Revolutionary 40,000 Kn Electric Injection Moulding Machine Debuts At K 2025
Japan Steel Works (JSW) has now added to their standard line by introducing the world’s first ultra-large all-electric injection moulding machine (e-IMM) with a clamping force of 4,000 metric tons (40,000 kN). This development comes as a direct response to the increased global demand for lighter and more sustainable components, particularly in the automotive space. With electric vehicles steadily changing the face of mobility, it is increasingly critical to make lightweight exterior parts from plastic such as bumpers, tailgates, and battery cases. The new 4,000-ton class machine also has various industrial applications in agriculture, industrial machines, general merchandise, and home appliances; all of which involve the very large, durable, and precisely manufactured parts. This development should resonate particularly well in the US, where demand for large-scale injection moulding continues to increase.
Traditionally, hydraulic systems have dominated the market for large injection moulding machines, largely because of their ability to deliver immense clamping forces. However, hydraulic machines also present well-known challenges, including high power consumption, quality fluctuations, increased maintenance requirements, and slower production cycles due to limited speed and acceleration. These drawbacks often compromise both efficiency and sustainability in manufacturing operations. JSW’s newly developed all-electric system addresses these long-standing issues head-on. By integrating advanced electric drive technology, it delivers high productivity, significant energy savings, and consistently superior product quality. Furthermore, the machine’s robust construction and long-life design provide a clear differentiator in the marketplace, ensuring reliability and performance for years to come.
Main Specification and Features
The new J4000F-22000H, a two-platen machine, boasts a clamping force of 4,000 metric tons (4,400 US ton), and a maximum injection volume of 22,000 cm (approximately 18.6 kg of polypropylene). It has a step-change feature set:
•Greater productivity: The machine achieves the fastest dry cycle in the industry, providing the industry best productivity, and this productivity is 10% greater than today’s most advanced hydraulic systems with elder technology. The electric servo motor drag, along with unique JSW mechanical innovations were leveraged to achieve shorter cycle times and more throughput.
•Energy and cost savings: Compared to hydraulic systems, the J4000F-22000H reduces power consumption by 15–20%, cooling water by 50%, and hydraulic oil by 70%. These improvements translate into tangible operational benefits, including a 15–20% reduction in annual CO emissions and over 20% lower running costs, helping processors meet both economic and environmental targets.
•Space efficiency: Despite its size, the machine’s design emphasizes footprint optimization. At 17.4 meters, it is 12% shorter than comparable hydraulic systems, saving valuable factory floor space and enabling more flexible production layouts.
•Long life and robust design: The J4000F-22000H features a high-rigidity mould platen and clamping bed, along with a high-performance movable platen support mechanism. These design choices ensure long-term precision, reliability, and minimal maintenance over the machine’s lifecycle.
JSW at K 2025: Spotlight on All-Electric Technology
At K 2025 in Düsseldorf, JSW will present the entire line of all-electric plastics machinery, located at Hall 13 Booth B 77. In addition to injection moulding offers, the company will introduce more machine innovations in blow moulding and extrusion, showcasing its full suite of experience across multiple processing technologies.
The main injection moulding machines being presented are three J series flagship models with clamping forces at 800 kN, 2,200 kN, and 6,500 kN. The J series are known for their precision and quality, and show how committed JSW has been at developing their all-electric technology since the inception of the J series.
•The J80ADS (800kN) will showcase the production of a cover panel in recycled ABS, then demonstrate automated (SCARA) part removal and inspection with a 6-axis robot.
•The J80ADS presents the integration of automation and sustainability, two important developments.
•The J220ADS will feature as a two-component application using a FLiP auxiliary unit, showcasing advanced moulding flexibility.
The J650ADS (6,500 kN) will highlight cutting-edge developments in large all-electric machine design, continuing the trajectory set by the ultra-large 4,000-ton model.
These examples demonstrate the efficiency of all-electric systems which only consume electricity when actively clamping or injecting. This engineering layout lowers costs of operation and provides a clean operation, much needed by industries that need to have a sterilized area, such as medical applications and clean rooms. By eliminating hydraulic oil from the system, the chance for accidents and contamination are reduced, while producing quieter machines that produce less heat. Additional engineering elements such as air-cooled drives and OPC UA interfaces that can integrate with neighbouring equipment promote higher connectivity, efficiencies, and less complicated usability.
Global and European Presence
JSW’s presence in Europe is anchored by JSW Plastics Machinery Europe, headquartered in Warsaw. This operation coordinates a network of 16 agencies across the continent, ensuring strong local support. In Germany, KT-Sakkas has partnered with JSW since 2007, providing comprehensive sales, service, and spare parts. The company also designs complete injection moulding systems by working with leading suppliers of peripheral equipment. To strengthen its customer engagement, JSW operates a technical center near Herzogenaurach, where prospective clients can experience its all-electric systems first-hand and explore solutions for specialized applications, from multi-component and vertical moulding to advanced two-platen systems.
The introduction of the world’s first ultra-large 4,000-ton all-electric injection moulding machine once again places JSW at the forefront of industry transformation. With a focus on energy efficiency, reliability, and high-precision output, the company continues to drive progress in plastics manufacturing—supporting industries from automotive and electronics to healthcare and consumer goods.
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