Stepping into the Injection Molding Division of Sunway Plastic & Electronics (Zhuhai) Co., Ltd., the old impressions of high temperature, noise, oil stains and dust have been overturned. Automated equipment operates in an orderly manner, the ambient temperature is comfortable, and green data displayed on the visual large screen. Under the dual pressures of the "Dual Carbon" goal and rising raw material costs, electricity bills have become the largest variable cost in injection molding production, second only to raw materials and labor. On May 21, 2026, we learned from the Project Director and Factory Manager of Qianshan Molding Dep. that this workshop is pushing cost reduction and efficiency improvement to the "extreme" through technological transformation, energy conservation and consumption reduction, and systematic management, daring to achieve self-"breakthrough" and realizing a counter-trend growth in benefits。

Exploring the Path of Technological Innovation, Cost Reduction and Efficiency Improvement in the Injection Molding Workshop

    Improving production efficiency is the key. By optimizing the form of the injection gate, improving the injection feeding speed, increasing the precise temperature and adjusting the position of cooling water to quickly lower the temperature of workpieces and injection gate, and optimizing the layout of cooling channel in the mold to enhance the cooling effect, the production efficiency of some parts has increased by more than 30%, achieving a self-"breakthrough"。

 ‌   Boosting Product Quality. Our team once faced a tough challenge with magnetic ring overmolding parts: the rare-earth magnetic ring stays at a low temperature, making it hard to bond with hot molten plastic, which make the one-time finished product qualification rate was less than 20%. Through pre-injection, improving the position of the injection gate, and setting a specific temperature around the magnetic ring, the one-time finished product qualification rate has exceeded 99%. This move greatly lifted production efficiency, cut the high cost of expensive rare-earth magnetic materials, won full recognition from our clients, and finally cracked the hard nut of magnetic ring overmolding technology — a solid self-breakthrough for our workshop。

Tapping Potential through Technological Transformation: Striving for Benefits from Every Kilowatt-hour of Electricity

   In Sunway Electronics' intelligent injection molding workshop, more than 60 injection molding machines are operating in an orderly manner. Traditional electric heating rings for heating cause a large amount of heat loss, which not only consumes high energy but also makes the workshop extremely hot. Now the heat utilization rate has been greatly improved, and the implementation of man-machine separation has also fundamentally improved the workshop environment. The working status, production efficiency and qualified rate of each equipment can be clearly seen on the visual large screen。

    The management of auxiliary equipment is also being upgraded. Taking the mold temperature controller as an example, the cooling system of the traditional mold temperature controller operates at high load all year round, resulting in huge "hidden waste".  By introducing fully intelligent variable-frequency constant-pressure water pumps, the circulating water system automatically adjusts the pump speed and output power based on real-time pipeline water pressure and flow sensing, delivering remarkable energy-saving results. After full-cycle recycling and comprehensive calculation, this optimized cooling solution cuts a considerable amount of annual electricity costs for the plant. In most operating scenarios, it can even replace mold temperature controllers for working temperatures below 50℃, achieving outstanding consumption reduction performance。

Recycling: Saving Every Ton of Water

    Water recycling and refined management have further consolidated our energy conservation defense line. Injection molding production consumes a large volume of cooling water. In the past, the open cooling water system faced prominent issues including massive water loss from evaporation and splashing, as well as low circulation efficiency. Our workshop has completed a full transformation of the water circulation system, adopting the combined solution of closed-loop circulating cooling towers and fully sealed stainless steel water tanks, paired with a 3-stage water purification device. This setup realizes fully closed recycling of cooling water, pushing the water circulation utilization rate above 95% and completely eliminating unnecessary water waste。

   Systematic Management:  No Waste Goes Unnoticed

    Hardware upgrades alone only lay the foundation. The real refined control lies in systematic management. The workshop has continuously introduced all-electric injection molding machines, and built dozens of automated injection molding production lines that integrate intelligent automatic feeding systems, robotic arms and automatic conveying lines. Frontline employees have given positive feedback that after the implementation of man-machine separation, the working environment has been greatly improved, labor comfort has been significantly enhanced, work intensity has been drastically reduced, and workplace safety has been substantially elevated. We have also built supporting intelligent storage systems and unmanned distribution AGV equipment. All key production equipment has been connected to the Total Productive Maintenance (TPM) system and the Industrial Internet of Things (IOT) platform. By breaking down cross-system data barriers between ERP, Manufacturing Execution System (MES) and other platforms, we have formed a unified shared data resource pool. The system supports full-process visualization and intelligent alarm functions: once abnormal standby energy consumption is detected, a rectification notification will be pushed immediately. This single optimization alone helps the enterprise save over 180,000 RMB in electricity bills every year, and greatly improves the overall power utilization efficiency。

    Energy conservation and consumption reduction is no overnight feat, and green development is an endless journey. Director Han shared a vivid metaphor: "In the past, we mopped the floor with the tap running wide open; now we make sure every single kilowatt-hour of electricity delivers tangible output." Going forward, the Molding Division will continue to deepen energy-saving renovations, keep optimizing production processes and management models, and tap into untapped energy-saving potential with more refined control and more advanced technologies. We will spare no effort to build a low-carbon, high-efficiency, green and intelligent modern production workshop, inject green momentum into the enterprise's high-quality development, and set a benchmark for energy conservation and consumption reduction across the industry.

Sunway (Group) Technology Center
May 25, 2026

author：Fang Yanfen

reviser：Luo Jia

approver: Kang Sheren