H T Mould China Limited
H T Mould China Limited
Posted by:H T Mould China Limited
Keywords: 8-cavity bubble tea cup mold, in-mold labeling, all-electric injection molding machine, 3 million-cycle mold life, return on investment in high-electricity-cost countries
In the production of plastic products, molds are often regarded as "one-time fixed inputs" by customers. However, H T Mould always believes that a set of high-precision, high-stability multi-cavity molds is the most powerful lever for customers to reduce unit costs and shorten investment return cycles.
Especially in countries with high industrial electricity prices such as Egypt, Turkey, Pakistan, and Nigeria (electricity charges are as high as 2.5-$0.506/kWh or even higher), the number of mold cavities, cooling efficiency, and cycle stability directly determine the energy consumption level and overall profitability of the injection molding machine.
At K 2025 in Germany, H T Mould and LKIMM jointly demonstrated an 8-cavity 650 ml bubble tea cup in-mold labeling (IML) mold, paired with a LKIMM ELETTRICA-S 450T all-electric high-speed injection molding machine, achieving:
This article will break down in detail how this solution can help customers from countries with high electricity bills, shorten the investment payback period to less than 6 months, and maximize long-term profits from three dimensions: mold design, injection molding machine selection, and economic cost comparison (USD/Egyptian pound/Turkish lira).
| project | parameter |
|---|---|
| Product name | 650 ml bubble tea cup (PP) |
| Number of mold cavities | 8 cavities |
| Mold size | 650 × 980 × 560 mm |
| Mold weight | ≈3.9 tons |
| Mold material | Mold core: S136 (HRC48–52) |
| Guaranteed service life | 3 million cycles |
| Actual service life | 5-6 million cycles under normal maintenance |
| production method | In-mold labeling (IML) |
| hot runner | 8-point needle valve type, independent temperature control |
| Cooling method | Conformal cooling + efficient water isolation sheet |
| Label positioning accuracy | ±0.1 mm |
1.2.1 Highly balanced hot runner system
It adopts 8-point independent needle valve hot runner, and each nozzle has independent temperature control. The filling weight deviation of 8 cavities is guaranteed to be ≤ 1.5%, which is much lower than the industry average of 3–5%.
Why is it important? Imbalanced filling will cause individual cavities to Maintenance pressure in advance and individual cavities to be underfilled, which directly lengthens the cycle and increases the scrap rate. In countries with high electricity bills, every second of cycle extension means lost electricity bills.
1.2.2 Efficient conformal cooling system
The interior of the mold core adopts 3D conformal cooling water channels, which are close to the contour of the cavity. With 16-20℃ cooling water, the mold surface temperature difference is ≤ ±1℃.
Effect: The product cooling time is shortened from 4.5 seconds of traditional molds to 1.5 to 2 seconds, providing the basis for a total cycle of 7.5 seconds.
1.2.3 Special design for in-mold labeling (IML)
The label vacuum adsorption hole and positioning groove are integrated inside the cavity. Cooperate with the robot to realize automatic label placement and pick-up, with label position deviation ≤ 0.1mm.
Advantages: No manual intervention is required, 24-hour continuous production, and the scrap rate is controlled within 2%.
1.2.4 Long life and easy maintenance design
H T Mould knows that the life and Maintenanceability of the mold directly determine the long-term profits of its customers. Therefore we specially designed:
It guarantees normal production of 3 million cycles, and can actually stably use 5 to 6 million cycles.
💡 Value to customers: Calculated based on a 7.5 second cycle, 3 million cycles ≈ 260 days of continuous production (24 hours non-stop). The actual life of 5-6 million molds means that one set of molds can cover full-load production for 1.5-2 years.
