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Small/large tonnage machinery

Providing for cost savings

Netstal. The compact design is as a result of water, compressed air and mould auxiliary controls integrated with the machine. Plus, Netstal says moulds with built-in heights are available.

Energy efficiency is the all new buzz word in the industry. Netstal’s Evos 3500 model was displayed at Fakuma

Machinery companies displayed

Machines make their debuts Wittmann Battenfeld played a similar energy and cost savings tune when it showcased its all-electric EcoPower machine series, which, in fact, made its debut at Fakuma. Available in clamping forces from 55-300 tonnes, a 110/350 model was displayed. Like most modern electric machines, the EcoPower uses direct drives rather than belts and pulleys and has energy recovery to recycle the braking energy of the drives.

a host of injection moulding machines at the Fakuma show in Germany, held from 13-17 October, lauding just this.

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apanese/German manufacturer Sumitomo (SHI) Demag Plastics Machinery, in cooperation with Siemens, demonstrated how energy consumption of an injection moulding machine can be measured and analysed. Also shown was the IntElect Smart, available from 50-160 tonnes, featuring an energy-efficient drive technology developed by Sumitomo. As opposed to the low-inertia, air-cooled drives used in the Smart, another IntElect model (Performance) uses water-cooled direct drives, making it suited for cleanroom technology. Another machine, the hybrid EL-Exis, is targeted at the closure and thinwall packaging markets that require high capacity and low energy consumption. The company claims its machine uses 40% less energy, compared to other similar high-speed machines. Austrian manufacturer Engel claimed energy savings of up to 25% on its new hybrid Duo Pico machine, which features variable drive motors to allow for optimised operation of each movement. The energy savings are said to place the machine in a similar league as its all-electric ones. Other features are the energy-saving Ecodrive system, speed controlled pumps and electric plasticising drive system. Another proponent of energy efficient machines, KraussMaffei, showed the EX 160-1000 Ultra all-electric machine that was producing thinwall PP food containers, using an inmould labelling process in a two-cavity mould. The machine is fitted with an Ultra injection unit for fast injection speeds and an SR80 robot for high levels of cleanliness and performance, according to the German company. Having launched its hybrid Evos at the K show in 2007, Swiss manufacturer Netstal demonstrated the production of a thinwall packaging application on an Evos 3500-2000. The machine features individually and digitally closed loop controlled axes, including secondary movements such as nozzle contact pressing. Process control is further improved by this and the reproducibility is enhanced as well, says

Wittmann Battenfeld debuted its new EcoPower at Fakuma

The injection unit is laid out for high injection speeds of up to 400 mm/second, even under maximum injection pressure, says the company. The drive and the circulating ball spindle are the heart of force transmission. The direct drive via the spindle minimises force transmission loss and ensures accurate control and repeatability of the metering and injection processes, says its German maker. Plus, the encapsulated drive system is compact and easily accessible and the barrel, which is compatible with Battenfeld’s HM and TM series, can be exchanged. The modular design of the machine allows modules to be preconfigured for standard moulding, cleanroom technology and high-speed applications. It has also been designed to allow ancillary equipment, such as temperature controllers and dryers, to be integrated with it, thus reducing the size of the machine. In addition, the setting and control of ancillary equipment has been integrated with the machine’s control system, reducing its size further. Another German machinery producer Ferromatik Milacron also premiered its new Vitesse series, claiming that it is “the fastest injection moulding machine”. Available in clamping force sizes of 200, 300, 400 and 500 tonnes, with injection units of international sizes 1,000, 1,650, 2,650 and 4,400, the electric screw drive of the Vitesse allows for parallel functions, resulting in short cycle times, says the company. The stability of the machine is provided by a reinforced base and linear guides. 3

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Small/large tonnage machinery The machine also comes with the GreenLine energy saving package. This is made up of an energy-efficient drive technology where the hydraulic pump comes with a high-efficiency motor and the hydraulic accumulator is filled to the required level for each application. Furthermore, energy use is measured by cycle, hour and shift. To make it more competitive in the market, Ferromatik Milacron gives a warranty of two years for the machine, as well as a three-year warranty for the electrical and electronic parts and four years for the steel or cast materials. The company was also promoting its all-electric Elektra series that is said to use 50-70% less energy and water than hydraulic machines. It comes in clamping forces of 30-300 tonnes and can be combined with injection units of international sizes from 55 to 1,540. Ferromatik Milacron’s new hybrid Vitesse 300

Honing in on energy-efficiency Arburg, in keeping with the energy-efficiency theme, had on display five machines with its e2 labelling of the nine machines it had at the show. It showed for the first time its latest hybrid Hidrive machine that incorporates an electric clamp system from the all-electric Allrounder Alldrive, hydraulic injection unit from the Allrounder S Advance and accumulator power pack technology from the Allrounder S machine range. The company claims the Hidrive allows for energy savings of up to 40% over a standard hydraulic machine, compared with 50% for an all-electric machine. Targeted at the medical and automotive sectors, the Hidrive series was producing a plug insert at the show, in a cycle time of 14 seconds on a 60 tonne Allrounder 370H, with a size 290 injection unit and a four-cavity mould. For the packaging sector, where energy efficiency is a priority, the German company showed its new large Allrounder 720A. This machine, with a tiebar distance of 720 x 720 mm and a clamping force of 320 tonnes, was exhibited with a new size 1,300 electric injection unit and a servo-electric dosage drive. The drives of the individual axes are independent from one another, enabling simultaneous movements and a reduced cycle time. A new feature from the company is an energy consumption measurement, which allows the operator to not only monitor the energy used during the injection moulding process online via the Selogica control system but to optimise it on a targeted basis. This option is a feature of the largest 500 tonne Allrounder 920S, with a size 4,600 inject ion unit and hydraulic accumulator technology. This was shown producing the well-known folding crate patented by Ifco Systems. ◆ Arburg’s energy consumption measurement is packaged with its Allrounder 920S

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Small-large Tonnage Machinery  

IMA features issue October 2009

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