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

Under the motto “It‘s all Wittmann”, Wittmann Battenfeld is presenting its machines and systems in the new Wittmann design for the first time.

Automation cell with SmartPlus 90 for manufacturing a spirit level.

Messe K-Kunststoffmesse

kunststoffe-international.com

kunststoffe.de

Spritzprägen

Energieeffizienz

Naturmaterialien

Verstärkungsstoffe

Kunststoff-Rezyklat

Green DC Current for the Injection Molding Machine

This year, the world’s leading trade show K has succeeded in presenting practical solutions for greater resource efficiency on a broad front. A first foray through the trade show grounds.

K 2022 gave numerous practical examples showing visitors how recyclates can be reliably processed with digital aids.

State-of-the-Art Injection Molding Solutions for Greater Resource Efficiency.

State-of-the-Art Injection Molding Solutions at K 2022

Doriat, Clemens, Dr.

Solar / PV

Energieerzeugung

Erneuerbare Energie

Temperiertechnik

Handling, Handhabungstechnik

Automatisierungstechnik

Elastomer-Spritzgießen

Digitalisierung

Silikonkautschuk

Kautschuk / Elastomere

Compoundieren

It Can Be Done!

Bio-Fed and Günther Heisskanaltechnik have performed various trials, which show that even supposedly sensitive bioplastics can be reliably processed in hot runner molds.

Fig. 4. Interchangeable inserts for various test samples can be installed in the two-cavity trial mold.

Bio-Fed and Günther Heisskanaltechnik have performed trials, which show that even supposedly sensitive bioplastics can be reliably processed in hot runner molds.

While Processing Trials Proved Highly Successful, an Intuitive Feeling Is Required

Processing Bioplastics  in Hot Runners

Until recently, common defects of the cardiac septum required open-heart surgery to seal them. Such holes can be sealed in a minimally invasive way with a transcatheter plastic implant. For this purpose a fully biodegradable umbrella-occlusion system has been developed. 

Laserschweißen

Medizintechnik

Absorbable Implant: An Umbrella for Mending Broken Hearts 

The market and technology behind bioplastics is going from strength to strength, enjoying high growth rates and a rapidly widening polymer base. The main driving forces are major plastics users and innovative companies. They are creating new raw materials platforms for established plastics that are now partially or wholly biobased. Whereas compostable plastics are focused on a few segments, “drop in” bioplastics are increasingly going mainstream. The only fly in the ointment is the skeptics – not content with scaremongering about oil and gas recently, they are now casting doubt on renewable resources. 

Growth despite High Hurdles: Bioplastics 

When the organic waste bin in the kitchen is full, it needs to be taken – usually dripping, stinking and full of semi-decomposed waste – to the trash can. For this purpose, BASF SE, Ludwigshafen, Germany, has developed organic waste bags made from ecovio FS, a compostable polymer. The bags make collecting and disposing of organic waste cleaner, less complicated and more hygienic. Unpleasant odors and pest infestations are prevented. This eliminates the hassle of scrubbing the bin in the kitchen, because the very good wet strength of the bags prevents liquid from teabags or fruit residues from leaking through. The bag remains intact. 

Decay on demand 

Organic Waste Bags Made from Ecovio FS 

Recent surveys by the European Bioplastics Association predict a fivefold increase of global bioplastics production capacity to almost 6 million tons between 2011 and 2016. Processors will have to get prepared for this new material, come up with solutions for the specific problems encountered when working with it, and optimize their processes. Injection molding of polylactide using hot runner technology is one step in this direction. 

Normalien und Heißkanaltechnik

Thick Film Technology: Bioplastics in Hot Runners 

For the first time, Lanxess has produced biobased polybutylene terephthalate (PBT) in a world-scale plant. It started from 1.4-butanediol (BDO) produced by a fermentation process from Genomatica with sugar as raw material. With this proof-of-principle trial, the specialty chemical group is underscoring its interest in chemicals based on renewable recources. 

Bio-Polybutylene Terephthalate: Opportunities for “Green” Plastics 

When organic waste spreads unpleasant odors and the trash bag tears on the way to the trash can, aggravation is preprogrammed. For this reason, a functional closure for reliable containment and safe transport is especially important. 

Environmentally Friendly and Reliable Closure 

Compostable Drawstring for “Organic Waste” Trash Bag 

Cost-effective manufacture of on-spec bioplastic components begins before the actual start of production. For example, pellets composed of hydrolyzable biopolyesters, such as polylactide, need to be pre-dried. Stabilizers can protect against loss of quality during processing and use in technical applications. Studies support this approach. 

Quality Assurance: Naturally Cost-Effective 

Comprehensive resource efficiency means far more than the preservation of natural resources. It also includes the productivity factors of material, machine and labor. The plastics industry has made a great contribution to resource efficiency, but often finds itself on the defensive. Yet a knowledge of the various relationships involved provides enough material to go on the offensive with arguments illustrating the benefits of plastics technology. 

The Plastics Industry Needs to Adopt a Bolder Approach 

Elektrische Antriebe

Verbundwerkstoffe / Werkstoffverbunde

Trockner

Extrusion

Pultrusion

Kunststoffverarbeitung

Resource Efficiency with  Plastics Technology 

Plastics packaging is one of the main contributors to the global waste mountain. To avoid potential environmental problems, biodegradable bioplastics are increasingly being used for this application. But what about the additives and colorants? A masterbatch producer provides the answer. 

Coloration with Biodegradable Color Masterbatches 

Masterbatches

Sustainable Solution for Coloration of Bioplastics 

When bioplastics are involved, there is never a lack of questions and controversy: Which markets offer the long awaited breakthrough? In which technologies does it pay to invest? Or wait and see what comes of the financial crises, the shale gas boom and the return of cheap coal? Do laws like those for biodegradable tote bags provide the groundwork for investment decisions and market success? 

Challenges for Bioplastics 

New Ideas and Political Markets  

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 09/2022

issue 08/2022

issue 07/2022

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