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SPECIAL K 2010 Injection Molding

INJECTION MOLDING (2). The plastic industry’s global flagship trade show will soon
be opening its doors. While the 2009 crisis drove the balance sheets of almost all
injection molding machine manufacturers into the red, the industry is now looking
optimistically to the future and presenting the latest developments in machine tech-
nology. Electric drives will continue to absorb the professionals.

An Industry on Tenterhooks
That the global economy is back on a complete cycle, without the opera-
an even keel can be seen from the tor needing to understand the control
companies’ order books, some of in detail.
which are full to overflowing. Many V Hall 13, booth A13
manufacturers have profitably used
some of their free resources last year
for intelligent enhancements to their Wittmann Battenfeld
machine portfolio. At this year’s K Full Force Ahead
show, they will therefore serve up a
number of attractive innovations and Wittmann Battenfeld GmbH, Kot-
improvements in detail. Besides en- tingbrunn, Austria, is expanding the
ergy efficiency, which continues to be product portfolio of its PowerSerie
a hot topic, exciting trade show ex- machine series in the upper and low-
hibits are focusing on functional and er clamping force range. The common
process integration. feature of all machines is the concept
Fig. 1. The Selogica assistant guides the operator through the complete of an overall solution on the principle
cycle in only five logical steps (photo: Arburg) of “everything from one supplier.”
Arburg Numerous ancillaries and robots are
Control in combining an 8 mm screw for injec- ticated mold features, such as col- compactly integrated and are oper-
tion with a second screw for plasti- lapsible cores and multiple slide de- ated via one control, the Unilog B6.
Dialogue cizing the material. This process al- molding. The all-electric machine type, re-
With a total of ten exhibits, Arburg lows a conventional molding com- In a separate area on its booth, cently launched under the name
GmbH + Co. KG, Lossburg, Germany, pound to be used, which is guaran- Arburg is underscoring the impor- EcoPower, will be presented in vari-
is presenting a wide range of appli- teed to be processed on a first-in tance of its enhanced Selogica ma- ous models with clamping forces
cation-oriented injection molding so- first-out principle. The implementa- chine control (Fig. 1). Now, not only from 550 to 2,400 kN. The braking en-
lutions. The topic of energy efficien- tion as an injection module permits machine sequences can be pro- ergy of the drives, which is conven-
cy continues to hold a high status. the use of inexpensive standard ma- grammed and centrally operated, but tionally returned to the energy net-
The booth is therefore dominated by chine technology. also entire production lines with the work, is used directly by the machine
hybrid and electrical machines of the At the other end of the spectrum associated ancillary equipment and for powering the control system and
Hidrive and Alldrive series. In these of machine sizes, Arburg has ex- six-axis robots. A new control assis- for cylinder heating. One of the ex-
exhibits, Arburg presents high-speed tended the Hidrive hybrid machine tant permits accompanying menu- hibits, an EcoPower 180/750, with a
packaging applications from the field series with the new Allrounder 920 H guided set-up, or 4-cavity mold from Braunform GmbH,
of in-mold labeling, multicomponent with a servo-electric toggle clamping short teach-in of the produces a medical part for a dialy-
injection molding, including for liquid unit with 5,000 kN clamping force. entire mold se- sis unit under clean-room
silicone and thermoplastic, the pro- The large Hidrive machine will be quence. Only five log- conditions.
duction of a medical part and ex- running a technical application from ical steps have to be
tremely small parts with a new mi- the packaging industry, with sophis- performed to achieve
cro-injection module.
The new micro-injection module
picks up on an old idea that has not Fig. 2. The special
yet been realized in this way, i.e. design of the Macro-
Power in many cases
Translated from Kunststoffe 9/2010, permits the installation
pp. 34–41. Article as PDF-File at of bulky molds without
www.kunststoffe-international.com; a tie-bar puller (photo:
Document Number: PE110515 Wittmann Battenfeld)

