FEATURE u Medical Equipment & Devices
Fit for purpose: Solving cleanroom height constrictions
M
edical device manufacturer, Europlaz Technologies, recently installed a small footprint 130-ton (130T) IntElect injection
moulding machine from Sumitomo (SHI) Demag with unique tie bar design to accommodate the low ceiling height in one of its production cleanrooms. Rather than hoisting weighty mould tools over the top of the machine, requiring considerable crane clearance space, the IntElect’s square configuration, small footprint and retractable tie bar option allows the Essex-based manufacturer to now easily manoeuvre and load tools into its newest all-electric energy-efficient machine sideways. Replacing a legacy hydraulic 150T injection moulding machine in one of the company’s eight Class 7 cleanroom facilities, Europlaz, which manufactures and assembles millions of medical device components annually, cites Sumitomo (SHI) Demag’s unique ability to supply an all-electric injection moulding machine with a retractable tie bar as the overriding factor in their latest investment choice. Already a strong advocate of the Japanese-German injection moulding machinery supplier, having installed a number of Sumitomo all-electric machines over a decade ago, the IntElect machine’s large platen area offers Europlaz greater production flexibility with the ability to accommodate various mould tool configurations, typically single, two, four and eight cavitations. Many of which were previously used in the larger tonnage hydraulic legacy machine. Downsizing from 150T to the IntElect 130T
has inevitably saved on floor space for the ISO 13485-accredited and FDA-registered medical moulder. Technical Director at Europlaz, Steve Sansom, estimates around three square meters. Allowing them to integrate supporting ancillary equipment to compliment the machine layout. Citing energy efficiency as a compelling advantage of all-electric injection moulding in a cleanroom production environment, Mr Sansom is quick to rate other unique precision moulding features included within their latest all-electric machine. Specifically, activeFlowBalance which helps to stabilise and evenly distribute the pressure of the expanding melt within multi-cavity mould tools with no additional pressure, as well as the activeLock feature that digitally controls the closing position on the non-return valve. Both of these technology features help to optimise the melt cushion that’s so critical in tight tolerance medical device applications, notes Steve. “The tolerance requirements for the medical sector
over the last decade has got increasingly stricter. The processing stability, dimensional accuracy and
28 October 2022 Irish Manufacturing
repeatability we’ve achieved on the IntElect 130T since the start of 2022 is exceptional,” exclaims Mr Sansom. Emphasising that this is equally essential for device assembly and finishing, another core Europlaz service. Performed within an adjacent airlocked cleanroom
for infection control, Steve references the assembly of an inhaler as an example. “Comprising up to 20 individual components, if just one element is out of tolerance, the device might not meet the performance expectations. Potentially putting the end user at risk,” cautions Mr Sansom. Being a specialist full service manufacturer of
life science, pharma, diagnostics and medical device components, precision manufacturing, coupled with robust quality conformance, underpins every aspect of production at the family-run business. Manufacturing, assembling, packaging and distributing millions of sterile products annually, Europlaz opened its first cleanroom in 1987. From asthma inhalers to neonatal respiratory flow sensors, operating kits to prosthetics and oral care devices, the breadth of technical projects and prototyping undertaken at Europlaz continues to accelerate at pace. Investing in a mid-sized IntElect machine with its large platen area that can accommodate this expansive tool estate, including moulds previously run on the 150T hydraulic machine, boosts production capacity. Additionally, having the option to rapidly switch between the four screw sizes (30, 35, 40 and 45mm) offered by Sumitomo (SHI) Demag, Europlaz has even greater moulding flexibility, ensuring that the optimum screw size is used to each application’s shot weight. The company leadership team is already holding
conversations to conclude its hydraulic replacement programme over the next few years and expand its all- electric machine fleet. Sustainability and reducing the company’s carbon
footprint is the key driver. Mr Sansom explains: “The most obvious way to address sustainability is within the production lines, distribution channels, and the products themselves whilst still adhering to the stringent regulations which are in place for medical devices. We made a conscious decision over a decade ago to opt for cleaner and more energy efficient all- electric machines. “Although several companies afforded comparable
energy savings data of around 60 percent, Sumitomo (SHI) Demag is the only machine supplier that could offer all this with a removable tie bar, in a smaller footprint,” ends Steve.
Sumitomo (SHI) Demag
http://uk.sumitomo-shi-demag.eu/
www.irish-manufacturing.com
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