Right: The BOY 35E injection moulding machine is particularly energy efficient, says the company

clamping force range and servo drive technology in combination with constant displacement pumps. “This not only results in energy savings of up to 15% compared to conventional drive technology, but also reduces noise levels by up to 7%,” say Bernhard Zöhling, Team Leader System Develop- ment and Patrick Chromy, Team Leader Application Development. “Furthermore, less heat is introduced into the

hydraulic system, which means less cooling power for the drive system and a further contribution to energy savings. This is all part of our programme to help protect the climate, use resources economi- cally and sustainably, and promote the circular economy.”

designed hydraulics system, the cooling require- ment is low. The latest addition to the company’s E series is the Boy 35 E injection moulding machine. The four-tie bar machine offers a clamping force of 350 kN and a universal injection unit with screw diameters from 14-32 mm. With a footprint of only 1.96 m², the Boy 35 E is particularly suitable for the production of precision parts within narrow tolerance ranges with a part weight of up to 69.5g (PS). A wide variety of thermoplastics, elastomers and silicones, as well as thermosets, metals and ceramics can be processed with the Boy 35 E. The company claims that the fully hydraulic

reciprocating-screw injection moulding machine with two-platen clamping unit, swivel-out injection unit and energy-efficient servo drive has been proven to achieve the lowest possible machine- hour rates. Equipped with the optionally available EconPlast plasticising unit, the energy consumption of a Boy 35 E is significantly reduced. Awarded with the efficiency classification 7+ according to Euromap 60.1, the energy consumption is 0.49 kWh/kg of material throughput. With a horizontal clamping unit and a vertically

arranged injection unit, the materials are injected into the parting line of the mould. This means that injection points on decor surfaces are avoidable. Expensive and complex hot runner techniques are not necessary. Sprues can also be avoided by injection into the parting line. The Boy 35 E is available in four different machine types, where the clamping unit and the injection unit are each arranged horizontally or vertically. The latest development from Wittmann

Battenfeld that can provide significant energy savings in injection moulding is the MacroPower large machine series with a 400-2,000 tonne

22 INJECTION WORLD | June 2021

Solutions for improved use of regrind are also being developed. “A long-practised approach in the injection moulding industry is the addition of regrind to virgin material,” say Zöhling and Chromy. “In the past, economic advantages have certainly been a greater driver than ecological considera- tions. However, the higher the proportion of regrind, the larger the window of material and processing properties. The goal is to produce a qualitatively consistent end-product. Material and energy savings through physical foaming of the plastic melt is also a viable option. In this case, the challenges are process consistency, reproducible foam quality and the extended complexity of the process.” Wittmann Battenfeld adds that changes in

material viscosity – resulting from different regrind proportions or batch fluctuations – can not only be detected but also be actively compensated. The HiQ Flow and HiQ Melt application software packages have been developed for this purpose. While HiQ Melt detects the change in viscosity during metering, HiQ Flow actively intervenes in the control during injection and holding pressure. The next development steps for these packages have already been initiated and are being carried out based on customer feedback. Wittmann Battenfeld says that future develop- ments will continue to focus on energy savings, as well as possibilities to integrate energy generating systems that operate without almost any energy loss.



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