Energy Savings in Injection Molding with Efficient Servo Valves
Velocity-to-pressure control, also known as P/Q control, is a function in injection molding applications that describes how the machine switches from controlling speed (or velocity) to controlling hold pressure once the cycle is complete. If this transition is unstable or inconsistent, it can lead to flash, short shots, dimensional drift, part-to-part irregularities, unnecessary scrap, and more.
Why Energy Savings Matters in Injection Molding
Injection molding systems can cut energy use in pre-existing systems by utilizing more efficient, precisely controlled components. Domin valves were created with energy efficiency in mind. They redesigned the hydraulic servo valve for better control that uses significantly less power.
Many hydraulic designs have remained fundamentally the same for about 70 years. Oak Ridge National Laboratories in 2012 estimated that traditional hydraulic systems operate at only about 22% efficiency. This lack of efficiency results in wasted flow, heat loss, increased operating costs, elevated CO2 emissions, and more.
In the European Union, a 2022 report stated that fluid pumps account for roughly 15% of total energy usage, with hydraulics alone wasting enough energy to power 82 million homes each year. Although these figures are based on EU data rather than North American metrics, they highlight how much electricity and fuel can be lost through general hydraulic motion control.
How Efficient Servo Hydraulics Translate Into Energy Savings
To address a problem long engrained in the hydraulics industry, Domin went back to first principles and redesigned core components using metal 3D printing, hall-effect sensors, modern electronics, and advanced design and simulation methods. This results in a compact, high-performance valve that reduces quiescent leak and cuts continuous power draw. In practice, this means better motion control over things like clamp force and injection speed without significant energy wasting. This holds additional weight on large injection molding presses that use higher energy levels. Read more about large rubber and plastic presses here.
Domin has measured their design impact by collectively saving 2,169 metric tons of CO2 emissions so far. These are based on installations in Europe and other regions, but still give a sense of scale overall. Every conventional valve replaced with a more efficient Domin alternative can decrease energy usage. When you add those savings up, considering servo-hydraulic molding production lines that run nonstop, it can make a big difference in carbon footprint.
The Efficiency of a Domin Servo Valve
Hydraulics are everywhere, powering so many sectors and industries from aviation to automotive to construction to plastics manufacturing. By targeting servo valves as one part of the system’s efficiency, Domin has addressed energy waste directly in applications where motion control is crucial, such as injection molding.
Because Domin’s valves still achieve highly dynamic control with reduced leakage and optimized flow paths, they not only provide the benefit of energy efficiency, but also outperforms legacy valve designs. This is especially important in North American molding plants where energy prices and sustainability commitments are requiring teams to “do more with less” while still meeting time and quality targets.