PACKAGING | TECHNOLOGY
and increase the response speed in urgent cases.” Sumitomo (SHI) Demag, Waldorf Technik and
Roth Werkzeugbau have collaborated to provide a fully automated IML production line for UK injection moulder Amaray that is repeatedly manufacturing, stacking and wrapping over 7,500 easy open, fully decorated rigid wipe lids per hour. The push button lids, designed for a major blue chip personal care client, are manufactured on a Sumitomo (SHI) Demag ultra-high speed 580-tonne El-Exis SP, fitted with a multi-cavity 12 + 12 stack mould. An integrated high speed IML Waldorf Technik robot places each label into the mould, and then removes and closes each of the 24-hinged lids as soon as they are extracted from the mould. This has to be done swiftly while the polypropylene is still malleable. Each lid is then placed on the conveyor where they are each quality checked by a camera. A robot then stacks 38 lids, passing to a binder, at which point nine stacks are fed into an automated wrapper to create a brick of 342 lids for loading onto a pallet. In order to maximise post-consumer recycling
efforts, Amaray made the decision to use polypro- pylene, so that that the entire component - lid and label - can be recycled after use. The design required the lid to be moulded as a single compo- nent and decorated and assembled in a seamless process. From an injection moulding perspective, using a 12 + 12 stack mould - although more productive - presented a tooling and processing challenge. Sumitomo (SHI) Demag’s UK packaging expert Kevin Heap says: “To create the flip-like hinge was challenging in itself, as the tooling needed to accommodate varying depths of raw material. Unlike a single face tool, the polymer is
www.injectionworld.com July/August 2019 | INJECTION WORLD 39
injected in the centre between the two plates and has to be evenly distributed in all 24 cavities.” Additionally, using a two-face 12 + 12 stack mould in conjunction with the IML system means that 24 cavities are opening at the same time, with a Waldorf Technik side-entry robot placing labels accurately within fractions of a second. “Typically, packaging moulders use a single face mould with a maximum of 12 cavities when integrating an IML system, so Amaray’s installation doubled the complexity. To insert labels on both tool faces required a much larger robotic system,” says Heap. StackTeck Systems has a new approach to fast mould deliveries, using automated design capabili- ties that work with a pre-set, optimised set of mould design rules. FastTrack projects compress engineer- ing and manufacturing stages, using automated design and product standardisation. As compared with custom designed moulds, the engineering phase of every project will be reduced from 3-4 weeks to just a few days. The first phase that StackTeck is now offering, will cover single face moulds for round lids and round air eject containers, with 2, 4, 6 or 8 cavities. Future development of this technology will cover a broader range of part types, as well as bigger cavitations and stack moulds.
CLICK ON THE LINKS FOR MORE INFORMATION: �
www.trexel.com �
www.husky.co �
www.wittmann-group.com �
www.arburg.com �
www.engelglobal.com �
www.kraussmaffei.com �
www.sumitomo-shi-demag.com �
www.waldorf-technik.de �
www.roth-werkzeugbau.de �
www.amaray.com �
www.stackteck.com
Left: Amaray’s packaging line comprises a 12 + 12 stack mould, producing 7,500 fully decorated rigid wipe lids per hour for a leading blue chip personal care customer
Below: The ultra-high speed 580 tonne El-Exis SP from
Sumitomo (SHI) Demag
PHOTO: SUMITOMO (SHI) DEMAG
PHOTO: SUMITOMO (SHI) DEMAG
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