PACKAGING | TECHNOLOGY
reinforce, or fill polymers to optimise material properties while reducing material degradation, energy consumption and CO2 generation. However, the DCIM process operates with a specially designed single screw extruder and is suited for operations with part weights from 50 to 2,000 g, while the more established IMC technol- ogy works best with shot weights of at least 1,500 g. DCIM technology is generally designed for use with injection presses with clamping tonnages from approximately 160 to 1,100 tonnes, while the IMC process is used with IMM units with clamp forces ranging from approximately 1,000 to 4,000 tonnes. The DCIM process is comprised of a standard injection moulding machine from KraussMaffei’s CX or GX series presses, coupled with a single-screw extruder to create one system. The specially developed extruder screw features a sizable 30:1 L/D that can reliably process a wide range of materials. The extruder unit is installed in a piggy- back position directly over the injection unit of the moulding machine. Compounded melt from the extruder is conveyed directly into the plasticising unit without cooling or buffer storage, so the material experiences a single heating cycle. Extruder operation is integrated into the control
software of the injection moulding control module for seamless operation. The extruder and injection operate intermittently, with the extruder stopping when the injection volume is reached for the next moulding cycle. At K2022, KraussMaffei demonstrated DCIM’s ability to process a wide range of materials in the production of a five-piece polyolefin collapsible crate, such as those used for transporting fresh fish, made using three different recycled materials. The demonstration combined PP staple fibre
fleece from FFP2 masks, with a melt volume rate (MVR) of 800-1,000, shredded HDPE from logistics packaging goods with an MVR of 5-15, and HDPE blow moulding straps from toy production, with an
Right: KraussMaffei’s Direct Compounding Injection Moulding system
MVR less than 1. The three starting materials, each with different viscosities, are combined into a single homogeneous melt in the DCIM, creating a new material. Masterbatch, stabiliser additives and micaceous iron oxide are added as fillers. DCIM eliminates the external production of a compound, saving as much as €0.6/kg on average. Use of recycled materials can trim material costs by up to 50%. At the K show, the DCIM unit produced the 1,000 g five-piece collapsible crate in a cycle time of 35 seconds. Users can create formulations at the machine
that incorporate a wide range of materials whether they are tough-to-process, sustainable, recyclable, polymer blends or gummy materials as well as reinforcement, additive or filler materials. Examples include PET flakes, regrind, bamboo, wood, or glass fiber in a range of loadings. However, if compounding is not needed the DCIM configured machine can be used as a standard injection press without any elaborate conversion work, simply by pivoting the extruder.
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IMAGE: KRAUSSMAFFEI
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