What is the late maintenance cost of the injection molding machine?

In the injection molding industry, injection molding machines are the core equipment, and their late maintenance costs are a key element that cannot be ignored by enterprises.This is not only related to the daily operating expenses of the enterprise, but also closely related to the stability and continuity of production.
1. Replacement cost of wearing parts
In the frequent mold opening and closing and injection molding actions of the injection molding machine, many vulnerable parts are under great pressure.For example, the screw and barrel, as the key components of plastic melting and plasticization, are in long-term contact with high-temperature, high-pressure, and high-friction plastic raw materials, and the wear rate is faster.Generally speaking, screws of ordinary materials, depending on the frequency of use and the characteristics of processing raw materials, may need to be replaced in 1-2 years, and the price ranges from a few thousand yuan to tens of thousands of yuan; the replacement cycle of the barrel is relatively long, but the cost is also in the thousands of yuan.
There are also seals, which ensure the sealing of the hydraulic and lubrication systems of the injection molding machine and prevent oil leakage.Because its material is mostly rubber or polyurethane, it is easy to age and deform. It usually needs to be inspected and replaced every six months to one year. Although the cost of a single seal is not high, from tens of yuan to hundreds of yuan, the many seals of the entire injection molding machine add up. It is also a big expense.
2. Maintenance service cost
When the injection molding machine fails, the maintenance cost varies depending on the type of failure.If the electrical control system fails, such as circuit board damage or sensor failure, the maintenance cost is higher.Professional maintenance personnel need to spend a lot of time troubleshooting circuits and detecting components. It may cost thousands of yuan to replace the circuit board. The replacement of sensors and labor costs may reach thousands of yuan each time.
Mechanical component failures, such as broken connecting rods and worn crankshafts, are difficult to repair. Not only do they have to replace expensive parts, but they also involve complex disassembly and installation processes, and labor costs have increased significantly.The total cost of a large-scale mechanical component repair may easily exceed 10,000 yuan, and during the shutdown and maintenance period, the company is also facing losses caused by stagnant production.
3. Daily maintenance costs
Although the cost of daily maintenance is relatively small, the accumulation of time is also a part that cannot be ignored.The regular addition and replacement of lubricating oil is the basis for ensuring the smooth operation of the moving parts of the injection molding machine. According to the specifications and frequency of use of the injection molding machine, the monthly expenditure on lubricating oil may be around a few hundred yuan.
The replacement of the filter is also important. It can effectively filter impurities in hydraulic oil and cooling water to prevent them from causing damage to the system.Air filters, hydraulic oil filters, etc., are replaced every quarter or half a year in accordance with regulations. The cost of each replacement ranges from tens of yuan to hundreds of yuan, and the cost of various types of filters in the whole machine will also be on a certain scale in a year.
Fourth, energy consumption and cost considerations
Although the energy consumption during the operation of the injection molding machine is not a direct maintenance cost, it is closely related to the long-term use cost of the equipment.The energy consumption performance of different models and brands of injection molding machines varies greatly.Due to the backward technology and low motor efficiency of the old injection molding machine, the energy consumption may be 30%-50% higher than that of the new energy-saving injection molding machine under the same production task.Taking a common medium-sized injection molding machine as an example, if it is turned on for 20 days a month and runs for 10 hours a day, the electricity bill is calculated at 1 yuan per unit. The monthly electricity bill for energy-saving injection molding machines is about 5,000 yuan, while older models may be as high as 7,500 yuan or more. In a year, the difference in electricity bills is quite considerable.
In summary, the late maintenance cost of injection molding machines covers many aspects. When purchasing injection molding machines, enterprises cannot only pay attention to the initial purchase price of the equipment, but also comprehensively consider these late cost factors in order to make the most economical decisions and ensure that enterprises move forward steadily in the field of injection molding production.