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Injection Molding SPECIAL

ing point optimization sets the best than 3 s. In addition, direct quality
servomotor speed and swivel angle control takes place via a Q-Vision
of the control pump to ensure maxi- system.
mum efficiency of the drive system for Engel is also presenting a new
each velocity and pressure size. small electrical injection unit, which
Engel is meeting the market’s is available for screw diameters 15,
high demand for closure cap produc- 18 and 20 mm, in two drive options
tion with an all-electric solution. The in each case, with injection speeds
newly designed e-cap (Fig. 3) is up to 330 mm/s (Standard) and
equipped with an improved premium 550 mm/s (High). The optimized
design of the injection unit, in- screw geometry, in conjunction with
creased ejector force and a more a specially designed filling opening,
Fig. 3. The e-cap is an all-electric solution for closure cap production powerful mold closing drive. In a permits standard granule types to be
(photo: Engel) trade show demonstration, an e-cap used. On the e-max 50/50 and e-vic-
3940/420 T produces closure caps tory 50/28, it allows reproducible
With the presentation of the cally adjustable control pump. Spe- from PE-HD on a 96-cavity mold from shot weights of below 1 g.
MacroPower (Fig. 2) with up to cially developed software for operat- Schöttli AG in a cycle time of less V Hall 15, booths C58 and B42
10,000 kN clamping force, the tradi-
tional manufacturer also has a gen-
uine large machine in its product port-
folio once again. Another advantage
of this machine generation is the sim-
ple mounting of molds from the rear
of the machine. The extended guard
mesh stroke at the rear side and rel-
atively short tie bars – the locking
system is integrated into the clamp-
ing plate – permit the installation of
bulky molds in many cases without a
tie-bar puller.
The newly developed all-electric
MicroPower micro injection molding
machine is presented in the two
clamping force sizes 50 and 150 kN.
The modular machine system is
equipped with a two-stage screw-
plunger injection unit with a shot vol-
ume of 0.05 to 3 cm3, and consists of
a basic platform, which can be ex-
tended in a modular system with a
turntable, removal handling, quality
control, clean-room module, right up
to a complete production cell (see
page 99).
V Hall 16, booth D22

Engel
Energy Efficiency
across All Series
Energy-saving systems were at the
heart of this year’s appearance by En-
gel Austria GmbH, Schwertberg, Aus-
tria, comprising eleven machine pre-
sentations. One of the focuses is the
Ecodrive servohydraulic drive system,
which has just become available for
type Duo large machines. Since these
machines require longer holding pres-
sure times, in this case stable hold-
ing pressure control is provided by a
servomotor together with an electri-

Kunststoffe international 9/2010

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SPECIAL K 2010 Injection Molding

KraussMaffei
Energy
Budget under Fig. 4. Clean-room com-
Control patible: The encapsulated
The latest development activ- joints of the Z-toggle and
ities from KraussMaffei Tech- the exposed tie-bars of
nologies GmbH, Munich, Ger- the EX series eliminate
many, also focus on energy ef- potential sources of con-
ficiency. Their trade show tamination
booth was therefore dominat- (photo: KraussMaffei)
ed by all-electric machines.
KraussMaffei is pursuing the strate-
gy of covering the variety of, in many
cases, very different demands on all-
electric machines in various indus-
tries with two fundamentally differ-
ent series. The AX series covers the
demand for inexpensive, resource-ef- Dr. Boy Ferromatik Milacron
ficient solutions for the production of Compact Automatic Injection Molding One for All
technical parts in the electrical/elec-
tronics applications and the automo- Machines “The result of intensive development
tive industry. The 16 exhibited machines from by Dr. Boy GmbH & Co. KG, Neustadt-Fern- work” – Ferromatik Milacron Maschi-
Products such as medical articles, thal, Germany, with clamping forces up to 1,000 kN show the entire technical nenbau GmbH, Malterdingen, Ger-
which place high requirements on bandwidth of compact automated injection molding technology. A highlight is many, unveils its new F series. From
the ambient conditions during man- the recently launched Boy XS series, with a total of nine machines, which can 2011, it is intended to successively
ufacturing can be produced on the EX be used to produce microparts and small parts with injection volumes between replace the existing all-electric (Elek-
series (Fig. 4). It emits fewer parti- 0.1 and 8.0 cm3 (Fig. 5). The manufacturer supplies the models optionally as tra), hydraulic (K-Tec) and hybrid
cles and less heat, and both the horizontal machines or as automated overmolding machines with footprints of (Vitesse) series. After complete mar-
clamping unit and injection unit are 0.8 and 0.6 m2 respectively. Ancillary and handling equipment are also inte- ket launch, the modular machines
clean-room compatible. Fewer, en- grated without increasing the footprint. will be available in ten clamping force
capsulated joints of the Z-toggle By the sprueless production of microparts from medical technology, Boy is classes from 500 to 6,500 kN. The
used, and exposed tie bars minimize demonstrating its machines’ clean-room compatibility acc. to ISO 14644-1. platform philosophy of the F-series
the risk of part contamination. Plas- Space is also made available for the Boy E series, which, with servo-motor permits the individual modules to be
tication and injection take place via pump drives, attempts to combine the advantages of traditional hydraulic ma- combined into a tailored product. The
two coupled direct drives. The elec- chines with the energy efficiency of electrical machines. user can choose between electrical-
trical main drives are water cooled V Hall 13, booth A43 ly and hydraulically driven individual
and permit direct dissipation of the axes, depending on how he distrib-
heat, so that the thermal loading of utes his priorities between perform-
the production environment is sig- ance and energy consumption, move-
nificantly reduced. The EX series can ment characteristics and positioning
be equipped with a high-perform- accuracy. With this offer, Ferromatik
ance unit that permits injection is focusing clearly on the packaging
speeds up to 600 mm/s. This permits and consumer goods industries and
the machines to produce thin-walled medical technology.
articles if required. At the K, the machine manufac-
A new energy analysis tool per- turer presents an F 160 with 1,600 kN
mits the current power consumption clamping force and an injection unit
to be determined. Via the machine of size GP 50 with a screw diameter
control, the instrument, developed of 50 mm (Fig. 6). The machine pro-
together with the chair of Engi- duces PP packaging on a two-cavity
neering Design and Plastics Ma- mold from the Italian mold manufac-
chinery of the University of Duis- turer Incos Stampi S.r.l. in a cycle
burg-Essen, Germany, shows the time of 6 s. Ferromatik Milacron is un-
specific energy consumption online derscoring its ambition as a system
for different machine functions, e.g. supplier with another innovation: the
plastication, injection and holding FMR 8-5 Advanced robot, which re-
pressure, and the energy consump- moves the injection moldings and
tion of the cylinder heater, to aid the stacks them. This is a product of
use in locating an energy-optimized Wemo Automation AB of Sweden. In
operating point. Fig. 5. The Boy XS series offers fully fledged machine technology for the future, the robots will be available in
V Hall 15, booth C24 production of microparts on a small footprint (photo: Dr. Boy) six sizes and two models (basic and

