Motor Controller for the Plastics Industry

Plastics manufacturing runs on motors that rarely sit at a steady, constant load. Injection moulding, extrusion and associated handling equipment all tend to cycle between heavier and lighter demand as different stages of the process take place, and that fluctuation is precisely the pattern that makes a standard, unadjusted motor inefficient. Integra from Suresense is designed to respond to exactly that kind of variable duty cycle.

Rather than running the motor at a fixed output sized for its heaviest moment, Integra continuously senses the real load and adjusts power delivery to match it, checking roughly every 10 milliseconds. Across a full production cycle, that means the motor is drawing significantly less energy during the lighter phases of the process, without any change to cycle times or output quality.

Suresense has direct, documented experience applying Integra within the plastics sector, where the combination of variable load and continuous, multi-shift operation makes the energy saving potential particularly strong.

On top of the running cost reduction, plastics processing equipment also benefits from Integra's soft start function, which reduces the mechanical stress placed on drive components every time heavy machinery starts up, a common source of unplanned maintenance in this kind of production environment.