When an old hydraulic injection moulding machine starts to lose performance, the most repeated question is how much it might cost to convert it to a modern electric system. An injection moulding machine has heavy movements: mould closing, opening, ejection and intermediate phases that punish the hydraulics with temperature changes, leaks and high consumption. Electrification solves many of these problems, but its cost depends on several factors that need to be analysed calmly.
How much does it cost to electrify an old hydraulic machine?
Most users expect an exact figure from the first minute, but it doesn’t work that way. Every old injection machine has its own history: hours of use, condition of the cylinders, integration with the PLC, mould size, force required and space available to install an electromechanical actuator. From these points, an investment range can be estimated and it can be calculated whether electrification is viable.
The process we follow at Kernova is based on the work we do with the Smart Eco-Motion Kit, where we analyse loads, stroke, speed and mounting points before putting forward any real proposal. That same methodology is applied to an old injection machine, but adapted to its duty cycle.
Factors that change the cost of electrifying an old hydraulic machine
For a plastic injection machine, the cost of electrifying varies with the force needed to close the mould, the stroke length and the mechanical rigidity of the frame. The greater the force and stroke, the larger the electromechanical actuator and the more complex the integration.
- Clamping load: there are machines of 50 tonnes and others of more than 500. This variable completely changes the economic range.
- Clamping stroke: a long stroke requires a sturdier actuator, together with reinforced supports.
- Cycle speed: in fast injection machines, the actuator must accelerate and brake precisely without losing stability.
- Condition of the frame: some old machines need structural reinforcement before the actuator is installed.
- PLC compatibility: if the control is very old, signals need reconfiguring or modules replacing.
These factors explain why no two electrifications are the same. A medium-sized injection machine may take a large-tonnage actuator, while a smaller one may need a complete redesign of the support where the hydraulic cylinder used to be.
How much does a basic electrification of an old injection machine cost?
Here we get into indicative figures, based on real industrial conversion projects and on the typical applications of the Smart Eco-Motion Kit. A simple electrification for a medium-sized injection machine can lie between:
- What it depends on most is the force–cycle speed ratio, that is, ultimately the power required. For high forces (>70 t) and speeds above 0.1 m/s, costs go above €60,000, and we would be talking about projects related to our KRN-H system.
- For loads between 4 and 10 t, the investment can range from €7,000 to €15,000.
- For loads between 20 and 50 t, around €20,000 to €40,000. But it should be stressed that these are estimates and that each project is analysed specifically in order to give a more precise price.
For most old machines the value falls within these ranges. The difference between one end and the other depends on the real load and the mechanical work needed. Larger machines may go above, but those figures already correspond to very high-tonnage projects that need actuators at the KRN-H level.
What share of the cost does engineering take?
In engineering we would distinguish between the design and mechanical adaptation of the actuator and the validation and simulation part. That is, work would be done to redesign the integration into the machine and, once all the components are defined, the finite element simulation would be run.
The analysis work is carried out with the FEM calculation service, where we analyse:
- Stresses in the screw, supports and joints.
- Deformations in the mould clamping.
- Vibrations and structural modes that can shorten the actuator’s service life.
- Force peaks at the start of closing.
This work can account for between €1,500 and €4,000, depending on the complexity of the machine and the number of components to be simulated. The cost is much lower if the parametric model of the actuator fits well with the geometry of the injection machine.
Mechanical integration and frame adaptation
A key part of the project is preparing the support where the electromechanical actuator will be installed. On old machines, this point is usually the most delicate because the frame may have play or deformations accumulated over the years. Reinforcing or replacing plates has a direct impact on cost.
- Simple reinforcements: €500 – €1,500.
- Partial redesign of the support: €1,500 – €5,000.
- These prices are only indicative, as they depend on the size of the machine.
The aim is for the actuator to always work aligned, without eccentric loads that cause uneven wear. Good mounting is what makes the difference between a durable actuator and one that starts to cause problems within a few months.
How does energy consumption affect the total cost?
The hydraulics of an injection machine work with a pump that maintains pressure even when there is no movement. The electric actuator only consumes when it actually moves the load. This produces savings that can exceed 35%, according to typical data from Smart Eco-Motion Kit applications.
For machines that run three shifts, the savings can recover part of the investment in under a year. For lighter shifts, the return is more gradual. The initial cost must always be compared with the machine’s real consumption, not with a theoretical estimate.
Reconfiguring the machine control
The electronics of an old injection machine can be limited. Sometimes it is enough to adjust signals; in other cases, modules must be updated to manage the actuator’s positions and ramps. PLC integration usually falls between €800 and €3,000, depending on the condition of the control.
When the system is ready, a full commissioning is carried out: closing tests, position measurement, braking checks, impact absorption and a test in real cycle. A well-configured machine reduces stoppages and offers a more stable mould closing.
How much does the complete electrification of an old injection machine cost?
Taking all the phases into account (actuator, engineering, reinforcements, control and assembly), a typical electrification falls within these ranges:
- €12,000 – €20,000 for small or medium machines with low load.
- €20,000 – €40,000 for machines with high forces or with frames that need adaptation.
A project can be cheaper or more expensive depending on the geometry, the mechanical condition and the size of the actuator required. But in most cases, these ranges make it possible to assess whether electrification is a reasonable investment.
If you are considering a similar upgrade or need to review an old machine that depends on hydraulics, you can write through the Kernova contact form. Each machine requires its own analysis and an estimate adjusted to its real conditions of use.
Can an old injection machine always be electrified?
Not always. It depends on the clamping load, the stroke and the condition of the frame. On machines with severe deformations or incompatible geometries, it is better to study alternatives.
Does the actuator require maintenance?
Electromechanical systems have simpler maintenance. It normally comes down to periodic greasing and inspection of critical points.
Can part of the hydraulic system be kept?
Yes. On some machines it is possible to electrify only the clamping or the ejection and keep other hydraulic functions if they are in good condition.
