Sumitomo (SHI) Demag UK Magazine Issue 09/2014

Transcription

1 Sumitomo (SHI) Demag UK Magazine Issue 09/2014 Interplas 2014 Come and see Sumitomo (SHI) Demag s new innovative technologies at Interplas 2014 It s as easy as AFB! Improved reliability and parts quality with activeflowbalance. Cap That! Precision mouldings at Guala Closures Food for Thought The El-Exis SP designed for high speed packaging applications.

2 EDITORIAL Dear Reader, This year Sumitomo (SHI) Demag UK is celebrating 40 years in business and I would like to take this opportunity to thank all our customers for their support. Since our foundation in September 1974, the UK & Eire market has changed beyond recognition both in terms of size and technology. However the key attributes of quality products and value for money that customers look for in a supplier has not changed, this means value for money both in terms of the initial purchase price as well as the overall cost of ownership. These attributes are core values for Sumitomo (SHI) Demag and over our 40 year history values we have continually aspired to deliver. Our original mission statement back in 1974 was to be to be the best value supplier of injection moulding equipment in the UK and Eire. This statement remains true today, so while many things have changed in the last 40 years, the most important things remain the same. Thank you to all our customers and here s to the next 40 years. We hope you enjoy reading our INJECT Magazine where you will find the latest information on some of our newest technologies and case studies. Nigel Flowers Managing Director Sumitomo (SHI) Demag Plastics Machinery UK Imprint Publisher Sumitomo (SHI) Demag Plastics Machinery GmbH, Altdorfer Straße 15, Schwaig, Germany Phone: , Fax: -750, info-dpde@dpg.com, Editorial team Bernd Tröger (responsible according to the German Press Law), Stefanie Lauterbach All data and information in this prospectus have been compiled with great care. However, we are unable to guarantee its correctness. 2

3 FAIRS AND EVENTS Three big reasons to celebrate with Sumitomo (SHI) Demag at Interplas 2014 Sumitomo (SHI) Demag is marking its 40 th anniversary at Interplas 2014 with two other big milestones. In a UK debut, two fully operational 100 tonne injection moulding cells will be exhibited on the company s 105m² stand, one focusing on plastic precision moulding, the other on packaging components. Wall plugs produced with activeflowbalance. Wall plugs produced without activeflowbalance. activeflowbalance was awarded a gold medal at Plastpol 2014 A fully-electric IntElect 100 machine (clamping force 1,000 kn) will enable visitors to experience first-hand the benefits of Sumitomo s award-winning active- FlowBalance technology. Suited to highrepeatability, mass-produced precision automotive and medical applications, the team will use a 32-fold rawl plug mould to demonstrate the immediate impact of activeflowbalance, which collected a gold medal at Plastpol 2014, and how it combats uneven and fluctuating filling of multi-cavity moulds. Sumitomo experts will reveal noticeable quality improvements and show how activeflowbalance addresses challenges like jetting, sink marks, short shots, flash, voids and warping without lengthening the cycle time. In just one cycle time, there s a visible difference, notes managing director Nigel Flowers. This is a rare opportunity for manufacturers to get a glimpse of what goes on inside the mould cavity and the ease in which activeflow- Balance can be deployed into existing injection moulding equipment. Pushing the productivity boundaries further still, bottle cap manufacturers will be excited to learn how Sumitomo s newest clamp unit innovation has shaved yet another 0.2 seconds of production cycle time. Interplas visitors have to wait until the opening day to discover how the Sumitomo engineers have mastered the heat and lubrication battle without compromising on reliability and affecting machine wear and tear. Visit the Sumitomo (SHI) Demag stand D30 to see how they have reduced cap and closure cycle times from 2.6 to 2.4 seconds. Listen out too for the popping of corks on 30th September it s 40 years to the day when Sumitomo (SHI) Demag launched and Nigel and the team are inviting everyone to share in their success and toast their future. For further information about precision and packaging injection moulding machines from Sumitomo (SHI) Demag, visit the Interplas stand D30 (30 September to 2 October 2014, NEC Birmingham). home.html This is the first time a public European audience will see the IntElect Smart equipped with the optional fast clamp for high speed applications 3

