 At KraussMaffei’s booth, automotive door modules are produced from former caps of insulin pens. The system supplier is presenting not only the machine hardware necessary for this but also new digital solutions.

Digital solutions are an essential component of the material loop from the insulin pen cap to the car door module.

16:9

Spritzgießen

Kunststoffverarbeitung: Verfahren

Messe K-Kunststoffmesse

kunststoffe-international.com

kunststoffe.de

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Kunststoff-Aufbereitung

Kunststoffverarbeitung: Maschinen und Komponenten

Energieeffizienz

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Spritzgießmaschinen

Medizinprodukte

Medizintechnik

Kreislaufwirtschaft

From the Insulin Pen Cap to the Automotive Door Module

The algorithms for identifying faults and optimization possibilities stored in assistance systems of injection molding machines are continually being expanded.

Intelligent assistance systems in the injection molding machine control help the machine operator to perform the work more efficiently.

Steuerungen (Hardware und Software)

Automatisierungstechnik

Digitalisierung

Intelligent Assistance Relieves the Strain on Production Staff

How do you bring 65 injection molding machines and various assembly lines – most of the manufacturing cells in the cleanroom – as well as, soon, a large number of ancillary equipment under one digital roof? A field report.

The Arburg host computer system ALS is the link between the shop floor and ERP system and connects order management with process and quality monitoring.

The Arburg Host Computer System as a Basis of Higher Productivity and Product Quality

Industrie 4.0 für die Qualitätssicherung

Doriat, Clemens, Dr.

Condition Monitoring / Prozessüberwachung

Instandhaltung

Kennzahlen, Q-Leitstand, Q-Monitor

Qualitätssicherung

Rückverfolgbarkeit, Traceability

Qualitätsmanagement

Montagelinien

Montagetechnik

Montage

Reinraumsysteme / -technik

Case Files for Patient Safety

Three solutions for increasing the productivity in the automotive, medical and packaging industries are presented by Tederic at K 2022 with the Neo injection molding machine series. T

The Neo·Ec combines electrical and hydraulic drives.

Mehrkomponenten-Spritzgießen

Polylactid

Kunststoff Werkstoffe

Thermoplaste

Spritzprägen

Applications in Three Key Sectors

iQ process observer, the new process monitoring platform from Engel monitors hundreds of parameters from the injection molding cell in the background.

The injection molder is truly not a friend of changes – if they occur in the running process. The iQ process observer helps him to keep an eye on the process and thus keep a handle on the quality

A Process Monitoring Platform Monitors Several Hundred Parameters Simultaneously

Prozessvisualisierung

Spritzgießmaschinen, allgemein

Spritzgießsimulation

Software

Simulation

IoT-Plattformen für die Kunststoffverarbeitung

An Eye on the Process –  a Handle on Quality

iQ motion control from Engel now allows reliable early start combined with fully automatically optimized motion planning. The assistance system has been part of the standard kit of all new Engel viper-type linear robots since October 2021.

If the robot travels into the mold area already during the mold opening movement, this can shorten the cycle time. The effect is particularly large in the case of parts with long cores, such as boxes

iQ Motion Control Brings the Injection-Molding Machine and Robot Closer together

Linearroboter für die Kunststoffverarbeitung

Handling, Handhabungstechnik

A Production Cell with Fluid Movements

Dr. Boy is picking up on the main themes of K 2022 with two trade show premieres and other specific applications. One of these themes, which Boy has espoused, is the digitalization or increasing networking of the plastics industry.

The diverse elements of the Boy digitalization package.

Hybridtechnik

New Control System before the Premiere

At K 2022, Engel, with its partners Alpla Group, Brink and IPB Printing, is presenting a quantum leap for the packaging industry. Thin-wall containers can for the first time be produced from PET directly by injection molding in only one process step.

Fig. 1. The thin-walled containers are injection molded from rPET.

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Schmelzefilter

Polyethylenterephthalat

Kunststoff-Rezyklat

Processing rPET by Thin-Wall  Injection Molding

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.

Schaumspritzgießen

Biokunststoffe

Naturmaterialien

Verstärkungsstoffe

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

Solar / PV

Energieerzeugung

Erneuerbare Energie

Temperiertechnik

Elastomer-Spritzgießen

Oberflächentechnik

Silikonkautschuk

Kautschuk / Elastomere

Compoundieren

It Can Be Done!

The iQ motion control assistance system from Engel optimizes the acceleration phases of mold movements and thus shortens cycle times.

