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.

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

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

Spritzgießen

Kunststoffverarbeitung: Verfahren

Doriat, Clemens, Dr.

Solar / PV

Energieerzeugung

Erneuerbare Energie

Schaumspritzgießen

Temperiertechnik

Messe K-Kunststoffmesse

kunststoffe-international.com

Mehrkomponenten-Spritzgießen

Condition Monitoring / Prozessüberwachung

Instandhaltung

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Biokunststoffe

Kunststoff Werkstoffe

Handling, Handhabungstechnik

Automatisierungstechnik

Elastomer-Spritzgießen

Oberflächentechnik

Energieeffizienz

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Digitalisierung

Spritzgießmaschinen

Kunststoff-Rezyklat

Silikonkautschuk

Kautschuk / Elastomere

Kreislaufwirtschaft

Compoundieren

Kunststoff-Aufbereitung

It Can Be Done!

In plastics processing, efficient production methods are required, especially for articles with high volumes and exacting quality requirements, and these must be constantly optimized. The container specialist Walther Faltsysteme has been successfully working together with the Austrian moldmaker Haidlmair for many years.

Left: products which are manufactured using the technologies of the Haidlmair Group companies. Right: an application example with folding boxes

Walther Faltsysteme Combines Three Mold Technologies from the Haidlmair Group

Industrie 4.0 für die Qualitätssicherung

Paletten und Behälter

Logistik

Verpackungstechnik

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Heißkanalsysteme

Komponenten für die Kunststoffverarbeitung

With Broad Sword and Data Collector

Family molds belong to the state-of-the-art in injection molding – at least when wall thicknesses and volumes of individual components vary considerably. Using a trial mold soon ready for series production, Synventive demonstrates that – though demanding – optimal process control can be achieved using the right technology. The filling of each mold cavity is controlled individually and in real time. The Kunststoffe editorial team were among the first guests at the new Tech Center.

View into the mold space of the Engel Duo 2700 at the Tech Center. In the background, a 6-axis robot with 180 kg load-bearing capacity which removes the components.

Single-Shot Injection Molding of Heterogeneous Components

Schröder, Susanne

Leading-Edge Process Control

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

Production systems for large molded parts can be flexibly and economically reconfigured or expanded using hot runner adapter plates.

Melt transfer from two on the side injection units of an Engel v-duo 2300 RTM into the middle of the hot runner intermediate plate mounted on the sliding table. 

Economical Solution for the Production of Thermoplastic Large-Structure Components

Normalien und Heißkanaltechnik

Co-Injektion (Barriere-/Sandwich-Spritzgießen)

Flexible Injection Solutions  with Adapter Plates

We look behind the cavity walls and along the data cable at what hot runner technology now offers in terms of mechanical, electronic and digital expertise.

The smart Control monitoring unit permits integrated monitoring of the injection molding production cell, including the mold, hot runner system and all ancillary components. The “Luer connector” application case was on show at K 2022.

State-of-the-Art Injection Molding Solutions at K 2022: Hot Runner Technology

Mikrospritzgießen

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Mess-, Steuer- und Regelgeräte

Qualitätssicherung

Qualitätssicherung Kunststoff

Temperaturregler

Messtechnik

Sensoren / Messwertaufnehmer

Additive Fertigung

Everything under Control

Witosa is replacing titanium with 3D-printed steel elements in its hot runner systems. Its long-term goal is carbon neutrality.

Reducing the CCF through Titanium-Free Mold Constructions

Hot Runner, Carbon Neutral

Injection molding: Family molds can produce a wide variety of parts in a single shot. Where the challenges lie in process control.

Three at once: a six-axis robot removes the final injection-molded assembly, consisting of door trim, map pocket and sill.

One Tool, One Shot, Three Parts

A solution, which is unique in Europe, significantly increases productivity and comprises the production from a 12+12 stack mold with fully automated in-mold labeling and removal with visual 100 % inspection of the parts.

Before relocation to the production site, extensive functional tests and the final trial were carried out at the roth technical center

Fully Automated Production Line with Stack Mold and In-Mold Labeling

Award-Winning Packaging Solution Increases Productivity

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

Temperiergeräte

Gießanlagen

Normalien für die Kunststofffertigung

Normalien

Spritzgießsimulation

Software

Simulation

Kaltkanalsysteme

Exhibitors See Green

The new Reverse Cube developed by Foboha manufactures various components or multi-component parts from varying materials in one step and assembles individual parts into finished products independently from the cycle time using an integrated handling robot. The automated process improves quality, accelerates cycle times by up to 40 % compared to separate injection molding and assembly processes, and thus enables substantial productivity gains at lower costs.