4 MACHINE TECHNOLOGY Sumitomo launches limited edition trade moulding range For the last 40 years, Sumitomo (SHI) Demag has shaped the injection moulding landscape, innovating and developing technology with a resolute focus on boosting efficiency. This autumn, to celebrate this milestone anniversary, Sumitomo unveils the Blue Edition; a unique range of competitively priced machines Sumitomo (SHI) Demag is unveiling the Blue Edition collection to mark its 40th anniversary. for trade moulders who want more features for their money, coupled with a faster return on investment. Available for just four months only, the Blue Edition collection gives small and medium-sized trade and technical trade moulders with the opportunity to upgrade to a top-level, fully integrated variant of Sumitomo s hydraulic machine. With prices starting from just 27,500 00* (ex works) this special offer applies to Blue Edition orders placed before 31 December efficiency. What s more, this variant includes additional specifications to further enhance and optimise productivity, over and above the standard product strengths. Included in the specification are bimetallic plasticising units for processing engineered and filled polymers, which are particularly useful when using abrasive materials. All machines are fitted with an insulated barrel jacket and servo pump, designed to reduce energy consumption. Darren Herron, Commercial Sales Manager With different sized machines, including 50, 100, 120 and 160 tonne, the Blue Edition range offers customers the highest level of hydraulic machine For added assurance, the high-end Blue Edition range comes with a full two year parts and labour warranty. Bespoke payment terms can be arranged on request. 4

5 MACHINE TECHNOLOGY Explaining the rationale behind marking Sumitomo s 40th anniversary with this special edition range, Darren Herron, Commercial Sales Manager says: Our hydraulic machine range still remains a popular choice among our clients for both technical and general purpose moulding. As well as Sumitomo Demag s name being synonymous with innovation, we re also great advocates of helping small and medium-sized (SME) manufacturers to continue thriving in today s fast-moving plastics industry. Although outlay can be perceived as a financial barrier for some SMEs, the Blue Edition shows that there are economically viable options, adds Sumitomo s Managing Director Nigel Flowers. Regardless of what sector our customers operate in they will benefit from this special offer. As birthday celebrations go, this one is not to be missed! For further information please contact Karen Lowe on alternatively mail karen.lowe@dpg.com Food for thought why thin walled food containers are a recipe for success The food industry, like so many sectors, is under constant pressure to increase productivity and maintain standards of manufacture, whilst complying with increasingly stringent legislation and reducing energy consumption. Food packaging needs to be engineered for increased strength, using less material, and always factor in the cost element. There has been a rapid growth in thin walled packaging, mostly for injection moulding and thermoforming applications, such as containers and lids for both food and non-food products. This has been driven by the need to reduce packaging weight, provide new designs and innovative shapes of pack and consumer convenience, highlights Neil Farmer, independent consultant and spokesperson for the packaging sector. Because of the rise in single serve packs and smaller size packs, plus the continuing requirements for light-weighting and pack size reduction, the technology is finding greater usage in many food packaging applications. In retail and catering outlets, thin walled containers are the packaging of choice. With thin wall thicknesses typically less than 0.6mm, food containers are lighter, cheaper to produce, easier to transport and store, use less materials and as a result are more sustainable. Manufacturers are also able to make substantial energy savings. And many containers, espe- cially those using in-mould labelling, provide simple indications of product tampering. The whole package, so to speak! It s a fast and every-growing segment offering multiple benefits over traditional and thermoformed packaging materials reiterates Nigel Flowers, Managing Director of Sumitomo (SHI) Demag. Thin wall packaging can be applied to tubs, cups, pots, trays, clamshells and plastic jars and are used in everything from margarine, yogurt, meat, bakery, fresh fruit, vegetables and microwave, freezer and oven-proof ready meals. As specialists in injection moulding machines and systems, Sumitomo provides injection moulders capable of thin walling to a number of food packaging clients in plants all over Europe. AMI Consulting, a leading market research consultancy, has estimated that over 2.8 million tonnes of polymer are used annually for thin wall packaging in Europe. The food market is by far the largest end-use category, says Neil. However, there are also nonfood applications such as pharmaceuticals, cosmetics, paint and adhesives. Putting this into context, Neil says that the global consumer goods packaging market show that rigid and flexible plastics account for 37% of all global packaging sales. Rigid plastics, which is the category thin walled containers sits in, is forecast to be the fastest growing packaging material up to 2015/16, with More ice cream tubs for your money; productivity boosted thanks to Sumitomo (SHI) Demag s advanced hybrid technology. an estimated annual growth of 4%. Light-weighting and convenience are important factors in this expansion. Catering to lightweights There are occasions when being a lightweight is a clear advantage. A lower moulding weight means significant reductions in material and shipping costs. Stackability of containers is another reason food suppliers and retailers choose it over thermoformed containers. With oil prices at an all-time high, more product can be stacked into transportation vehicles, which does its bit to cut fuel emissions in the logistics supply chain. 5

