Transformation for Survival in the Traditional Plastics Industry: All-Electric Injection Molding Machines Pave the Way for Sustainable Circular Solutions
According to a survey by Global Information Inc. (a Japanese company), despite the decrease in demand for plastic injection molding during the COVID-19 pandemic, the market has now steadily recovered, reaching pre-pandemic activity levels. The main factors driving growth are population growth, the increasing prominence of sustainability issues, rising disposable incomes in developing countries, and the growth of the retail sector in emerging markets. These factors are leading to applications across various end-user industries, from bulk packaging to thin-wall containers and bottle molds.
In particular, industries such as lightweight electric vehicles and packaging materials for consumer and electronic products are experiencing increased demand, along with innovative manufacturing applications such as the delivery economy. By 2025, it is estimated that revenues from the food and beverage industry will reach USD 25 billion. Furthermore, new applications in healthcare may provide lucrative opportunities for growth in the plastic injection molding market.
Additionally, in response to the global focus on sustainable development and net-zero emissions, ESG—Environmental (E), Social (S), and Governance (G)—sustainability has become a key focus for global industrial innovation opportunities. Against the backdrop of intensifying global environmental changes and limited resources, green intelligent manufacturing is sure to be a crucial aspect for the future of Taiwan’s plastics and rubber industries.
For the plastic injection molding industry, “energy-saving strategies” were once optional, but under the impetus of global carbon neutrality regulations and trade demands, they have become a “necessity for survival.”
FCS Focuses on Value-Added Applications
In recent years, topics such as intelligent manufacturing, the circular economy, and ESG have been inseparable from innovative energy-saving and carbon-reduction solutions. Especially with the significant attention given to the new energy vehicle market, plastics have been widely used to replace steel in various automotive parts. FCS is continually assisting customers in testing the molding of various components, including those reinforced with carbon fiber or glass fiber, to meet the needs of industries such as automotive, bicycles, and even aerospace.
1. "MuCell Microcellular Foaming Technology" for Green Energy Footwear
FCS has been applying MuCell microcellular foaming technology for many years, and with the recent global focus on energy-saving and carbon reduction, it has gained increasing attention, particularly in the footwear industry. As a result, FCS has partnered with Tien Kang, one of the world’s top three shoemaking machinery manufacturers, to launch the “GENTREX Multifunctional Physical Foaming Injection Molding System” for producing thermoplastic green energy footwear materials.
Last year, with the support of the Ministry of Economic Affairs’ "Smart Machinery Industry Upgrade Program," FCS successfully passed international beta-site customer validation and entered NIKE’s international supply chain with its "smart manufacturing solution for plastic injection molding of athletic shoe soles." This success has empowered FCS to serve related markets with greater confidence, receiving positive feedback and continuing to generate orders. By August of this year, nearly 40 injection molding machines had been ordered to supply footwear production bases across China, India, and Southeast Asia.
2. "Low-Carbon Plastic Injection Ecosystem" Collaborates with the Supply Chain to Reduce Carbon Emissions
FCS’s sustainability strategy focuses on two key aspects of energy conservation and carbon reduction: First, reducing energy consumption during the injection machine’s lifecycle by improving energy efficiency through peripheral equipment; second, replacing raw materials with recycled materials to help customers achieve a low-carbon circular economy roadmap.
In FCS’s production facilities, beyond lean production and scheduling management, they utilize smart meters for real-time monitoring and have completed carbon audits by improving high-carbon equipment such as air compressors, forklifts, and chillers. In 2023, FCS took the lead in establishing the "Green Innovation Project Team" to create the 1+10 "Low-Carbon Plastic Injection Ecosystem" project, working alongside 10 supply chain partners to collectively reduce carbon emissions.
This project involves developing a carbon reduction roadmap for the injection molding industry, focusing on three main areas: ① smart energy optimization, ② integration of low-carbon equipment and peripherals, and ③ development of recycled material technologies. Concrete action plans include self-conducted carbon audits, integrating energy-saving injection peripheral equipment, enhancing the use of recycled materials, upgrading energy-saving technology for new machines, and retrofitting older machines for energy efficiency.