24 © Carl Hanser Verlag, Munich Kunststoffe international 9/2010

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Injection Molding SPECIAL

keyboard with trackball and two mon-


itors. The lower monitor is used for
programming the process with freely
selectable parameters. For a more
comprehensive picture of the control,
a training center has been set up in
the top story of the booth.
With the PET line Plattform 2000,
Netstal has so far covered the lower
cavity range with 24 to 48-cavity
molds. Together with the mold man-
ufacturer Otto Hofstetter AG, Netstal
has now succeeded in operating 60
cavities, which were previously filled
Fig. 6. Focus on modular design and on a 3,500 kN machine, on the small-
three industries: The new F-series will supersede the er platform with 2,000 kN clamping
existing models (photo: Ferromatik) force. The demo at K produces 0.5 l
preforms with a weight of 15 g in a
cycle time of 9 s and, with a volume
advanced). The robot control in each and precision. In the clamping force of different screw and injection of over 24,000 units/hour, achieves
case is integrated into the machine range up to 4,500 kN, the series is plunger diameters.
(Mosaic). equipped with a kinematically im- V Hall 15, booth A41
In addition, Ferromatik has two proved 5-point toggle system; from
more exhibits: a Vitesse demon- 5,300 kN, it has a newly developed
strates an in-mold labeling applica- compact twin-platen solution. Netstal
tion on a 4+4-cavity stacked mold and The all-electric machines from Hybrid High
an Elektron, a budget machine based Zhafir Plastics Machinery GmbH,
on the Elektra and assembled at Mi- Ebermannsdorf, Germany, on the oth- Speed
lacron China, produced a visiting card er hand, are aimed at technically Netstal-Maschinen AG, Näfels,
case on a mold from the sister com- challenging production tasks requir- Switzerland, presents the Elion se-
pany DME. The special feature is the ing high precision, repeatability and ries, expanded with clamping force
Quick Strip demolding unit, which ful- speed. Besides the “packaging” vari- sizes 2,200 and 2,800 kN, in which the
ly automatically triggers demolding ant Venus/p, which is immediately electrical clamping units can be com-
of the molded parts during mold available in Europe, and offers high bined with the hybrid clamping units
opening without the need to actuate acceleration during injection, the of the Evos series. The dry cycles of
the machine ejectors. completely newly developed Zhafir about 1.4 s that are feasible permit
V Hall 15, booth C06 Mercury series (Fig. 7) is also on the use of machines in fields that have
show, which takes a new approach so far been the preserve of all-hy-
with some technical solutions: for ex- draulic machines. Fig. 8. With the freely programmable
Haitian ample, the tie bars simultaneously Netstal is also demonstrating the aXos control, the process sequence can
A New Approach act as side-wall braces, the number performance of the newly developed be tailored to requirements (photo: Netstal)
of moving parts in the clamping sys- freely programmable sequence con-
in All-electric tem has been clearly reduced, and troller aXos (Fig. 8), which is intended
Machines the separation of plastication and in- to permit tailored process sequences an unparalleled output for this size
The Haitian International Holdings jection unit – unusual for this ma- and rapid and flexible process design. according to the manufacturer.
Ltd. group of Ningbo, China, is pre- chine size – permits the combination The controller consists of a folding V Hall 15, booth D24
senting the latest models of its two
brands Haitian and Zhafir at a joint
booth. Haitian is targeting its prod-
uct portfolio at the competitive pro-
duction of standard parts. Besides Fig. 7. The entirely
the twin-platen Jupiter machine, the newly developed
company is therefore presenting the all-electric Mercury
energy-saving Pallas series and the series takes a new
new Mars Eco hybrid machine series. approach with its
The latter is available with immedi- design details
ate effect in several clamping force (photo: Haitian)
classes between 600 and 10,000 kN
– with a more modest package of op-
tions than the full version, but less
expensive. For Pallas, Haitian has
combined the energy properties of
the Mars series with greater speed