6 MACHINE TECHNOLOGY El-Exis SP injection moulding equipment has lived up to its reputation for performance and reliability. Thin walling allows for faster cycle times compared to thicker walled plastic parts. This naturally ticks the cost efficiency and productivity boxes for manufacturers of injection moulded food packaging who are always seeking shorter lead times and reduced cost per part, without compromising on quality or competitiveness. Nigel elaborates: To successfully succeed in the thin walling arena it s vital for food packaging manufacturers to examine every potential application to ensure that the selection of materials, machine and tooling give the optimum blend of speed, quality and consistency. Demands to create smaller, lighter parts have made thin-wall moulding one of the most sought after capabilities for injection moulders in the fast-paced world of food packaging and production. The choice of machine is obviously important, and it s here that Sumitomo (SHI) Demag s expertise in hybrid electric/hydraulic machine technology is assisting existing users and new customers alike, adds Nigel. Designed to withstand higher stresses and speeds in a 24/7 production environment, the company s El-Exis SP machines have become the equipment of choice for many thin wall moulding specialists. One food area where Sumitomo equipment is increasing output with minimal operating costs is ice cream. Recently, Sumitomo worked with a leading supplier of thin-wall dairy and ice cream packs, installing its 250T El-Exis SP hybrid injection moulding machine. The El-Exis SP range of hybrid moulding presses is designed for high-speed thin walling production, continues Nigel. It incorporates a number of innovative mechanical and software features and typically achieves 3-5% more productivity than other machines on the market. When fast production speeds and frequent changes are required, machine versatility is vital. It s here that advanced The demand for thin walling is increasing as manufacturers look for lighter, cheaper and more sustainable packaging. system controls combine with superlative build quality to minimise maintenance requirements, changeover times and energy consumption. Efficient production of thin wall plastics also relies on operator skills and experience, and Sumitomo (SHI) Demag places great emphasis on pre-installation training and familiarisation, as well as ongoing process optimisation. From a machinery manufacturer point of view, thinner wall containers brings changes in processing requirements: higher pressures and speeds, faster cooling times, and modifications to part-ejection and gating arrangements. These process changes have in turn prompted new considerations in mould, machinery, and part design. Thinwalled containers provide a range of storage and functionality benefits, as well as tackling the on-going debate surrounding sustainability. Far from reaching its limits, there is significant growth in territories beyond Europe too. Asia, Oceania, Africa and the Middle East have increased their share of the consumer goods packaging market, now matching that of Europe. This, and the trend towards light-weighting and the rising sales of convenience meals and on-the-go snacks, means thin walling in the food industry looks set to stay. 6

