AUTOMOTIVE TAIL LAMP HOUSING
8.9%Cycle-time reduction
74.3 seconds → 67.7 seconds
Calculated from the values published in DME’s iControl brochure.
PERFORMANCE & TECHNICAL RESOURCES
Understand the gains.
Measure your process.
Energy reduction and thermal control are the core benefits of STS insulation. Evaluate them separately from cycle time and overall plant energy use.
STS PRODUCT PERFORMANCE
30%+
Reduction in energy required
Less thermal variation.
Greater process control.
The energy figure is an STS product claim. Results depend on the application, baseline, insulation coverage and operating conditions. Establish the measurement boundary for your installation before projecting savings.
Track energy for the insulated system and distinguish it from total machine consumption, auxiliary equipment and total facility electricity.
COOLER PROCESSING. FASTER CYCLES.
15% average
cycle-time reduction.
With greater process control, most companies choose to run cooler. STS reports that this can unlock cycle-time reductions of 15% on average, with the same or better part quality.
This is an STS performance claim for process optimization. It is separate from the energy-reduction claim and the individual DME examples below. Results depend on resin, part geometry, tooling and processing conditions.
Qualify the optimized process against your part specifications and production requirements.
PUBLISHED DME APPLICATION RESULTS
Evidence from hot runner applications.
These cycle-time examples concern iControl hot runner insulation. They do not establish the separate 30% energy claim.
AUTOMOTIVE AIR BOX
10.9%Cycle-time reduction
46 seconds → 41 seconds
Calculated from the values published in DME’s iControl brochure.
TECHNICAL REFERENCE
DME iControl brochure
Review application conditions, insulation configurations and installation information.
Read the DME brochureApplication-specific examples; results are not guaranteed for other molds. Percentages are rounded.
A PRACTICAL EVALUATION
Build a useful baseline.
Define the system
Choose the barrel, hot runner or complete machine and record what the energy meter includes.
Compare like conditions
Record resin, part, throughput, settings, ambient conditions and operating hours before and after installation.
Track energy and variation
Compare kWh per accepted part and temperature behavior. Record cycle time and quality separately.
Calculate the business case
Use measured annual kWh savings, your electricity rate and installed cost. Confirm rebates with your utility.
STS RETROFIT EXAMPLE / PACKAGING CAPS
Cooler settings.
A shorter production cycle.
Eight-cavity LDPE cap mold, 250-ton press, Husky hot runner. Insulation was applied to the main hot runner; hot drops were not insulated.
| Process measure | Before | After |
|---|---|---|
| Manifold set temperature | 425°F | 375°F |
| Barrel set temperature | 450°F | 390°F |
| Cycle time | 7.69 seconds | 5.96 seconds |
| Startup time to setpoint | 808 seconds | 381 seconds |
Approximately 22.5% shorter cycles and 52.8% faster startup in this application.
STS reports an equivalent short-shot study at the lower manifold setting and increased injection speed without sacrificing quality.
Source: STS customer technical presentation, “Hot Runner Insulation,” November 2025, retrofit example. Percentages calculated from the reported values. Single application results, not a universal performance guarantee.
THE STS OPTIMIZATION PROCESS
Insulate. Optimize.
Verify the result.
Only STS provides full process optimization for STS insulation. Every cycle-time project follows a structured review of the mold, material, process and business case. DME provides sales, logistics and in-country support.
Establish the baseline
Record the resin, machine, tooling, temperature settings, cycle breakdown and part-quality requirements.
Review the mold & design
Check CAD, manifold and nozzle geometry, clearances and access. Define the insulation configuration.
Install & document
Confirm the installation and preserve the baseline settings for a traceable comparison.
Optimize the process
Evaluate lower temperatures and changes to injection, screw recovery, pack/hold and cooling as the application permits.
Verify performance & quality
Compare cycle components, accepted output and part quality. Distinguish measured results from projections.
Build the business case
Translate validated results into capacity and cost opportunities using explicit volume, runtime and rate assumptions.
Identify the next constraint
Document machine, tooling and material limitations. Keep future improvement targets separate from achieved results.
THE COST OF ELECTRICITY
Energy costs
remain elevated.
By 2025, the US industrial electricity price was 26.6% above 2019. The EU business benchmark was 55.2% higher, despite easing from its 2023 peak.
Insulation gives molders a practical way to reduce the energy their process requires. Use your own tariff and measured consumption to evaluate savings.
US industrialEU non-household
View values & sources
| Year | US | EU |
|---|---|---|
| 2019 | 100.0 | 100.0 |
| 2020 | 97.9 | 104.3 |
| 2021 | 105.4 | 113.6 |
| 2022 | 122.2 | 163.7 |
| 2023 | 118.1 | 172.4 |
| 2024 | 119.4 | 158.8 |
| 2025 | 126.6 | 155.2 |
US: EIA annual industrial averages; 2025 preliminary. EU-27: consumers using 500–2,000 MWh/year, excluding VAT and recoverable taxes. EU annual values are the arithmetic mean of two half-year prices. Indices compare changes, not absolute tariffs; no currency conversion. Data reviewed September 7, 2026.
LET’S TALK ABOUT YOUR PROCESS