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ENERGY MANAGEMENT | PROCESSING


controller connected in the OPC UA network via the Euromap 82.1 protocol. On a similar theme, Engel says Procter & Gamble Manufacturing has improved the transpar- ency and consistency of temperature control processes using its E-Flomo and iQ flow control. “This not only results in reproducible component quality, but also in significantly higher levels of efficiency,” it says. “Temperature control was a black box for us,”


says Andreas Franz, process engineer at P&G in Marktheidenfeld, Germany. For a long time, only the supply temperature was known. It was only possible to investigate how the temperature was distributed over the individual heating-cooling channels during injection moulding using ther- mography, a complex process that does not give more than a snapshot. Three years ago, the Molding Technology division in Marktheidenfeld began to analyse and optimise temperature control in the injection moulding process. The plant focuses on oral hygiene products such as Oral B electric toothbrushes. The moulding shop currently includes 100 injection moulding machines in the 500 to 5,000 kN range. Engel says that with its Flomo electronic tempera-


ture control water manifold system, introduced at K 2010, it laid the groundwork for more transparency and consistency in the temperature control process. Flomo replaces the maintenance-intensive cooling water distributors, and even the basic version can individually monitor and document all cooling and temperature control circuits. The latest generation E-Flomo can control the flow rates or the tempera- ture difference (ΔT) in all individual circuits. With iQ flow control, introduced at K 2016, Engel took a further step. This automatically compensates temperature differences in the cooling water manifold circuit, based on the measurements determined by E-Flomo, and adjusts the pump speed in E-Temp electronic temperature control units to the current process conditions. Engel developed the E-Temp units in collabora- tion with temperature control unit manufacturer, HB-Therm. These enable integration of tempera- ture control into Engel’s CC300 control unit. P&G was the first company to adopt them. A mould with 56 heating-cooling channels (for


production of toothbrush charger housings) was used for testing the new temperature control technologies. The complex structure of the housing makes high demands on precision and process consistency during injection moulding. “In the past, we frequently experienced warpage due to uneven temperature control,” says Andreas Spitznagel, who


www.injectionworld.com


manages the Process Technology Group for P&G in Marktheidenfeld. “But what exactly was causing the fault was difficult to determine because there was simply too little information.” The stack mould has a total of 32 cavities in two


parting surfaces. Since the polymer melt is routed through the first parting surface to the second, a lot of heat is generated on the centre mould plate. Ten temperature control units were used in the original set-up.


In collaboration with Engel, P&G planned a new


production cell with a mould design optimised for the use of E-Flomo. The cell was planned from the outset with just three temperature control units, instead of the ten used before. Each mould plate now has its own temperature control unit. Initially, three-quarters of the 200 l/min flow rate available on each device was still used, but it has been possible to reduce the flow rate to 40 l/min in the course of system validation. “This is significantly less than we expected”, says Christian Rieb, Equipment Engineer at P&G. Fewer temperature control units and smaller flow rates mean lower investment costs, compact systems and, above all, significant savings in energy consumption.


CLICK ON THE LINKS FOR MORE INFORMATION: � www.shell.co.uk/lubricants/businesswww.mobil.com/industrial � www.chevronlubricants.com � https://oil-additives.evonik.com � www.gwk.com � www.engelglobal.com � www.tangram.co.uk


The stack mould for manufacturing the charger housings has 56 heating- cooling channels, which can be dynamically controlled using Engel’s E-Flomo. The difference between the media temperature in the flow and return lines of a temperature control channel is a measure of the uniformity of the temperature distribution in the mould


May 2019 | INJECTION WORLD 39


PHOTO: ENGEL


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