7 MACHINE TECHNOLOGY Attention moulders! Now s the time to reap the rewards of all electric moulding All-electric or hydraulic? This is the burning question faced by many users of precision plastic injection moulding machines. Since the early 1990s all electric injection moulding machines have been trickling into the market with precision and energy savings always being cited as the top reasons for their purchase. With the escalation of oil prices globally, it s no wonder why rising energy prices has been a contributing factor to their success. An exciting upward trend in the sales of electric presses began several years ago in Japan and has been spreading in The Americas and recently in Europe, bringing cost-effective all electric solutions to makers of precision plastic products. Direct drives offer leaps in efficiency Fundamental to the fully electric IntElect Smart injection moulder from Sumitomo (SHI) Demag is the main axis of the clamping unit and the injection unit being driven by full electric direct drives. Direct drive machines offer a huge leap in efficiency giving processors many advantages over conventional hydraulic machines including; up-to 75% reduction in energy usage during operation, improved repeatability and fast cycle times making them the perfect choice for manufacturers of mass produced precision parts. Lower energy costs Significant energy savings are made as a direct result of the lower power requirements of the electric drive for the main movements of plasticising, injecting and opening of the mould. Less heat is generated than hydraulic drives and less cooling is required. Electrical direct drives have a high level of efficiency as they do not use gearboxes which cause friction and energy loss. The braking energy of each main axis does not go to waste. Kinetic energy can be recuperated through the use of several frequency drives installed on a common power bus, thus the braking energy of one drive can be passed on to another drive via the inverter, preventing energy from being lost. For example whilst the clamping unit is braking, the energy generated can be used for the energy intensive step of plasticisation. No consumables and low maintenance Unlike traditional hydraulic machines all electric machines have no consumables, such as oil and filters that must be periodically replaced and disposed of, and there is no chance of fluid leaking which means less opportunity for material and surface contamination. This lowers the housekeeping and downtime typically associated with hydraulic machines by up to 50% making all electric machines Valve in the open position. Valve in the closed position. Sumitomo (SHI) Demag s activelock active closing of the non-return valve is possible which increases process consistency and minimises rejects. such as the IntElect when equipped with activecell ideal for clean room operations. All electric technology also boasts quiet operation, making a better working environment on the factory floor. Higher part quality and consistency With the all-electric machines, users can expect less maintenance as there are fewer moving parts and greater manufacturing precision. All electric machines are digitally controlled via encoders making movements of the injection more precise and controlled. Unlike hydraulic machines, their processes do not vary over time as they have no hoses to expand, no valves to potentially stick and no hydraulic fluid to heat up or compress. Once set up correctly, the moulding machine runs without needing attention making the process very repeatable. The screw position during filling and hold is controlled digitally which allows just the right amount of material through, optimising resin usage and preventing unnecessary stress to the mould. Sumitomo (SHI) Demag s all Electric IntElect injection moulder boasts high accuracy, repeatability, and consistency. The non-return valve often forms the weak spot with high precision parts. Traditional systems are only closed passively through the injection pressure applied during the injection phase. Fluc- 7

8 SUCCESS STORIES tuations in the melt viscosity frequently also lead to fluctuations in the closing behaviour, the melt cushion and therefore the shot weight and quality of the parts. Thanks to Sumitomo (SHI) Demag s activelock, active closing of the nonreturn valve is possible. A defined closing movement after the dosing phase completely closes the non-return valve and ensures absolutely consistent closing behaviour which can be actively influenced. The non-return valve is securely closed during the entire injection and hold pressure process. ActiveLock works using a rotating lock ring, which is closed through a counterrotational movement of the screw. During plasticising, activelock opens due to the rotation of the screw and the melt flows through the free channels into the space in front. Post dosing, the screw turns in the opposite direction and reliably closes the melt channels of the non-return valve. This enables manufacturers to enjoy a highly consistent production process. For precision industries such as the medical industry with high tolerance requirements, all-electric machines turn injection moulding into a predictable and precise operation the same process setup can be used repeatedly without the worry of part consistency or poor quality. Variations to parts can be as low as g, which means less waste and reworking. Once a process is set up correctly, it is able to be run with little supervision allowing the workforce to be utilised productively elsewhere. All electric for high accuracy, repeatability, and consistency In the UK, hydraulic injection moulders are still the dominant species when it comes to injection moulding machines. However, the future of precision moulding looks to machines such as the IntElect all electric for high accuracy, repeatability, and consistency. The price of an electric machine is higher than that of an equivalent hydraulic machine but when you weigh up the savings over say a 10 year period, the savings in reduced energy consumption alone justify the extra investment. Cap that! The future s electric for precision mouldings at Guala Closures At its plant in Kirkintilloch, Guala Closures UK works around the clock, producing over millions of components each week. These precision mouldings include innovative products, such as tamper-evident bottle caps, valves and internal devices to make counterfeiting increasingly difficult, as well as decorative closures, all of which are critical to the integrity and visual appeal of premium global brands. Since adopting IntElect injection moulding technology from Sumitomo (SHI) Demag, the company continues to deliver distinctive packaging and customised bottle-cap closures, whilst also reducing energy consumption and boosting output by over 12%. In 2011, Guala, which has 26 plants in five continents, installed two all-electric presses from Sumitomo (SHI) Demag into its Kirkintilloch manufacturing centre. The rationale behind the purchase of the 100 and 160-tonne machines was to speed up production and increase the manufacturing consistency of Guala s precision components, whilst also reducing energy consumption, says its The adoption of IntElect injection moulding technology has reduced energy consumption and boosted output for the Guala plant in Kirkintilloch by over 12% 8

