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medical | Innovation

and ran a cycle time of 20s. Ferromatik sees considerable opportunities for

overmoulded production of cannula needles. “Today over 95% of all cannulas are still made using glue,” says Sven Engelmann, head of applications & systems at Ferromatik Milacron. “Adhesive-free production of disposable syringes is completely new.” The Germany-based machine maker will also be

demonstrating a medical application at the K fair in October on a 30 tonne Elektron moulding machine – a new addition to the lower end of its all-electric line-up. The machine will be moulding 1ml ampoules weighing 1.6g on a four cavity mould manufactured by Germany’s Braunform. Cycle time will be 9.1s. Braunform is an established player in the medical

Above: Close-up view of Zahoransky’s cannula system showing

finished parts in the mould bar (lower right corner)

cannula production system earlier this year at Arburg’s Technology Days open house in Germany. Based on the rotary system developed for its Integrated Dental Product (IDP) system, the system used an Arburg Allrounder 275 V vertical injection moulding machine with the production process taking place over eight manufacturing stations. At the first station, eight steel injection needles are

fed from a needle magazine and separated by a proprietary Needle Feed System (NFS) before a handling system transfers the eight separated needles to a mould bar. The needles are inspected using a camera system at station two, where they are checked for length and distortion, before being passed to station three, where they are overmoulded in PP in an 8-cavity mould. The moulding process, including insertion of the mould bar, takes just 8s. The overmoulded parts are then indexed through

three further stations which can be configured for specific customer requirements. These could include further visual inspection, siliconisation or attachment of cannula protectors, says Zahoransky. Finished parts are removed at station seven, with any non-conforming parts left in place for removal at station eight. “The integration of upstream and downstream

operating steps in the injection moulding process improves material flow and logistics, says Berthold. “What’s more, the automated feed of inserts and the gentle removal of the final product ensures process reliability and increase productivity.” Zahoransky also manufactures automated production

systems for adhesive-free cannula for use on horizontal injection moulding machines. During the Plastpol exhibition in Poland earlier this year it demonstrated production of disposable cannula in COC (cyclo-olefin copolymer) on a 4+4 cavity rotary mould running in a 110 tonne all-electric machine from Ferromatik Milakron’s Elektron line. The mould produced four parts per cycle

12 INJECTION WORLD | September 2013

industry and worked with customer Gerresheimer Bünde to develop its TELC (Tamper Evident Luer lock closure) for prefillable syringes. The two component closures are produced on a 16+16 cavity mould with a rotary table in a combination of PC and TPE (which requires maintaining the mould cavities at tempera- tures of 100˚C and 40˚C). The parts are moulded by Braunform in a Class 5

cleanroom production cell, with a rubber seal inserted in a post-moulding automated assembly process. Swiss machinery maker Netstal, part of KraussMaf-

fei, demonstrated automated state of the art medical production at the Plastpol show, manufacturing needle protectors in a Sabic PP grade on an all-electric 120 tonne moulding machine from its Elion range on a 5.5s cycle. The machine was running a 48-cavity mould supplied by Kebo of Switzerland with cooling and materials handling supplied by Piovan of Italy. During the upcoming K show, the company will show another Elion machine running a high speed medical application. The 220 tonne Elion machine will be producing 1ml syringe bodies weighing 1.54g on a 9.6s cycle time using a 48-cavity mould from Tanner, also of Switzerland. LyondellBasell supplies the PP resin while materials handling is by Motan Colortronic of Germany and temperature control by Switzerland’s EF Cooling. Arburg’s K show presence includes two medical

manufacturing exhibits based on all-electric versions of its Allrounder machines. An Allrounder 470 A model will be moulding dose units on a 2s cycle time using a 64-cavity mould supplied by Männer of Germany. Meanwhile, an Allrounder 520 A machine in a full stainless cleanroom configuration will be moulding pipettes on a 4.5s cycle using a 64-cavity Tanner mould. The machine will be paired with a Vario-TIP pipette handling system developed by Waldorf-Technik of Germany. Engel will also show a medical automation project

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