Two thermally separated cube molds rotate in opposite directions at a 90° angle. Bottom: injection and cooling of component 1 (roller made of PP) and component 2 (female connection made of POM), staggered by 180°

Manufacturing and Installing Multi-Component Parts on a Two-Part Cube Mold

Montage

Montagetechnik

Steuern, Regeln

Werkzeugtemperatursensoren

Industrieroboter

Reverse Rotation

A Polish pharmaceutical company is developing inhalation therapy for the treatment of lung disease and the appropriate drug delivery drug. The inhaler has a complex interior and consists of 14 components. In order to be able to produce these with the required precision, Celon Pharma has formed a partnership with the mold making company Glittenberg and its hot runner sister Witosa.

For its complex functional mechanism, the inhaler requires 14 components

Glittenberg Supplies Tools for Vital Medical Devices to Celon Pharma

Medizintechnik

Medizinprodukte

Plastic in the Service of Medicine

Jessica Poliner has been appointed President of Barnes Molding Solutions. She replaces Norbert Scheid, who retired from Barnes Group in December 2020.

Jessica Poliner has been appointed President of Barnes Molding Solutions

Werkzeug- und Formenbau

New Management to Head Barnes Molding Solutions

The Institute for Plastics Processing (IKV) at RWTH Aachen University is investigating a new control approach for injection molding in which the cavity pressure is controlled by different positions of the hot runner valve pin. The influence on the cavity pressure of different strokes in the holding pressure phase is investigated.

The experimental mold with the cavity of a bicycle saddle has a servo-electrically driven hot runner

20:7

Cavity-Specific Pressure Control to Increase Process Consistency

The Hot Runner Valve Pin  as Actuating Variable

Pipette tips feature a challenging wall thickness/length ratio, an inner geometry that is key for analysis results, and a tip opening just a few tenths of a millimeter wide. They have been in extremely high demand during the coronavirus pandemic, which is why the mold construction and hot runner specialist Männer has developed a mold with an innovative cluster concept.

At the Männer test center in Bahlingen, Germany: an injection mold for manufacturing pipette tips, shown here in operation. Automation of the system is currently being set up

Pipette Tips: Männer Presents a Mold with Replaceable Clusters

Maintenance During (Nearly)  Uninterrupted Production

Complete Digital Hot Runner Solution for Automated Biopolymer Processing

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.

Ecozema is one of the leading brands for biodegradable and compostable catering products, such as tableware, cutlery or containers made of paper, compostable plastics and wood. 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 project included a 16-drop valve gate family mold for the production of a complete cutlery set with knife and fork, another 16-drop valve gate system for a single fork and a 24-drop system for the production of an ice cream spoon (Fig. 1). For all three tools, Ecozema planned full automation right through to the packaged product. Also included in the planning was comprehensive digital process monitoring. “Cost-efficient mass production while maintaining high hygienic standards are essential factors for being competitive in our industry,” explains Antonio Munarini, managing director at Ecozema, “so it is important to have a high level of automation with minimal human involvement and optimal process control.”

Demanding Material Processed Safely and Automatized

With a multitude of already realized applications with biopolymers and an extensive database of material tests in the company’s own technical center, hot runner manufacturer Ewikon has the necessary extensive knowledge for the safe processing of this demanding material family. During extensive tests, which toolmaker Uniform and Ewikon carried out together with the customer at the company’s headquarters in Frankenberg, Germany, various valve gate concepts were tested for their suitability for processing the compostable starch blend (type: Mater-Bi, manufacturer: Novamont). Due to the performance of the solutions presented, Ewikon was able to beat out international competitors.

In the case of the 24-drop ice cream spoon mold – originally designed for open gating – the decision was made to give preference to side gating after simultaneous tests with the HPS III-MH multi-nozzle concept (Fig. 2). “The direct side gating solution proposed by Ewikon convinced us”, says Antonio Munarini, “it is much more compact than a standard system and is also more cost-efficient with shorter cycle times and lower production costs”.

The two valve gate systems mentioned above are equipped with HPS III-S hot runner nozzles with powerful direct heating and a flow channel diameter of 6 mm. Valve pin actuation is synchronized by using plates with pneumatic drive, which are directly networked with the injection molding machine via position sensors, thus enabling a precisely coordinated injection process. To increase ease of maintenance, gate exchange inserts made of wear-resistant material have also been integrated. These contain the prefabricated gate contour and can be quickly changed individually for each cavity in the event of wear, without having to replace the entire mold insert. The 24-cavity system for direct side gating features six in-line HPS III-MH nozzles in linear design, each with two melt outlets on the long side. These are positioned centrally between two vertical rows of cavities.

