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Generating power only when the process needs it

Project Name Plastic press
industry Plastics machines
Technologies Hydraulics, electric drives

Increasing energy efficiency in plastic presses


Initial Situation

Plastic presses work with high forces and long holding times. In these partial load phases, the hydraulic system needs only little or no flow, since it applies holding forces without using energy by closing the valves.

The Rexroth 4EE Solution

The machinery manufacturer replaced the original constant speed drive for the hydraulic power unit with a variable speed pump drive from the Sytronix family. It lowers the rotational speed as needed. Aside from those direct energy savings, Sytronix also lowers the cooling power required for the hydraulic system by over 80 percent in this application. In addition, the new concept features high-efficiency synchronous motors and energy recovery through drive amplifiers.

The result

The new automation solution with the Rexroth 4EE levers lowers energy consumption by 78 percent without any loss in performance.


  • Operating process: 67,000 kWh/a
  • Auxiliary process: 45,000 kWh/a
  • Total: 112,000 kWh/a

After Rexroth 4EE

  • Operating process: 17,700 kWh/a
  • Auxiliary process: 7,300 kWh/a
  • Total: 25,000 kWh/a
  • Savings: 87,000 kWh/a

Top product


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