TECHNOLOGY | THIN WALL MOULDING
lis together with 30% homogeneous PP recyclate to produce thin-walled round cups at K 2019. These cups were recycled live at Erema’s stand, and were subsequently turned into durable folding boxes made from 100% recyclate as an example of what can be done. This application shows that, if it is possible to collect plastics in a sensible and safe manner, they can be
IMAGE: ARBURG
Above: Injection moulding
machines such as the Arburg Allrounder 1020 H in the Packaging version with Gestica control system are able to process recyclates
second data set additionally simplifies the start of production, which automatically switches to the standard setting after an adjustable cycle pre-selec- tion. With this assistance, we not only simplify the start of production, but also minimise start-up scrap significantly.”
In a thin-walled injection moulding example, the company says that it recently undertook a project with a Belgian customer to produce a 150 ml food container with a wall-thickness of 0.3 mm in a cycle time of less than 3s. The demand for thinner wall thicknesses will continue to increase due to requirements for better material utilisation, adds Schramm. This is where the dynamics of the EcoPower Xpress have particular strengths. Wittmann Battenfeld will conduct further studies in this area, together with mould manufacturers, in order to optimise technologies and processes in this area. The overarching trends in thin-walled injection moulding are conservation of resources and the circular economy, according to Arburg, particularly for packaging. “For example, high-performance hybrid injection moulding machines can be used to produce even very thin-walled products with high process reliability, low consumption of materials and, hence, excellent cost-effectiveness,” says Bertram Stern, Packaging and Circular Economy Manager. “As an example of recyclate processing, an Allrounder 1020 H in the Packaging version processed new polypropylene material from Borea-
returned to the value chain.” In order to give more impetus to the circular economy, Arburg adds that it is collaborating with mould makers, material producers and recycling experts to develop innovative technologies. For example, as part of the HolyGrail 2.0 project, the company is working with over 85 companies to advance the sorting of waste plastic packaging by means of digital watermarks. Another project dealing with the labelling and recycling of high-quality recyclates is R-Cycle, initiated by Reifenhäuser.
Significantly increasing the quality and quantity
of recyclates remains a key priority. “When it comes to processing, fluctuating material qualities present a major challenge,” says Stern. “To cope with this and optimise the injection moulding processes, we are collaborating with partners such as the Institute for Plastics and Closed-Loop Technology (IKK) at Leibniz University in Hanover, Germany. They are using two Allrounders to characterise the process- ing behaviour of recyclates and new bioplastics and to develop combinations of recyclates and virgin materials. The focus here is on Design for Recyclate, technical aspects relating to the process, and technical and material issues in respect of the product properties.” Engel has expanded the E-speed series for
more sustainable production of plastic packaging using thin-wall technology. Designed for continu- ous high performance in the packaging industry, the company says that E-speed injection moulding
Right: The E-speed 280 expands the Engel series into the lower clamping force ranges, with a particu- lar focus on manufac- turers of thin-walled containers, buckets and matching lids
32 INJECTION WORLD | March 2021
www.injectionworld.com
IMAGE: ENGEL
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