For a cutlery series made of a new biopolymer, three full hot runner molds with digital process monitoring were developed in close cooperation with mold maker Uniform and hot runner specialist Ewikon.

The 16-drop family mold on the machine. The removal and packaging of the parts are fully automated

16:9

Complete Digital Hot Runner Solution for Automated Biopolymer Processing

Spritzgießen

Kunststoffverarbeitung: Verfahren

Condition Monitoring / Prozessüberwachung

Instandhaltung

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Biokunststoffe

Kunststoff Werkstoffe

Virtual Reality für die Qualitätssicherung

Industrie 4.0

Industrie 4.0 für die Qualitätssicherung

Heißkanalsysteme

Komponenten für die Kunststoffverarbeitung

Process Reliability Is Crucial

Over past months, many in-house workflows and development processes have slowed down and also changed. Nevertheless, time has not stood still, also not in injection molding technology. The debate and development have been shaped by two themes: digitalization and the circular economy. Below are some examples of developments and projects that underpin this trend.

Two displays are seamlessly integrated into the continuously 3D-formed instrument panel

Innovative Injection Molding in Times of Pandemic

Schaumspritzgießen

Künstliche Intelligenz für die Qualitätssicherung

Steuern, Regeln

Software

Mehrkomponenten-Spritzgießen

Folientechnik (IMD, IML, FIM, u.a.)

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Spritzgieß-Sonderverfahren

Nachhaltigkeit

Umweltmanagement

Spritzgießsimulation

Simulation

Schnecken und Plastifiziersysteme

Spritzgießmaschinen

Industrie 4.0 für die Kunststoffverarbeitung

Machine Learning / Künstliche Intelligenz für die spanende Fertigung

Industrie 4.0 für die spanende Fertigung

Kunststoff-Recycling

Kunststoff-Aufbereitung

Lasermarkieren

Oberflächentechnik

Laserbearbeitungen

Inline- / Online-Messsysteme

Qualitätssicherung

Qualitätssicherung Kunststoff

Kreislaufwirtschaft

There Is More beyond the Horizon

Material savings in the packaging sector contribute to sustainability only if they also guarantee the safety of the packed product. Projects in this direction are already underway with the goal of developing an eco-efficient, flexible packaging material from renewable raw materials for both the food and the non-food sector. 

Packaging Materials: Both Ecological and Economical 

Glass fiber reinforced plastics (GRP) have so far been valued for their mechanical strength. But other criteria such as the weight, price, and climate compatibility of a material are also becoming increasingly important. This is where natural fiber reinforced plastics can offer advantages. A comparison with GRP shows their potential. 

Verbundwerkstoffe / Werkstoffverbunde

Compounds: Eco-Friendly and Cost-Effective 

It has recently become possible to make ceramics from highly filled wood-plastic composites (WPCs). Such biogenic ceramics afford a comparatively cheap way of making complex shapes. Parts can already be produced with very accurate contours. 

Wood-Plastic Composites: Ceramics on the Double 

Visions of the green economy, climate protection, the impending scarcity of resources, growing environmental awareness by consumers, and the construction of biorefineries are giving new impetus to the development of plastics. In addition, the market is increasingly demanding more climate-neutral, renewable products with a low carbon footprint and high sustainability. 

Trend Report (Part 1): Is the Future of Plastics Green? 

Tiles, too, can be bio – if they are made from renewable resources. With this aim in mind, the Fraunhofer Institute for Mechanics of Materials IWM, Halle, Germany, has developed a tiling system based on polylactide (PLA). The new tiles are more eco-friendly and lighter in weight than conventional ceramic materials. Their manufacturing process and material properties also make them more resource- and energy-efficient. 

Tiling system based on polylactide (PLA) 

Ceramics Made from Renewable Resources 

In surgical treatment of neck vertebrae inserts are often used which following removal of tissue from the intervertebral space prevent fusion of the vertebrae in an incorrect position. In order to overcome the disadvantages of previously used systems an absorbable metal polymer composite insert has been developed. 

Schäumen / Reaktive Verarbeitung

Medizintechnik

Research: Absorbable Spinal Implants 

Melt volume flow rate (MVR) measurements provide information on the flow behavior of a polymer melt. With wood plastic composites (WPC), MVR measurements allow the flow and viscosity functions of unknown compounds to be easily predicted. 

Rheology: Characterization of WPC Melts 

The number of biobased monomers and plastics is growing. “Green” polyesters and polyolefins, for example, can be sustainably produced from biomass, sugar or recyclate. Suitable technologies and plants are available. Applications include packaging and everyday utility items. 

Trend Report (Part 2): Is the Future of Plastics “Green”? 