9 SUCCESS STORIES Guala Closures produces millions of precision mouldings, including tamper-evident bottle caps, valves and internal devices as well as decorative closures Sumitomo (SHI) Demag s injection moulding equipment has sped up production and increased the manufacturing consistency of Guala s precision components Manufacturing Manager, Stevie Houston. Satisfied with the results achieved, Guala has since invested in a further six 100 and 160T IntElect machines. The relationship between the two companies began eight years ago when the plant purchased a hydraulic Sumitomo press. Today, the Kirkintilloch centre has seven Systec hydraulic machines with NC4 and NC5 controllers in situ. Right from the start we were impressed by the degree of support and flexibility that we received from Sumitomo Demag, and it s enabled us to build a first-class relationship, comments Stevie. Just like us, they thrive on innovation and we can be sure of getting precisely the equipment we need to meet the fast-changing needs of our market. For instance, we have been able to tailor new machines to work with some elderly moulds with special platen requirements. And we are currently installing two new 120-tonne machines, one of which is equipped for twin shot production so we can produce mouldings in two colours, or from composite materials. Transition to all-electric runs smoothly and pays rapid dividends Rising energy costs was just one factor behind Guala s decision to invest in allelectric moulding technology. The eight IntElect machines installed on site have contributed to some impressive results in speeding up production and meeting quality targets, repaying the company s faith in innovative thinking. Over the last four years, output of closures has increased by 12% and our overall equipment efficiency (OEE) rating has seen a 5% increase, highlights Stevie. This has consistently made us one of the group s top performing plants since In addition, the technology we ve adopted has made a real impact on our quality targets, with a 40% reduction in scrap. Visitors to the Guala plant are invariably impressed by the smooth, orderly atmosphere in the production unit, despite its impressive output and 24/7 operation. This is no accident, smiles Stevie. This is what manufacturing should be a calm, controlled environment with everything running like clockwork. The company s investment in high-speed automatic assembly equipment has paid dividends. Fed by a stream of consistently accurate components, assembly of the finished closures progresses without a hitch. To illustrate the importance of quality, Stevie showcases a particular spirits cap. We produce 16 million of these per year for a premium brand in the Asian market. With an expensive retail price per bottle, we can t take risks with quality. According to Guala, every year all over the world, hundreds of millions of bottles of the most prestigious spirits brands are counterfeited which is a threat to manufacturers and consumers alike. Guala Closures Group produces a huge number of non-refillable pourers, including valve systems and tamper-evident systems. The group also develops and produces innovative cap solutions for the water and beverages, oil and pharmaceutical industries. Dave Raine, Technical Sales Manager at Sumitomo (SHI) Demag UK, comments on this aspect of the company s IntElect range of machines: Our all-electric technology was developed specifically for applications like this. Manufacturers of mass-produced precision parts are choosing IntElect machines to improve the quality and production speed of their products, from closures to medical devices, packaging, automotive and electrical components. The IntElect range of machines combines Demag s mechanical engineering know-how with advanced direct drive technology from Sumitomo. These allow customers to achieve new standards of precision, performance and productivity for critical moulding applications. The savings in reduced energy consumption alone brings rapid payback and IntElect is fast becoming the technology of choice for leading manufacturers the world over. 9