The pressure to work efficiently is huge, especially in the packaging industry. The production of thin-wall containers clearly shows the potential of  iQ motion control to shorten cycle times.

iQ motion control Shortens Cycle Times in High-Performance Injection Molding

Elektrische Antriebe für Spritzgießmaschinen

Antriebe

Elektrische Antriebe

Qualitätssicherung Kunststoff

How about a Little Bit Faster?

The road to the energy-optimized injection molding cell is often stony. A saving plan can be drawn up when there is transparency about the individual consumers.

The most varied measures help to save energy, but not all of them are equally profitable for every company.

Nachhaltigkeit

Umweltmanagement

Transparency as a Basis for  Energy Efficiency

New process technologies, new machines – a selection of what will be on show at Fakuma 2023.

Making its debut at Fakuma 2023 is the next representative of the hybrid Hidrive series with new machine technology: an Allrounder 520 H in the “Premium” performance variant.

Solutions for Injection Molders

At Pharmapack 2023 Trelleborg Healthcare & Medical is showcasing e.g. application-specific hoses, LSR or thermoplastic injection moldings, and the production of parts using multicomponent processes.

At Pharmapack 2023 Trelleborg Healthcare & Medical presents e.g. application-specific hoses, liquid silicone rubber or thermoplastic injection moldings.

Mikrospritzgießen

Trelleborg Presents LSR Implants

In comparison to its existing custom manufacturing business area, Wirthwein Medical plans to achieve above-average growth with its own products.

Growth on the Second Pillar

Netstal presents new solutions for high-performance injection molding in Düsseldorf.

Netstal presents new solutions for high-performance injection molding in Düsseldorf. For example, an Elion 1200 all-electric machine will produce pipette tips in 64 cavities.

At the Netstal booth, the attention of visitors will be drawn by two powerful production systems. “Processors face tough competition from the challenge to increase their productivity and minimize costs per manufactured part. Short cycle times, maximum precision and high reliability of the machines are the principal levers. But the efficient use of resources is also relevant, for example minimized energy consumption or lower wall thicknesses,” says Renzo Davatz, CEO of Netstal and member of the executive committee of KraussMaffei. The appropriate solutions are at hand.

An Elion 1200 all-electric machine will produce pipette tips in 64 cavities. The system solution includes a precision mold from Otto Männer and a high-speed handling system from MA micro automation. It processes an electrically conductive compound from Premix, specially developed for manufacturing pipette tips for in vitro diagnostics. The pace is set by the energy-saving injection molding machine equipped for medical production, which achieves a cycle time of about 5.3 s, which is particularly fast for this application. The machine is equipped with the “Smart Operation” 4-key control unit (Fig.). This option allows users to achieve additional productivity increases by automation, standardization and shortening of recurring process steps in shift operation. For customers from medical technology, the regular calibration of the injection molding machines acc. to ISO 17025 is also interesting – Netstal has been an accredited calibration lab since the end of 2021.

The enhanced Elios 4500 is celebrating its trade show premiere. By conversion to an all-electric positive connection, the dry cycle could be accelerated by 0.1 s. Users not only benefit from increased productivity, but also from the optimized energy efficiency: with respect to the dry cycle, the average power consumption falls by 7 kW. Another bonus is provided by the 450 mm shorter machine length. The machine will manufacture thin-walled 150 ml yogurt cups by in-mold labeling (IML) from a certified renewable PP from Sabic. The material is based on tall oil, a waste product of paper manufacturing. One cup weighs only 6.5 g. The 12-cavity mold, like the handling system, is from IML Solutions. The cycle time is about 5 s. The in-mold labels from Verstraete are provided with digital watermarks of the HolyGrail 2.0 initiative. Codes invisible to the human eye are printed on the entire surface of the label. The machine-readable codes contain information about the contents, packaging material and origin and thus permit homogeneous separation of different types of plastic.

As a member of the OPC Foundation, Netstal is advancing the development of the OPC UA interface standards for plastic machinery. At the tradeshow booth, Netstal will present the complete ancillary integration of a manufacturing execution system from bfa solutions, temperature-control equipment from HB-Therm and Gammaflux hot runner control equipment. In addition, Netstal participates in the OPC US showcase from VDMA. All the Netstal machines exhibited at K, including those at partner booths, are integrated in the umati demonstrator. The show visitors can scan the QR codes applied to the machines with their smartphones and thus obtain information about machine, status, the current job as well as process values in real time in the umati app.

NETSTAL Maschinen AG  

https://www.netstal.com

aXos control unit with “Smart Operation:” the guided machine operation enables users to achieve additional productivity increases.

2022-10-10 - Netstal

issue 07/2023

issue 06/2023

issue 05/2023

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