Many so-called “low carbon footprint technologies” are already available and could be utilized immediately in plastics processing. But what carbon reduction measures are not only environmentally effective? Using practical examples, gwk shows how the use of efficient temperature-control technology rapidly pays off economically, too.

Fig. 1. Differences in power consumption and quantity ratio

Even in Difficult Economic Times, It Is Worthwhile Investing in Energy-Efficient Temperature Control

Spritzgießen

Kunststoffverarbeitung: Verfahren

Temperiergeräte

Kunststoffverarbeitung: Maschinen und Komponenten

Gießanlagen

Temperiertechnik

Energieeffizienz

Advantages through Sustainable Temperature-Control Technology

New polymer composites for the production of multi-layer small tubes are being developed to give products specific functions. With suitable co-extrusion dies and a thermal barrier option, even complex layer composites with melt temperature differences of more than 50 °C can be processed reliably and in high quality.

CV-T 5-layer co-extrusion die in pilot plant operation: tubes with small cross-sections that fulfill a multitude of demands can be produced by  co-extrusion

Combining Polymers with Very Different Processing Temperatures

Extrusion

Baugewerbe (Hoch- und Tiefbau)

Medizintechnik (KU)

Kunststoffverarbeitung

Bautechnik, Sanitär

Rohr- und Profilextrusion

Extrusionswerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Extruder-Folgeeinrichtungen

Extrusionsanlagen

Extrusions-Zubehör

Automotive

Fahrzeugbau

Co-Extrusion with Thermal Control

In order to minimize the risk of contamination in the production of medical products, Scholz HTIK (High Tech in Kunststoff) decided to change its temperature control processes from oil to water as a heat transfer medium.

P230S temperature control unit with mobile water treatment system waterCare in operation

Processing of High-Performance Plastics without Purity Problems

Medizintechnik

Temperature Control with Water up to 230 °C as a Substitute for Oil

Starting with the systematic design of manufacturing processes and the precise simulation of part manufacture, through smart tooling technology and sophisticated melt guidance, to efficient mold temperature control, numerous exhibitors have many innovations in the field of tooling technology on offer at K 2019.The current debates concerning marine pollution as well as anthropogenic climate change and its consequences seem to be having an effect at this world-leading trade show for plastics processing in Düsseldorf, Germany. A number of companies are noting the growing customer interest in sustainable, carbon-neutral and resource-efficient modes of production, and offering products and services intended to satisfy this interest.

Resource-Efficient and Environmentally Friendly Products Are the Trend in  Tooling Technology

Werkzeuginnendrucksensoren

Messtechnik

Sensoren / Messwertaufnehmer

Normalien für die Kunststofffertigung

Normalien

Spritzgießwerkzeuge

Spritzgießsimulation

Software

Simulation

Heißkanalsysteme

Komponenten für die Kunststoffverarbeitung

Kaltkanalsysteme

Exhibitors See Green

Hammann markets its own developed pulsed flushing process under the name Comprex. The flushing technology is a purely physical process, which does not use any chemicals – just air and water.

Multi-cavity mold for manufacturing preforms for PET bottles © Hammann

Cleaning of Mold Cooling Channels for PET Preforms

Werkzeugreinigung, Kunststoffe

Avoiding Shutdowns

The ZKW Group manufactures premium lighting systems for automotive customers. In order to be able to produce trouble-free and in permanently high quality in the injection molding process, several hundred temperature control units from HB-Therm are also used, among others.

ZKW manufactures both complete lighting systems and the necessary components, such as diffusers and lenses or the associated electronics

16:9

The ZKW Group Manufactures Innovative Lighting Systems for the Automotive Industry

Kfz-Leuchten, Beleuchtung

Elektronik

Kfz-Systeme

KFZ-Zulieferer

Dienstleistungen

Where Night Becomes Day

Comprehensive standard equipment, lifetime warranty on key components – HB-Therm presented at Fakuma 2021 the new Series 6 generation of temperature control units. With the Thermo-6 temperature control units, the Swiss company has also further developed equipment technology, improved energy efficiency and expanded digital services.

This is what the Thermo-6 series looks like. The smallest of the three was introduced to the market in October 2021. The larger and more powerful variants are expected to follow in 2022 and 2023.

