Method of energy distribution and consumption control based on melt quality improvement for plastic injection and extrusion processes

A method of operating an injection molding or extrusion machine, the method comprising the steps of:

• establishing set values of a plurality of operating and process parameters;
• measuring a present value of at least one of the process parameters;
• and
• comparing the present value of the at least one process parameter with the set value;
• and
• if the present value of the at least one process parameter deviates from the set value by more than a predetermined amount, adjusting the set value of at least one of the operating parameters to optimize energy consumption or improve melt quality.

A system, comprising:

• an injection molding or extrusion machine;
• at least one sensor connected to the machine and configured to measure a present value of at least one process parameter indicative of energy consumption or melt quality;
• a controller connected to the machine and the at least one sensor;
• and
• a memory connected to the controller and configured to store instructions executable by the controller,
• wherein the controller is configured to compare the present value of the at least one process parameter with a set value of the at least one process parameter, and, if the present value of the at least one process parameter deviates from the set value by more than a predetermined amount, adjust a set value of at least one operating parameter controlling the operation of the machine.