MACHINERY | THIN WALL MOULDING


Right: Netstal produced 10ml syringe barrels on an all-elec- tric Elion MED at Fakuma


showcased its all-electric IntElect S machine – mak- ing thin-walled packaging in a live demonstration. The company says that the machine combines fast cycle times with low energy consumption. “Fluctuating energy costs create uncertainty – par- ticularly for packaging manufacturers, where energy is the highest and most unpredictable expense,” said Arnaud Nomblot, director of business development for packaging at the company. “To counteract this, fast processing repeatability and reduced waste, combined with halving energy costs, is imperative.” On its stand, the company showed how the IntElect S series helps processors of narrow tolerance and thin-walled packaging lids and containers to more than halve their energy use. The exhibit featured an IntElect 2 S 220/660- 1400 to manufacture four decorated food contain- ers made from PP, with an integrated IML side entry robot – in less than four seconds. “Cycle times for the all-electric S series start at


around four seconds,” said Nomblot. “The optimi- sation of tool movement, nozzle position, metering speed, injection and ejector movements increases productivity significantly.” The combined cost savings and increased


throughput can lead to a return on investment (ROI) of 18 months, he claimed. During the live exhibit, the 220-tonne machine made IML 250ml dairy and spread containers with a shot weight of 45g on a four-cavity mould tool supplied by Société Nouvelle Caulonque. “Combined with the PAC-E series, which halves


Below:


Sumitomo (SHI) Demag made thin-walled packaging on its IntElect S at Fakuma last year


energy costs for mass-manufacturers of beverage caps and thin-walled packaging, the benefits of all-electric technologies are now more widely available to packaging applications,” said Nomblot. The company also has plans to develop 350-tonne and 420-tonne PAC-E machines.


Medical moulding At Fakuma last year, Netstal produced 10ml syringe barrels on an all-electric Elion MED with a clamping force of 1750 kN. The part weight was 7.8g and the cycle time around 20 seconds. It was made from COC


IMAGE: SUMITOMO DEMAG


material from Topas using an 8-cavity mould from Fostag.


During moulding, a lot


of data is generated that provides information about production quality. A large number of process parameters are available in the control system, which can be evaluated, displayed and monitored. The main focus is on the shaping phase. The quality of the moulded part is largely determined during this phase. Continuous monitoring of relevant parameters ensures compliance with tolerances. Histograms are used to detect a possible deviation trend at an early stage and issue a warning. Manufacturing processes in medical technology must be kept within the specified tolerance limits. Netstal avoids software-based adaptation of setpoint specifications, as this can lead to the validated process window being exceeded or undershot. Netstal’s solution, called Responsive Filling Control (RFC), is based on a force-dependent pressure changeover. The technology works with accurate and dynamic sensor technology, which is developed and produced exclusively for Netstal.


Thin cups Earlier in the year, at NPE, Netstal demonstrated the moulding of a thin-wall cup – made from 100% PET – on a hybrid Elion 3200 machine. The clear cup weighs around 15g and has a filling volume of 450ml. Netstal processed virgin PET from Eastman. The cups were returned to the PET cycle via the NPE recycling programme. Labels for the cups were also made of PET and


provided by Belgian IML specialist MCC Ver- straete. The test mould with two cavities and the IML robot – which inserts the label into the cavity and removes and stacks the finished cups – were supplied by Canadian partner StackTeck. The PET cup was moulded in a cycle time of


around 4 seconds on an Elion 3200, which has the necessary speed, performance and dynamics with its electric toggle clamping unit and hybrid injection unit. In high-speed applications, it operates in efficiency classes 8 and higher of the latest Euromap 60.1 standard. In addition, visitors saw a live demo


of closures production, using a production system from US customer Alltrista. The 26mm water closures were produced in a mould with 128 cavities. The system ran with a cycle time of 1.9 seconds.


24 INJECTION WORLD | January/February 2025


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