Increasing production efficiency in EPS styrofoam molds

EPS (Expanded Polystyrene Foam) is prepared by subjecting the raw material of polystyrene to a number of processes in the pre-blow molding process before it is transferred to the molds in the production process. The raw material that has passed through the preliminary preparation process must be sent to the EPS injection molding machine between 8-24 hours and turned into the final product. Dec. The raw material is delivered to the EPS injection molding machine via a central line after the pre-inflation process. After the preparation process is completed in the pre-inflation process, the EPS is filled with the help of injectors connected to the injection molding machine, hot steam is supplied to the steam chamber to cook the product, cooling is performed to cool the product and mold, after vacuuming, the products are lowered down from the mold with the help of pushers. Since the majority of the energy in eps production is used in mold heating and cooling processes, these steps in the process are very important. The molds used within the scope of this study are manufactured with both conventional aluminum (GA) and open-pore aluminum (AGA). Nozzle holes were also drilled into one of the molds produced using AGA material as in the traditional method. As a result of the findings and experiences obtained by evaluating these patterns in terms of energy efficiency, some suggestions have been made. AGA material has many properties such as energy absorption, absorption of sounds, thermal insulation, damping and distribution of vibrations. AGA; in the aerospace industry, automobile industry, petrochemical industry and construction materials, etc. it has the ability to be used in many different areas. As a result of the experiments carried out; It has been observed that in EPS mold designs made with AGA, it is necessary to increase the strength and reduce the flexibility compared to EPS mold designs in the traditional method. It was found that the cycle time of the mold using AGA material with nozzle holes drilled decreased by 15% and steaming time by 17%, while the cycle time of the AGA mold without nozzle holes opened increased by 3.6% and steaming time by 212%, according to the molds used in GA. It is estimated that when 750 molds are used annually, approximately TL 81.000.000 profit will be made in this process based on the annual total energy and water consumption prices according to 2022 prices.