing, advancing green supply chain development, and achieving long-term sustainable operations.
