TECHNOLOGY | THIN-WALL MOULDING


Arburg says the Allrounder 1020 H in Packaging version is “ready for digitalisation. It comes equipped as standard with Arburg’s four assistance packages 4.set-up, 4.start-stop, 4.production and 4.monitoring, which get the injection moulding process up and running quickly and reliably.” The exhibit on the Arburg stand processed a mix


of virgin polypropylene in combination with 30% recyclate, provided during the show by post-con- sumer recycling technology specialist Erema. This was not the only Arburg machine carrying out thin-wall moulding at the show. On the Robop- las stand, a thin-walled IML application was presented on a hybrid Allrounder 630 H in Packag- ing version with 2,300 kN of clamping force. This exhibit used a mould from Erkoc, Turkey, to produce four rectangular cups, each with a capacity of 280ml, in a cycle time of around 3.5 s. Another hybrid Allrounder 630 H in Packaging version produced four thin-walled PP cups in a cycle time of around 3.5 s on the Ilsemann Automa- tion stand. The system was automated with Ilsemann’s own robot, which featured a low-weight carbon fibre composite gripper. Sumitomo (SHI) Demag came to the show with


two “energy-enhanced” high-speed El-Exis SP units for packaging applications. With the introduction of a new control valve regulating the hydraulic pressure during the loading of the accumulator, the machines consume up to 15% less energy than previous generations of El-Exis machines. This saving is dependent upon the packaging applica- tion, moulding cycle time and process parameters. “Capable of delivering the lowest dry cycle times [under 2 s], the machines in the latest series have high process consistency and high energy


efficiency,” says Arnaud Nomblot, Director Business Development, Packaging, at the company. The hydraulic accumulator enables them to achieve injection speeds of up to 1,000 mm/s. Being able to adjust the accumulator charging to the injection pressure required for the exact moulding process not only lowers energy usage, but also reduces wear and tear on parts. The El-Exis SP range, available globally, now comprises 10 machines, with a clamp force range of between 1,500 and 10,000 kN. The range is aimed squarely at high volume manufacturers of polymer products, including caps and closures, thin-wall containers and lids. Kevin Heap is a packaging specialist with Sumitomo (SHI) Demag UK. He says: “To succeed in the thin walling arena, injection moulders need to examine every potential application to ensure that the selection of materials, machine and tooling give the optimum blend of speed, quality and consistency.” Heap also points to the advantages of combining injection and compression moulding for production of thin-walled parts. Injection-compression is now increasingly being applied to the mass-production of PP packaging applications, he says. “By applying injection compression techniques to stack moulds, packaging moulders can now reduce the wall thickness of containers and lids from 0.45mm to 0.35mm. This saves around 25% in raw PP materials compared to the standard injection moulding process, while maintaining comparable mechanical properties. Again, El-Exis SP machines are used for this technique.” Heap highlights one example of the technique


in use. Last year, major UK-headquartered rigid packaging specialist Amaray unveiled what he describes as a pioneering IML production line featuring technology from Sumitomo (SHI) Demag, Waldorf Technik and Roth Werkzeugbau. The line features an ultra-high speed 580-tonne El-Exis SP, fitted with a multi-cavity 12+12 stack mould. “Although there are several examples in Europe


Above: View inside a Sumitomo (SHI) Demag El-Exis SP 200/920 machine. Injection-compression moulding reduces clamp force requirement by 30%, saves energy and allows processors to opt for smaller machines


18 INJECTION WORLD | March 2020


of moulders using 8+8 stack moulds for producing IML margarine lids in high volumes, using a 12+12 stack mould means that Amaray is really pushing the packaging boundaries in thin walling,” he says. Milacron, meanwhile, highlights its ThinPAK- Series Mold-Masters thin-wall packaging hot runner system. This was first seen at Fakuma 2018. The company says it has been rapidly adopted by many thin-wall moulders since. “The secret to this system’s success is Mold-Masters’ patent-pending MasterShield Technology, which offers superior leakage protection,” it says. This protection


www.injectionworld.com


IMAGE: SUMITOMO (SHI) DEMAG UK


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50