HB-Therm: Sixth Unit Generation Celebrated Premiere at Fakuma

Spritzgießen (KU)

Tailored to Injection Molder’s Needs

Frigel introduces the latest developments in cooling and mold temperature control solutions at K 2022.

The Microgel RS series includes high-performance single- and dual-zone temperature control units.

Messe K-Kunststoffmesse

kunststoffe-international.com

kunststoffe.de

High-Performance Mold Cooling

The fifth broadcast by arburgXvision was all about the exciting question of how productivity can be optimized by bringing together technology, organization and digitalization in the ideal manner.

Christoph Kiefer, Team Manager Technical & Commercial Sales Support (left), and Dr Thomas Walther, Head of Application & Process Development (center), had a discussion with presenter Guido Marschall on how to increase production efficiency by taking advantage of “hidden benefits“

Automatisierungstechnik

Spritzgießmaschinen

5. arburgXvision: „Savings through Hidden Benefits!“

For the further development of the Streamrunner and also for customer demonstration purposes, Hasco hot runner has developed an innovative 32 cavity injection mold tool.

The special feature of the mold is the 32-cavity Hasco Streamrunner

Normalien und Heißkanaltechnik

New Design Possibilities in Moldmaking

The process stability of injection moulding is negatively influenced by disturbing influences. An adaptive, close-phase process control strategy, which defines the reference curve for a subordinate cavity pressure control, should enable constant part quality. The influences of the cyclical changes are analysed for different control strategies by evaluating the process variable curves and the part weight during the start-up process. Up on that, it is evaluated whether the examined process variables are relevant for process control and therefore cyclical adjustments of the cavity pressure reference are necessary.

Prozesssimulation

Effects of cyclical process influences on the cavity pressure curve and part quality in the injection moulding process

With a new process, Engel makes it possible to process plastic waste as flakes in injection molding directly after grinding. Since a complete process step, pelletizing, is eliminated, the innovation significantly improves cost efficiency in plastics recycling.

The aim of the innovation is to process plastic flakes, for example, from post-consumer collection, directly in injection molding without pelletizing

Kunststoff-Recycling

Kunststoff-Aufbereitung

Kreislaufwirtschaft

Processing Plastic Flakes Directly

Frank Schuster, Regional President Metai, takes over the management of Engel Machinery India. Stalinjose Selvanayagam is the new Sales Director.

Frank Schuster, Regional President Metai, is the new Managing Director of Engel Machinery India

New Leadership at Engel Machinery India

Kistler’s ComoNeo process monitoring system is now much more precise thanks to an envelope curve adapted to the process, and is WLAN-compatible for the first time.

Growing numbers of injection molding professionals seek resource efficiency and high product quality. The solution: the ComoNeo process monitoring system

Qualitätssicherung Kunststoff

Qualitätssicherung

Everything under Control

Aside from offering high mechanical strength, versatility and durability, polymer materials are ideal for applications in the electrical industry because of their ability to isolate electrical current.

For the conduction cooled MicroTCA systems, Harting processes LCP, a material that is flame-resistant, dimensionally stable at high temperatures, chemically resistant, and has only a low thermal expansion

Connectors for Industrial Lifelines: High-Tech Injection Molding at Harting

Hybridtechnik

Polymere, flüssigkristalline

Kunststoff Werkstoffe

Thermoplaste

Stanzen

Verfahren für die spanlose Fertigung

Schneiden

Hybrid-Spritzgießen (Metall / Kunststoff)

Steckverbinder

Elektromechanik

Well-Balanced Hot Runner Technology for LCP Processing

Sixth Unit Generation Celebrated Premiere at Fakuma 2021

Comprehensive standard equipment, lifetime warranty on key components – HB-Therm presented at Fakuma 2021 the new Series 6 generation of temperature control units.

According to HB-Therm CEO Reto Zürcher, insights such as the practicality of the units in daily use and a brilliant touchscreen for convenient operation with modern designs and colors were not only derived from a comprehensive market analysis, but also from collaboration with key customers who brought the needs of injection molders into the evolution phase. “Our thoughts were influenced not only functionally but also visually. In addition, of course, we verified our findings repeatedly in practice for their suitability for everyday use. For us, highest quality has a clear foundation: And that means testing, testing and testing again!”

