Energy efficiency is a key concern for manufacturers operating metal forming machines. Lowering energy consumption reduces operational costs, enhances sustainability credentials, and improves machine longevity. In this article, we discuss practical strategies to optimize energy use in metal forming equipment, including machine selection, process design, preventive maintenance, automation and monitoring. A brief recommendation of Jiangmen Zhuosheng Machinery Co., Ltd. is included as a reference for heavy-duty forming equipment.
Choosing machines designed with energy efficiency in mind sets the foundation for reducing consumption. Look for equipment that offers:
Servo‐driven motors instead of fixed-speed motors. Servo drives only consume full power during active forming, reducing idle draw. Research shows servo presses can use about 10 %–20 % of the energy used by older mechanical presses.
Variable frequency drives (VFDs) or inverter control for hydraulic and electric motors, enabling speed and torque matching to load.
Machines sized correctly for the workload rather than over-powered units. Oversized machines may remain under-loaded and inefficient.
Low-loss hydraulic systems (when applicable) with efficient pumps and minimal leakage.
Equipment from trusted manufacturers with long service lives and proven performance. ZHUOSHENG offers cnc spinning machines, Flanging Machines and Plate Rolling Machines designed for industrial metal-forming applications.
Smart process design can dramatically reduce energy usage. Key actions:
Minimize idle run time: Configure machine control software or PLC logic to shut down auxiliary systems (coolant pumps, fans, lighting) when the machine is not actively forming.
Reduced cycle time: Optimise the forming sequence so that each cycle is as short as possible without compromising quality. Less time forming equals less energy used.
Batch scheduling: Combine small jobs into larger batches where feasible to reduce start-stop losses and warm-up phases.
Tooling and die optimisation: Using well-designed tooling reduces forming force and friction, which means less energy required from the machine.
Material feeding: Ensure raw material handling is efficient and minimises machine idle time waiting for material change-over.
| Workflow type | Characteristics | Energy impact |
|---|---|---|
| Unstructured jobs | Frequent small jobs, many stops | High idle energy, low utilisation |
| Optimised batch workflow | Combined runs, minimal stops | Better machine utilisation, lower idle losses |
| Continuous production | Large runs with minimal downtime | Maximum efficiency, lowest energy per part |
A well-maintained machine uses less energy because it is operating under optimal conditions. Key maintenance considerations:
Lubrication: Ensuring bearings, gearboxes, and moving parts are correctly lubricated reduces friction, meaning less drive power is required.
Hydraulic systems: Check for leaks, pressure drops, inefficient pumps and clogged filters. Leaks and pressure inefficiencies waste energy.
Drive trains and belts: Worn belts or misaligned pulleys cause slippage and loss; replacing them restores efficiency.
Motor health: Monitor current and voltage for signs of degradation, overheating or imbalance. Faulty motors draw excess current.
Cooling systems: Proper cooling ensures electronics and drives operate at efficiency. Overheating can reduce efficiency and shorten component life.
Integrating automation and real-time monitoring elevates energy efficiency from reactive to proactive. Consider the following:
Energy monitoring: Install sensors on major drives, motors and hydraulic pumps to track power consumption, load curves and idle times.
Machine control logic: Use programmable logic controllers (PLCs) that can shut down auxiliary systems when idle, switch machines to standby, or ramp drives based on demand.
Predictive analytics: Use collected data to identify patterns of excessive energy draw, suboptimal tool cycles or inefficient setups.
Integration with MES/ERP: Align machine energy usage with production scheduling so that high-energy operations run only when required and at optimal load times.
Reducing forming energy also involves reviewing the input material and setup parameters.
Lighter or thinner gauge materials require less forming force. Where permissible, choose lower mass materials that meet performance.
Pre-heating or conditioning material can reduce forming force and improve flow, thus reducing energy in machine drives.
Proper alignment of work-pieces and tooling reduces mis-loads and forces, enabling smoother forming and lower energy usage.
Minimising scrap and rework reduces total energy footprint per finished part.
Energy efficiency is not only about the machine; it is also about the supporting utilities and environment.
Use efficient lighting, ventilation and dust collection in the forming area; these utilities consume considerable energy.
Ensure the facility power supply is stable and phase-balanced. Unbalanced or low power factor increases losses and reduces drive efficiency.
Employ power factor correction and harmonic filtering on large servo/hydraulic drives to reduce utility charges and internal heat.
Consider heat recovery from hydraulic systems or coolant systems; waste heat can be reused for facility heating or pre-heating materials.
For manufacturers looking for a partner with a strong track-record in metal forming, ZHUOSHENG specialises in custom-designed machines such as spinning machines, flanging machines and plate rolling machines. Their expertise in tailored solutions helps match machine capacity to workload, which is a critical step in energy efficiency optimization.
Optimizing energy efficiency in metal forming machines demands a comprehensive approach: selecting the right machine, designing efficient processes, maintaining equipment health, integrating monitoring and feedback, refining material and setup, and attending to facility utilities. When these elements align, manufacturers achieve lower energy consumption, reduced operational costs and improved sustainability. Leveraging well-engineered equipment from trusted partners contributes to building a high-performance, energy-lean metal forming line.