| parameter | ELS450 |
|---|---|
| clamping force | 4500 kN (450 tons) |
| Internal spacing of tie rods | 870 × 870 mm |
| Maximum mold thickness | 820 mm |
| Minimum mold thickness | 400 mm |
| Mold opening stroke | 1620 mm |
| Recommended injection unit | 1700MS (high speed) |
| maximum injection speed | 350 mm/s |
| maximum injection pressure | 230 MPa |
| Rated power of the whole machine | ≈75 kW (actual operation≈28 kW) |
| Comparative item | Traditional hydraulic machine (450T) | LKIMM all-electric machine (450T) |
|---|---|---|
| average operating power | 45–55 kW | 25–30 kW |
| Cooling water consumption | benchmark | 60% reduction |
| Maintenance cost | high | Low |
| Injection/pressure holding accuracy | ±0.1 mm | ±0.01 mm |
| IML tag stability | generally | excellent |
| noise | 75–80 dB | < 68 dB |
| Overall machine life | 8–10 years | More than 15 years |
| Power saving rate | — | Save 25–30% electricity |
Hydraulic machine: 50 kW × 24h × 300 days = 360,000 kWh/year
All-electric motor: 28 kW × 24h × 300 days = 201,600 kWh/year
Annual power savings: 158,400 kWh
Egypt’s annual electricity bill: 158,400 × 15.75 EGP = approximately 2.495 million EGP
| parameter | numerical value |
|---|---|
| Stable production cycle | 7.5 seconds |
| Cycles per hour | 480 |
| Production per hour | 3,840 |
| Daily output (24h) | 92,160 |
| annual production days | 300 days |
| annual output | ≈ 27.65 million cups |
| Yield rate | 98% |
| project | Hydraulic machine | all-electric machine |
|---|---|---|
| Average power (kW) | 50 | 28 |
| Annual power consumption (kWh) | 360,000 | 201,600 |
| Annual power saving (kWh) | — | 158,400 |
| Expense items | Hydraulic machine ($1,446.9/year) | All-electric motor ($1,446.9/year) | Annual savings ($1,446.9) |
|---|---|---|---|
| Electricity bill | 28.8 | 16.13 | 12.67 |
| cooling water | 1.5 | 0.6 | 0.9 |
| Maintenance | 4.0 | 1.5 | 2.5 |
| Labor | 18.0 | 4.5 | 13.5 |
| scrap loss | 6.0 | 3.0 | 3.0 |
| total | 58.3 | 25.73 | 32.57 |
Investment difference: $94,048.28, payback period ≈ 24 months
| Expense items | Hydraulic machine (10,000 EGP/year) | All-electric motor (10,000 EGP/year) | Annual savings (10,000 EGP) |
|---|---|---|---|
| Electricity bill | 567.0 | 317.5 | 249.5 |
| cooling water | 6.8 | 2.7 | 4.1 |
| Maintenance | 18.0 | 6.8 | 11.2 |
| Labor | 81.0 | 20.3 | 60.7 |
| scrap loss | 27.0 | 13.5 | 13.5 |
| total | 699.8 | 360.8 | 339.0 |
✅ Egyptian customers can recover their investment in just 3.2 months
| Expense items | Hydraulic machine (10,000 TRY/year) | Full electric motor (10,000 TRY/year) | Annual savings (10,000 TRY) |
|---|---|---|---|
| Electricity bill | 423.4 | 237.1 | 186.3 |
| cooling water | 5.0 | 2.0 | 3.0 |
| Maintenance | 13.4 | 5.0 | 8.4 |
| Labor | 60.5 | 15.1 | 45.4 |
| scrap loss | 20.2 | 10.1 | 10.1 |
| total | 522.5 | 269.3 | 253.2 |
✅ Turkish customers can recover their investment in just 4 months
| nation | Electricity price (local currency/kWh) | annual operating savings | Equipment balance | Payback period (months) |
|---|---|---|---|---|
| China | $0.116 | $47,168.83 | $94,048.28 | 24 months |
| Egypt | 15.75 EGP | 3.39 million EGP | 900,000 EGP | 3.2 months |
| Türkiye | 11.76 TRY | 2.53 million TRY | 840,000 TRY | 4.0 months |
💡 Conclusion: The higher the electricity price, the shorter the investment payback period of all-electric machines.
| frequency | Maintenance content |
|---|---|
| every shift | Check and apply lubricant |
| Every 100,000 cycles | Clean the exhaust holes, side air grooves and cooling water channels |
| Every 500,000 cycles | Check the hot runner and replace the fragile ejector pin |
| Every 1 million cycles | In-depth maintenance by professional technicians |
| project | Cost per transaction (EGP) | frequency | Annual Fee (EGP) |
|---|---|---|---|
| Daily lubrication | 30/day | 300 days | 9,000 |
| 100,000 cycles maintenance | 2,000 | 3 times/year | 6,000 |
| 500,000 cycles maintenance | 10,000 | 0.6 times/year | 6,000 |
| Total annual cost | — | — | ≈21,000 |
Guaranteed life: 3 million cycles ≈ 260 days of continuous production
Actual life: 5 million–6 million modes ≈ 1.5–2 years
The amortized cost of the mold only accounts for 6% of the selling price of the cup, and the electricity cost savings covers more than 2 times.
| project | Original plan (2 hydraulic machinees) | New solution (1 unit all-electric) |
|---|---|---|
| Number of cups produced per year | 18 million | 27.65 million |
| annual electricity bill | 3.4 million | 1.6 million |
| annual labor | 600,000 | 100,000 |
| Annual maintenance | 120,000 | 21,000 |
| total annual cost | 4.12 million | 1.721 million |
| annual profit | 4.88 million | 12.099 million |
Total equipment investment: 4.8 million EGP, payback period ≈ 8 months
Cumulative savings in 10 years: 33.9 million EGP, equivalent to 28 sets of 8-cavity molds for free.
Exchange rate recommendation: Quote in USD pricing, or adopt profit sharing model.
In countries with high electricity bills, the payback period of H T Mould's 8-cavity mold + LKIMM all-electric machine solution is only 3-4 months.
H T Mould not only sells molds, but also sells "verifiable and efficient production units".
Contact us now to get your exclusive ROI analysis form!
| project | information |
|---|---|
| Company Name | H T Mould China Limited |
| Official website | www.chinamoldshop.com |
| sales@chinamoldshop.com | |
| Telephone | +86 186 8865 7336 |
H T Mould - Use molds to earn profits from every kilowatt-hour of electricity for you, and promise to protect your long-term profits with 3 million molds