3. "Smart Energy Saving + Scientific Molding" for an AI Sustainable Future
Regarding equipment energy-saving improvements, FCS will offer servo energy-saving systems, all-electric technology, power recovery systems, low-heat-loss technology, and MuCell development. Additionally, FCS will apply self-developed intelligent manufacturing technologies to help customers improve product yield, enhance carbon reduction capabilities, and, through AI fault prediction technology, increase machine utilization efficiency, thereby indirectly reducing machine carbon emissions.
Currently, FCS primarily uses the Austrian KEBA control system for its injection machines and maintains close partnerships with Delta Electronics. Whether foreign or domestic brands, the industry’s development trend is closely tied to policy direction. It is hoped that major domestic system manufacturers will play a more prominent role in the government’s vigorously promoted “energy-saving + intelligent dual-axis transformation” industrial strategy, providing higher-efficiency production solutions for the equipment industry.
Generative AI applications are one of the dreams of the plastic injection molding industry. Although FCS has discussed this with experts and they believe it is still quite challenging at this stage, some basic modules may be developed first, such as accelerated solutions for stabilizing mold testing and addressing molding defects, provisionally named "Scientific Molding Guide" and "Systematic Abnormality Elimination Guide," which could benefit the industry and be prioritized for development.
4. "Green Energy, Carbon Reduction/Circular Sustainability" Shines at the FCS Booth
At this year’s TaipeiPLAS 2024 exhibition in September, FCS focused on the themes of green energy, carbon reduction, and recycling, showcasing a range of applications including intelligent optics, sandwich molding, precision two-color molding, and microcellular foaming technology. These were all equipped with the self-developed iMF 4.0 intelligent manufacturing system, with four machines connected live on-site to demonstrate new achievements. Attendees were treated to innovative applications and process integrations that improve efficiency and yield, as the exhibition explored the best strategies for tackling the challenges of carbon neutrality through equipment, process technology, and production management.
The “Precision Optical Intelligent Molding System” theme includes the ultra-short energy-saving injection molding machine SA series and the ultra-precision all-electric injection molding machine CT-e series, which both produced optical goggles that could be assembled and worn on-site.
The newly launched ultra-short SA series is an outward toggle hydraulic servo energy-saving model with clamping forces ranging from 100 to 3200 tons, suitable for household goods, stationery, automotive, 3C, and home appliance industries. Due to its structural characteristics, the SA can provide a relatively large mold opening stroke in a smaller space, making it popular among customers producing deep bucket-shaped products.
The SA-160 with a clamping force of 160 tons will be used to automatically produce a four-cavity PC material goggle leg with a cycle time of 35 seconds, fully showcasing FCS's superior performance in high-end precision industries. During TaipeiPLAS, the MuCell microcellular foaming system will also be demonstrated, presenting a material-saving, low-carbon solution, and winning the TaipeiPLAS Award’s "Gold Quality Award" and "Aesthetic Award."
The CT-e all-electric series injection molding machines feature high efficiency, stability, and energy-saving advantages. Compared to traditional injection molding machines, the CT-e series has achieved 55% energy savings. Since its launch, over 300 units have been sold. At the exhibition, the 180-ton all-electric CT-180e will be shown producing a two-cavity PC material goggle lens with a cycle time of 40 seconds, providing a reference for precision and clean mass production applications in optics, medical, electronics, and food packaging industries.
This entire precision optical intelligent molding system is also equipped with the iMF 4.0 intelligent manufacturing system, integrating various intelligent sensing modules, including a product weight stability monitoring system, a mold water flow temperature sensing and control system, and a tie-bar clamping force monitoring system, truly achieving stable mass production monitoring, improving yield, and reducing production waste.
Additionally, FCS, Tien Kang, and Trexel have collaborated to launch the new-generation GENTREX physical foaming injection molding machine TK-927, which achieves net-zero carbon emissions and sustainability goals. The machine was recognized for its high performance, material versatility, innovative features, intelligence, and aesthetics, winning the TaipeiPLAS Award 2024 "Silver Quality Award" and "Special Award for Circular Sustainability."