Almost unnoticed by the public, a manufacturer of elastomer injection molding machines two years ago founded a subsidiary aimed at biodegradable materials. The development of natural fiber-reinforced biomaterials is now gaining speed, and their adaptation to injection molding is opening the door to a world of “green” applications. 

Natural-Fiber-Reinforced Biomaterials: Injection Moldings for the Compost 

The plastics industry is working intensively to cut greenhouse gas emissions and save energy in the manufacture of its products. Whether biomass or carbon dioxide is the right route to choose will be shown by the eco and carbon dioxide balance over the complete product lifecycle. 

Trend Report (Part 3): Is the Future of Plastics “Green”? 

A manufacturer of blow molded articles from Thuringia, Germany, has succeeded in mass producing bottles from a natural fiber compound. These bottles, which look as though they have been turned from wood and smell like wood, offer a promising alternative to conventional packaging and new application opportunities. 

Polyethylen

Füllstoffe für Kunststoffe

Extrusionsblasformen

Packaging: Bottles from Wood 

Excellent flame retardant properties can also be achieved using biobased plastics for high-performance applications. Most of the time, however, they are not perceived as being a serious alternative unless rethinking with a green bias has taken place, or whilst such new applications are being developed. 

Polyamide

Green Polyamides: Ecologically Flame Retardant 

Incineration and composting are no longer the only options for treating waste plastic packaging made from renewable raw materials. A solvent-based process now offers new ways for recycling polylactide packaging materials. 

Recycling: Recycling Biopackaging Materials 

ANA-U relies on injection molding technology from Wittmann to make molded parts from natural materials

Under the „Green Quality“ brand, the company ANA-U produces molded parts from natural ingredients consisting to 100 % of renewable materials. The parts are manufactured on an all-electric injection molding line from Wittmann.

ANA-U, established in 2007 by Ewald Ulrich, specializes in the development, production and global sale of cards, card printers and electronic components, as well as the development and design of lighting solutions for stationary retailers, shopfitters, museums and galleries. In addition to its facility in Gleisdorf, the company has another production plant in Austria and one in Shenzhen, China. In Japan, the company’s products are sold via a local agency.

For just under 3 years, ANA-U has been producing molded parts from natural substances under the „Green Quality“ brand. These consist to 100 % of plant-based renewable materials and are compostable just like wood. Typical products are event cards, voucher cards, wood-to-wood connecting parts and plastic-free housings. In this way, ANA-U has delivered, for example, 40,000 access passes for students of Karl Franzens University in Graz for the summer semester of 2022. For next year, the production of cards with imbedded electronics is planned as well.

The materials ANA-U is using for its Green Quality products grow again within one year. At present, the company keeps 100 tons of material in stock for its customers. The material mix is composed in-house according to each customer’s specific requirements. To provide a further benefit for the environment, Ewald Ulrich offers his customers to take back and recycle the Green Quality parts. The recycled material is then mixed with virgin material.

The Green Quality molded parts are manufactured on an all-electric machine of the EcoPower series from Wittmann Battenfeld with 1,600 kN clamping force. The EcoPower 160/750 is equipped with a fully integrated W918 robot, which removes the parts and deposits them on a conveyor belt. A Tempro basic C90 temperature controller and a Gravimax 14 gravimetric blender are also integrated in the machine’s Unilog B8 control system. The line is completed by a Coolmax C40 cooling device, an Aton plus 30–70 VS segmented wheel dryer, a Feedmax plus 206–40 material loader and a Dosimax MC Balance metering device.

In addition, the machine is fitted out with the HiQ Melt software package for monitoring the material quality, a feature of prime importance in processing plasticfree and recycled materials to enable fast response to viscosity fluctuations. A G-Max 12 granulator from Wittmann is used to recycle sprue, faulty parts and returned parts.

Ewald Ulrich and his son Sebastian, who is mainly responsible for the Green Quality product line, are very satisfied with the equipment from Wittmann. The most appreciated feature apart from the machine’s energy efficiency and low noise level is its high control accuracy. Ewald Ulrich comments: “Molded parts made of renewable raw materials require production machinery with high precision and extended options for parameter setting. This is provided in every respect by the EcoPower 160. In addition to the high quality of the machine, the perfect training programs and excellent customer support were decisive factors in reaching all our ambitious project goals.

Wittmann Technology GmbH  

https://www.wittmann-group.com/

Bio access passes for the students of Karl Franzens University Graz, printed with ink

from the left: Ewald Ulrich, CEO of ANA-U, Roland Pechtl, Regional Sales Manager

Wittmann Battenfeld, Sebastian Ulrich, Project Manager Green Quality projects ANA-U

2022-04-27 - Wittmann

issue 03/2022

issue 02/2022

issue 01/2022

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