10 MACHINE TECHNOLOGY Improved reliability and parts quality? It s as easy as AFB! An innovative option from Sumitomo (SHI) Demag allows injection moulders to optimise their processes and achieve significant improvements in quality. Dave Raine, Technical Sales Manager, outlines the secrets of activeflowbalance. Thanks to the drive and control systems offered by Sumitomo s all electric IntElect Smart, the system maintains an absolutely fixed screw position, with no additional pressure applied once the injection phase is complete. Jetting, sink marks, short shots, flash, voids and warping these are just some of the problems that affect productivity and eat into profits. Many of these have their roots in the transition from injection to holding pressure. Parts with multiple gates, parts with thin-wall areas at the end of the flowpath, and parts which are very small in relation to their sprue weight can all too often incur unacceptable reject rates. Increasing the injection pressure can cause flash caused by pressure peaks and malformed parts due to stress. By adjusting the holding pressure and altering the switch over point, the pressure peak problems are avoided but only at the risk of short shots incomplete mouldings due to insufficient material. A question of balance The introduction of activeflowbalance by Sumitomo (SHI) Demag gives manufacturers a unique tool to combat uneven and fluctuating filling of multicavity moulds. Suitable for a broad range of applications, the activeflow Balance option allows mould setters to avoid the potential problems of uneven filling of the mould without extending the filling time. What would previously have been a complex injection profile, requiring many years of experience and training to implement, can now be achieved in under one-minute, with minimum input from the setter or technician. Faced with these issues, the mould setter s usual remedy is to adjust filling speeds, pressures and change over positions to reach a compromise which achieves the best result given the issues faced. However, this solution is far from ideal. Sumitomo s activeflowbalance option is perfect for automotive component manufacturers wanting to avoid the potential problems of uneven filling of the mould. 10

11 SUCCESS STORIES Once the injection process is complete, the activeflowbalance function controls switch over, holding the screw at a fixed position for a pre-selected period of time before moving on to the standard hold pressure setting. During the activeflowbalance phase, no additional pressure to the material is activeflowbalance delivers improved weight distribution, more even fill and less wear and tear on machinery and moulds thanks to lower clamp pressure. applied, allowing the existing cavity pressure within the melt to equalise throughout all the cavities. As the pressure is allowed to stabilise across the system, pressure flows into the cavities which are under-filled, reducing the imbalance, and producing a more even fill pattern. Maintaining an absolutely fixed screw position, with no additional pressure applied once the injection phase is completed, is only possible due to the drive and control systems offered by Sumitomo on its all electric machines. The duration of the activeflowbalance stage is contained within the entire period of holding pressure, so there s no increase in cycle time. activeflowbalance is available as an option on all IntElect Smart all-electric machines, and can be retrofitted to existing machines. This unique development delivers a much improved weight distribution, a more even fill, and with clamp pressures reduced by up to 40% less wear and tear on machinery and moulds. The operator-friendly, intuitive controls make it easy to achieve consistently high product quality, even on challenging applications. No wonder that leading manufacturers of such diverse products as automotive components and medical devices trust Sumitomo (SHI) Demag and activeflowbalance to help attain market-leading levels of productivity. Turbulent flow temperature control cuts cycle times at Warden Plastics Sumitomo s powerful temperature control units have enabled Warden Plastics to cut the cycle time of its Biomarble biological filter production process by 10%. Fitting Sumitomo (SHI) DEMAG temperature control units on two of its highest output machines has enabled injection moulding specialist Warden Plastics to not only stabilise its process but also accrue significant financial savings by shaving 10% off cycle times. Besides providing contract manufacturing of extruded and injection moulded parts and products to the automotive, elec- tronics, medical, construction, point of sale and vending industries, Luton-based Warden Plastics produces its own range of Biomedia branded biological filter media. One of these products, the Biomarble, is a spherical polypropylene filter used in industrial and municipal wastewater treatment plants. To keep pace with rising demand for these filters, last September Warden Plastics decided to upgrade the moulding tool on its Sumitomo Systec 160-tonne machine from an 8-impression to a 16-impression tool. The increase in cavities meant more heat was entering the tool, and Warden Plastics quickly realised it needed some serious mould temperature control if it was to maintain a stable process at high speed. As more heat was entering the process, we were unable to run the tooling for any length of time due to overheating. Because of the size of the tooling and the speed of the cycle we needed a temperature controller with more powerful flow and heat transfer capabilities, says Mark Barrett, managing director of Warden Plastics. Sumitomo recommended fitting two AEC TrueTemp TCU 300 9kW water temperature control units on the mould. These stand-alone units can be fitted to any make or model of injection moulding machine to provide highly accurate control for applications requiring a continuous supply of temperature-controlled water. Their innovative design promotes turbulent water flow to maximise heat transfer performance, delivering far more efficient and effective control than the indirect cold water systems that are widely used in the industry. Nick Smith, processing and training manager at Sumitomo, explains: Our TCUs use a powerful pump to create a turbulent flow action. This results in a high 11

