Energy Consumption Estimator
Quickly estimate machine energy use (kWh) and electricity cost from heater power, cycle time and operation hours.
Calculate NowUse this tool for production cost estimation, bid pricing, and energy-saving retrofit evaluation in thermoforming processes.
Input Parameters
成果
Calculations & Formulas
1) Instantaneous average power during operation (kW)
P_avg = P_heater × D + P_standby + P_other
2) Energy consumption per hour (kWh)
E_hour = P_avg (kW) × 1 hour = P_avg kWh
3) Energy per day (kWh/day)
E_day = P_avg × H
4) Electricity cost
Cost_hour = E_hour × Price
Cost_day = E_day × Price
5) Energy per cycle (kWh/cycle)
E_cycle = P_avg × (T_c / 3600)
6) Cost per unit (if units_per_cycle provided)
Cost_per_unit = (E_cycle × Price) / units_per_cycle
Heater power = 30 kW
Duty cycle = 80% → D = 0.8
Standby = 0.5 kW
Other loads = 2 kW (vacuum pump)
Operation hours H = 8 h/day
Electricity price = $0.12/kWh
Cycle time = 12 s, Units per cycle = 4
Common Industry Scenarios
Thin-Gauge Thermoforming
High-speed production with multiple heaters and quick cycle times.
Thick-Gauge Thermoforming
Longer cycle times with higher heater power requirements.
Twin-Sheet Forming
Dual heating systems with additional vacuum requirements.
Energy Saving Tips
Optimize Heater Control
Implement PID controllers to maintain precise temperature with minimal overshoot, reducing duty cycle by 10-20%.
Standby Power Reduction
Use smart power management to reduce standby consumption during breaks by up to 80%.
Improve Insulation
Upgrading oven insulation can reduce heat loss by 15-30%, directly lowering heater power requirements.
常见问题
The duty cycle represents the percentage of time heaters are actually powered during a cycle. For precise measurement, use a power logger. For estimation: timed observation (e.g., heaters are on 45s of a 60s cycle = 75% duty) or consult machine specifications.
Include vacuum pumps, hydraulics, drives, and control systems in "Other loads". Typical values: vacuum pumps 1.5-5 kW, hydraulic pumps 2-7 kW, servo drives 0.5-3 kW. Check motor nameplates or power supply ratings for exact values.
Shorter cycles increase hourly energy use (more cycles/hour) but may reduce per-unit energy if heaters can maintain temperature efficiently. Optimal cycle time balances production rate with thermal efficiency.
Need a Custom Energy Analysis?
Our engineers can perform a detailed assessment of your production line and identify specific energy-saving opportunities.