A Guide to Upgrading Small and Medium Thermoforming Machines

Knowing the Choices: Servo Retrofit versus Full Replacement

Servo Retrofit

A servo retrofit is a modification of an existing hydraulic machine by installing a servo drive. This choice carries many benefits:

- Energy Efficiency: Retrofits are a good way to save energy by increasing efficiency by as much as 20-50%. Replacing inefficient hydraulic systems with efficient electronic servo motors allows operators to save significantly on electricity.

- Prompt Response: Servo drives provide instant and precise control of the molding process.

- Low Downtime: The retrofitting process is less disruptive than replacing the whole machine, minimizing production downtime. Though installation can be lengthy, it usually wouldn't compare to the downtime and logistical problems involved in acquiring and installing new equipment.

- Reduced Initial Investment: Cost is an important factor. Retrofitting is usually much less than buying a new machine, making it an appealing decision for operators who are trying to save money.

Yet, it is important to recognize that retrofitting has its limitations. Old machines may have worn barrels, outdated controls, and fatigued parts problems that cannot be fixed by a new system. Thus, carrying out a detailed assessment of the overall state of the machine is of utmost importance.

Replacement with a New Machine

Choosing full replacement shows commitment towards modernization. The new machines come with advantages, but they require higher capital investment:

- Precision: The new machines are created with advanced technologies to ensure the best performance. Their high-end features match the requirements of new production processes.

- Connectivity: New machines feature opportunities to connect to advanced data and also provide the opportunity to perform monitoring and improvements during the process of production.

- Long-term Investment: The initial costs are high, but new machines tend to be more durable and come with warranty support.

- Sustainability: With the new technology used for molding machines, the equipment can provide greater energy efficiency and lower environmental impact, meeting the standards of modern marketplaces.

However, the long payback period of the equipment can make some operators reconsider their decision.

Cost-Benefit Analysis

It is important to use metrics to compare both options.

1. Energy efficiency: Evaluate how much energy will be saved by each option.
- Retrofit: Energy efficiency is 20-50%.
- Replacement: New machines usually provide the same level of efficiency as existing machines.

2. Maintenance: Evaluate costs of both options.
- Retrofit: Reduced maintenance but still need to take care of old equipment.
- Replacement: New machines often have warranty support.

3. Downtime: Determine the amount of time that production may be affected.
- Retrofit: Minimal installation.
- Replacement: Usually, one has to deal with long downtimes.

4. Productivity: Evaluate how the machines can contribute to the improvement of production processes.
- Retrofit: Improved cycle time—improved efficiency.
- Replacement: The result is that the productivity rises significantly due to the use of advanced technology.

To sum up, it is quite hard to choose between installing a new system and fully replacing an old machine because each option has its own advantages and drawbacks.