12 SUCCESS STORIES Warden Plastics has installed two Sumitomo temperature control units on the Systec 210 machine it uses to produce balloon sticks for one of its customers. flow rate and better cooling capacity than a system with laminar flow. On these systems, the water temperature rises as the water circulates around the tool, whereas with our system, the temperature differential between the water entering and leaving the tool is minimal just a couple of degrees. It s a far more efficient method of cooling. Nick continues: The direct cooling design also makes for far more efficient heat extraction than an indirect unit with a heat exchanger. Plus, direct cooling provides constant flushing of the tool circuit to minimise corrosion. He adds: All injection moulding machines use some form of basic temperature control, but the advantages of optimising this operation are often overlooked. Anyone wanting to improve process control and reduce cycle can benefit from a TCU whatever their product or industry. There are other companies who make direct cooling systems, but they cost approximately three times as much as the AEC unit. What s more, Warden Stand-alone temperature control units can be fitted to any make or model of injection moulding machine to improve process control and reduce cycle whatever their product or industry. Plastics has a lot of faith in Sumitomo s knowledge of its product and process. Sumitomo was able to demonstrate an understanding of our product. With their advice and optimisation, I was confident we d be able to run the product successfully, says Mark. Since installing the units, Warden Plastics reports that it is able to run a stable process, producing a consistent, repeatable product with zero defects. What s more, the TCUs have shaved a second off the cycle, reducing cycle time from 12 to 11 seconds. When calculated across 5,236 units per hour on a 24 hour operation, this represents a considerable cost saving. We expect the TCUs will pay for themselves within a year, says Mark. This was not the first time Warden Plastics had installed TCUs on its injection moulding machinery. Five years ago, the plastic moulding and extrusion specialist purchased two TCUs for a Systec 210 machine it uses to produce balloon sticks for one of its customers. It was a similar story to the Biomarbles, recalls Mark. Following mould flow analysis, we optimised the design of the stick to make it faster to produce and to use less material, and the mould was upgraded from a 12-cavity to a 16-cavity tool. However, we found we had to slow the cycle to maintain and control the temperature of the mould itself; to achieve the designed and desired cycle time we switched to a bigger, better TCU. Equipping the injection moulder with two AEC TrueTemp TCU 300 9kW units not only restored productivity, but took 1.5 seconds off the cycle time. Cycle time is a key determinant for our profitability, comments Mark. Warden Biomedia designs, manufactures and supplies Random Biological Filter Media to improve aerobic treatment across the full range of applications from the largest municipal sewage treatment plant down to a garden fishpond. With the philosophy of increased surface area, the eco-friendly trickling filter and biological filter media are injection-moulded in recycled polypropylene with specific design features to increase the efficiency of the effluent treatment process. In a choice of spherical and tube formats, to suit the application, the random filter media provide excellent ventilation to speed-up the aerobic reaction, and also have high voidage to prevent blocking (and the resulting slowingdown) of the wastewater treatment process that might occur. 12