Kunststoffe international 9/2010 25

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SPECIAL K 2010 Injection Molding

Desma Negri Bossi


Servohydraulic Electrified in All
Vertical Machine Variations
Klöckner Desma Elastomertechnik The traditional Italian brand Negri
GmbH, Fridingen, Germany, presents Bossi S.p.a., Milan, Italy, part of the
the completely redesigned Benchmark Sacmi Group, is presenting a new
S3 vertical machine. For the first time, “Full Electric” series of injection mold-
an energy-efficient servohydraulic con- ing machines with belt drives and en-
cept with a twin-pump system is used, ergy recovery, and the development
which at Desma is designated “Servo of the BiPower, Vector and Janus hy- Fig. 10. Similar energy efficiency to an all-electric machine: the Janus
Gear.” The patented Fifo A injection brid machine series, as well as the re- with "Smart Energy" system (photo: Negri Bossi)
unit has been overhauled; the new vamped all-electric VSE series. In hy-
generation, “Fifo-Advanced,” increas- brid machines, the intelligent combi-
es the range. Thus large silicone plug nation of electric and hydraulic drives The Janus (Fig. 10), is an almost tomer. The PA body and the rubber
systems can be integrated even with is being pursued with different aims completely electrically operated ma- component each weigh 3 g. The total
small injection volumes. Another in- depending on the application. The chine with a hydraulic injection axis. cycle time is 60 s. The preform is
novation in the Version S3 is the hy- BiPower, available with clamping Also to be seen is a unit with 3,300 kN transferred to the rubber side via an
draulically operated “PlastControl“ forces from 12,000 to 60,000 kN, is an clamping force, which – equipped index plate; vulcanization takes place
nonreturn valve. The plant is equipped almost completely hydraulically op- with the so-called “Smart Energy” in the mold.
with the new DRC 2020 HT operating erated twin-platen machine with system – promises a similar energy V Hall 15, booth B24
terminal, which forms the visual hu- electrical plastication, which, at K, is efficiency to all-electric machine con-
man-machine interface. Within this integrated into a complete manufac- cepts. The company’s presence is
unique system, the terminal also gives turing cell as VH1500. Similar con- rounded off by the presentation of the
sensitive feedback to the operator. siderations apply to the Vector, all-electric VSE series, which, like the
V Hall 16, booth F56 though it has a toggle clamping unit. hybrid machines, is completely digi-
tally controlled and, with servohy-
draulic drives, achieves a significant
Sumitomo (SHI) Demag increase in energy efficient compared
Intercontinental Platform Strategy to conventional concepts.
V Hall 15, booth B22
Sumitomo (SHI) Demag Plastics Machinery GmbH, Schwaig, Germany, is demon-
strating the first results of its platform strategy, which is defining the future de-
velopment of all-electric, hybrid and hydraulic machines. Thus, the newly pre- Billion
sented IntElect Smart, with a clamping force of 4,500 kN extends the top end All-electric
of the all-electric machine spectrum. The concept of air-cooled direct drives that
are specially designed for injection molding machines and therefore feature Thermoplastic-
rubber Process
Billion S.A.S., Bellignat, France, is un-
derscoring its competence in multi-
component applications with the all- Fig. 11. Two-component single-step process:
electric 2-component machine Select With the mold, geometrically challenging thin-
H150-260/150T (Fig. 11), whose two walled sealing membranes are produced in
injection units produce a gastight, PA6.12 and rubber (photo: Billion)
ozone-resistant membrane for the gas
appliance industry. For the production
of the part, a mold from Motzener
Kunststoff- und Gummiverarbeitung Presma
Fig. 9. The refined hybrid concept of the El-Exis SP series is particularly GmbH was adapted from a hydraulic Micro-injection
targeting high-speed packaging applications (photo: Sumitomo Demag) to an electrical injection molding prin-
ciple, while integrating all the move- Molding
minimum power loss has already proven its worth in the SE machines from Sum- ments and functions into the (Dixit 3) with Elastomers
itomo (SHI) and is now available as a joint platform for both series. machine control. According to the
The new El-Exis SP series (Fig. 9) has a refined hybrid concept. Covering a manufacturer, the result is a genuine Presma SPA, Varese, Italy, will
clamping force spectrum from 1,500 to 7,500 kN, it is targeting high-speed one-step process, which, in the used demonstrate several examples of its
packaging applications. The result of the enhancements to the El-Exis can be material combination of a polyamide special machine program, including
seen in the greater dynamic response and precision of the hybrid drive of the and a rubber component, makes an for elastomer and silicone process-
clamping unit. The NC5 control, too, has some new features. The operator can adhesion promoter unnecessary. The ing to expert visitors. One of the chief
now specifically adapt the machine’s dynamic response to the application with three-zone screw from Billion, due to innovations is the all-electric Pres-
a slide control, in order to save cycle time in important areas. the low compression and shearing, mall mini-injection molding machine
V Hall 15, booth D22 permits gentle processing of the elas- with 60 kN clamping force, which can