In addition to the lifetime warranty on the heater uniquely offered by HB-Therm for the predecessor units, customers of Thermo-6 units also benefit from a lifetime warranty on the ultrasonic flow meter. All components were designed to be extremely robust and durable. Martin Braun, CTO of HB-Therm says: “This step has been made possible by the expertise gained from the development of the high temperature water units Thermo-5 up to 230 °C!”

Based on the proven technology of the Thermo-5, the new units have been consistently enhanced, standardized and modelled with useful aids such as a visual alarm via LEDs in the front base area. The very low maintenance requirements also make the Thermo-6 attractive in terms of upkeep.

HB-Therm considers the standard integration of a speed-controlled pump in the new unit series to be part of its environmental commitment. With the Energy-Control Assistant, an optimal operating point can always be achieved, even without any prior knowledge on the part of the user.

The result is up to 85% less power consumption. In addition, a new sealless Direct-Drive pump is used for the units up to 100 °C, which was developed exclusively for HB-Therm together with a renowned pump supplier. This canned motor pump sets new standards in efficiency and compactness.

“A pump that does not always run at full load not only saves energy, but also has a longer service life. In addition, speed-controlled pumps can be used universally for large and small molds, thus reducing the variety of types of temperature control units. One unit for all tasks”, explains Martin Braun, Head of Development at HB-Therm.

A difference to the Thermo-5 that immediately catches the eye is the touch display of the Thermo-6, which is four times larger at seven inches. The operation is clearly oriented towards modern smartphones, allowing users to master the Thermo-6 in no more than ten minutes. Individual settings and favorite selection modes, plain text instructions with QR codes for further information, wizards for setting up the units, swiping and scrolling also make it easy to find the desired operating pages quickly on the display of the new Series 6 units. Graphic and text pages make intuitive navigation easy. The Expert system helps, warns, reports and optimizes unit operation. In this way, even complex setting procedures are very easy to handle.

The process data is recorded locally. Unit history and unit-specific documents such as certificates, calibration data, operating and assembly instructions can be displayed quickly and clearly on the new, large screen. Clearly arranged, setters and operators can always find exactly the parameter page they need quickly and with just a few clicks.

HB-Therm defines digitalization as contemporary, mobile, independent, useful and supportive. The future-oriented hardware and software architecture of the Series 6 allows comprehensive access to the digital world of HB-Therm. The digital solutions in addition to the standard OPC-UA Ethernet interface on each Thermo-6 are called Gate-6 and e-cockpit.

Gate-6 is an interface server that establishes the connection (gateway) to the Android app e-cockpit and the digital services of the HB-Therm world as well as between several Thermo-6 and/or Thermo-5 units and other external systems such as injection molding machines.

Gate-6 accesses the functions of the HB-Therm cloud via the LAN connection of the units. This allows users to send analysis data, track the “digital twin” in the company’s Ticket system, generate unit statistics and overviews as a part of customer service, the keeping of a maintenance overview as well as the preventive maintenance of the connected units.

The e-cockpit app is a mobile application for smartphones and tablets and accesses a Gate-6 locally as well as the temperature control units connected to it. It secures access to the company’s Ticket portal with several functions. Via this access, the user can, among other things, process error messages and warranty cases as well as obtain technical support. Ticket is therefore a central application that brings together data from several Gate-6 interface servers and temperature control units and makes it available online. This requires a central data server and Internet access. Recorded data and settings are only sent to HB-Therm Support if they have been released by the customer and in accordance with the highest security standards.

In addition to the standard features already mentioned, the Cleanroom package, OPC UA interface and pump status monitoring are now also standard. A separate screen protector is also no longer necessary, as the new screen has a very robust design. Also new, but available at a later date, will be filter screen monitoring. This makes it easy to clean clogged filters whenever the need for it actually arises.

HB Therm AG  

https://www.hb-therm.ch

This is what the Thermo-6 series looks like. The smallest of the three was introduced to the market in October 2021. The larger and more powerful variants are expected to follow in 2022 and 2023

HB-Therm attached great importance to the design from the very beginning. The units can also be customized in terms of color according to the customer’s wishes

The smallest of the new Thermo-6 series was presented for the first time at Fakuma 2021