Rheological Balancing via Stepped Flow Channel Diameters

The first delivered and at the same time the most sophisticated system was the family mold for the simultaneous production of fork and knife, which not only have different shot weights but also significantly different geometries (Title figure). In addition to the automated removal of the articles by means of a handling system, the complete packaging is integrated into the process. After the fork and knife have been placed on a conveyor belt, they are picked up in pairs under camera control, automatically placed on a paper napkin and finally packed and sealed. When developing the hot runner solution, the highest process reliability and uniform filling behavior therefore had top priority in order to minimize rejects and thus avoid malfunctions or downtime in the subsequent automation steps.

The balancing of the hot runner system with two horizontal rows of four cavities for knife and fork in each mold half was therefore of particular importance (Fig. 3). Two possible solutions were considered: a naturally balanced system with one synchronous plate each for the simultaneous actuation of all valve pins of one article type, in which the filling differences are compensated by a time-delayed opening, or a rheological balancing via stepped flow channel diameters, in which all valve pins are actuated by only one plate. After carrying out extensive filling simulations and calculations at Ewikon, in which the material manufacturer was also involved, the decision was made in favor of the rheological version, which is more cost-effective in terms of mold technology.

Digital Process Monitoring Provides Transparency

To guarantee consistently high performance, Ewikon supplied the system with a complete digital package consisting of a matching 24-zone hot runner controller with external touch-screen operating unit (type: pro Control) and the Ewikon smart Control process monitoring and diagnostic unit. This unit is installed directly on the hot half (Fig. 4) and integrated into the Ecozema company network. It enables seamless recording and logging of all operating parameters of the hot runner system in real time (Fig. 5). In addition, it also monitors the temperatures of the mold plates, which have been equipped with thermal sensors for this purpose.

“For us, this is a very useful additional investment,” says Riccardo Passuello, sales manager at Uniform, “especially for applications with such a high degree of automation, a high level of process transparency is important. With smart Control, Ecozema has an overview of the system performance at all times and, at the same time, a valuable tool for quality control in the process. In case of deviations, it is possible to react at an early stage – for example, by initiating maintenance measures – before a drop in part quality or an unplanned shutdown of the system occurs”.

The second 16-drop valve gate mold and the 24-drop side gating mold were completed shortly after the family mold. Since automation with a handling system for fully automatic article removal and packaging is also used here, both molds are also monitored by digital “smart Control” units.

The family mold was put into operation for the first time at the end of January 2020. The good results in article filling confirmed the decision for the rheologically balanced variant. After the project had experienced some delays due to the Covid-19 pandemic and the lockdown measures in Italy, the mold has been producing trouble-free in series for a few months, just like the two other molds, which produce alternately on one machine.

At the same time, Ewikon has already launched the second smart Control generation. It offers significantly enhanced performance features and can now be fully integrated into networked injection molding production via OPC UA. In addition to monitoring the hot runner mold, communication with the machine, peripherals and higher-level software systems is also possible and thus the recording and monitoring of all relevant injection molding parameters.

Furthermore, the optionally integrable “Virtual Rheology” function enables live simulation of the shear rates and the residence time in the hot runner system based on the material and geometry data stored in the system as well as the hot runner temperatures and injection parameters of the injection molding machine recorded for the current shot. This offers the possibility of targeted process optimization, especially when processing shear-sensitive or residence time-critical materials, and thus guarantees optimum part quality. Especially for processes that require a high level of safety, monitoring with smart Control represents a useful additional investment.

EWIKON Heißkanalsysteme GmbH  

https://www.ewikon.com

Ausgabenartikel

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

Fig. 1. The product: cutlery made of compostable biopolymer

Fig. 2. View of the contour plate on the hot runner side of the mold for the production of the ice-cream spoon. The parts are side gated

Fig. 3. 16-drop valve gate family mold for the production of knife and fork, delivered as hot half

Fig. 4. The compact smart Control process monitoring unit is attached to the wiring box in a space-saving manner

Fig. 5. With smart Control, all relevant operating parameters can be monitored in real time, shown here by Managing Director Antonio Munarini

Name - Hauptartikel

<b> Henning Becker</b> is head of marketing at Ewikon Heisskanalsysteme GmbH, Frankenberg, Germany.