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Injection Molding

BMB
Efficiently Packaged
BMB Spa, Brescia, Italy, is also placing energy efficiency at the center of its trade show appearance. Two
all-electric exhibits and one hybrid machine, in which only the injection axis is hydraulically driven, will
be demonstrating this by manufacturing packaging articles. An all-electric eKW16Pi/480 (Fig. 12) with
1,600 kN clamping force manufactures four PP drinking cups with a cycle time of about 2.1 s in an IML
application. In addition, a manufacturing cell with an eKW28Pi/1300 machine molds and then packages
a set of plastics flatware. The third exhibit, a hybrid machine with 7,000 kN clamping force produces 32
yoghurt cups in a stack mold in 5.5 s.
V Hall 13, booth A33

Fig. 12. Electro-


mechanical
details: The
eKW16Pi/480
operates in an IML
application
(photo: BMB)

be equipped with a feed unit for rubber or liquid or K show. Admittedly, not least because of the cri-
solid silicone (Fig. 13). sis, the weight has shifted between Asia and Eu-
A further innovation is based around the rope and within Europe in the last three years. Nev-
RS 300/4000F vertical press (see page 58) and tar- ertheless, the individual companies are each ca-
gets conventional rubber and LSR processing. For pable of offering competitive solutions with dif-
cycle time optimization using insert parts, the twin- ferent detail solutions.

Fig. 13. The all-


electric Presmall
mini injection
molding machine
can be equipped
with a feed unit
for rubber or sili-
cone (photo: Presma)

platen machine is equipped with a displaceable Besides the sustained trend towards all-elec-
ejector table, which permits the use of two lower tric machines and different measures for improv-
mold halves with a fixed upper mold half. ing energy efficiency, there are a conspicuous num-
V Hall 15, booth C57 ber of refined hybrid machine concepts. Similarly,
with hydraulic systems, most manufacturers have
Summary introduced servo pumps. An attentive excursion of
the trade show may give the visitor a clue as to
For the injection molding industry it is clear that ru- which of the presented solutions will become suc-
mors of its death have been greatly exaggerated. cessfully established on the market. 
Almost all world-ranking injection molding machine Oliver Grönlund,
manufacturers are impressively represented at the Aachen, Germany

Kunststoffe international 9/2010

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