13 MACHINE TECHNOLOGY Sumitomo s hydraulic tackles escalating energy costs Reducing running costs remains a common challenge for all manufacturers and energy consumption power, water and other operating resources is a key consideration when calculating total cost of ownership. A growing number of injection moulders who want to save on energy costs are turning towards hydraulic machines equipped with a servo drive Initial outlay for hydraulic machines is often less than switching to all-electric, often at another cost; conventional applications are traditionally more energy intensive. But there are other alternatives highlight Sumitomo (SHI) Demag, the specialists in injection moulding machines and systems. A growing number of injection moulders who want to save on energy costs are turning towards hydraulic machines equipped with a servo drive. Sumitomo (SHI) Demag reports that over half of the hydraulic machines they have delivered to customers in the last year now feature the company s activedrive hybrid technology, which reduces energy consumption by up to 60%. The market for hydraulic machines remains buoyant, especially in the UK and across Europe, observes Nigel Flowers, Managing Director at Sumitomo (SHI) Demag. While it s true that there s a shift towards all-electric machines for precision work, hydraulic machines still remain a popular choice for general purpose moulding. Thanks to applications like activedrive, hydraulic machines deployed in all sectors, including precision and automotive, can benefit from variable-speed drives, bringing energy-savings in closer alignment to that of all-electric injection moulding systems. For injection moulders with plenty of life left in their hydraulic machines, active- Drive can be easily retrofitted to Sumitomo equipment, even those from twodecades back. We can quickly assess the feasibility on a case-by-case basis, says Nigel. The actual process itself is straightforward and the cost minimal compared to the immediate energy savings. We fit a frequency converter to the machine pump and modify the controller. This has no impact on output or quality. With sustainability high on everyone s agenda, it s important that every customer has access to a viable energy-efficient option that matches their operational requirements, adds Nigel. Sumitomo s Systec Servo plugs an important gap and offers an alternative to all-electric Launched just 12-months ago, it has proved extremely popular with Sumitomo s loyal customer base; one out of every two hydraulic machines dispatched and installed by the team is now equip- ped with this energy-saving servo drive. To have achieved a 50% switch in such a short timeframe demonstrates that customers are eager for a quick solution to cut their energy bills, adds Nigel. Sumitomo s Systec hydraulic injection moulder is built to suit customer s needs, it combines the advantages of servo technology with hydraulic pump control. This is especially attractive for partial load operations typical of general purpose moulding applications, where activedrive guarantees optimum performance for every phase of the machine cycle. Whereas standard hydraulic pumps will run at a fixed speed continuously, the frequency-controlled servo motor automatically matches the amount of oil volume required for the output task being undertaken. If no additional flow is required, the pump simply stops operating. As a result, hydraulic machines equipped with activedrive can be up to 60% more energy efficient, depending on the application. Managing partners Norbert and Sven Borscheid and Carlo Wenig of the German-based plastics manufacturer 13

14 MACHINE TECHNOLOGY Borscheid + Wenig GmbH has adopted this technology and is extremely satisfied by the hybrid s performance. So much so, they are about to take delivery of a new Systec machine featuring activedrive, which the partners advocate further supports their company environmental policy. It offers a good price/ performance ratio, energy-efficiency, and considerably reduces cycle time, they say. Nigel. Hydraulic injection moulding machines used to emit noise levels of over 70dB, which is why operators wear eardefenders. With activedrive, it s down to 60dB. That s equivalent to a normal conversations or a household air conditioning unit, and well below the recommended industry standard of around 68dB. While the argument for all-electric machines is a compelling one, hydraulic machines are far from redundant. Zero energy waste is the real target, and thanks to technologies like activedrive, fully hydraulic machines are closing the energy-efficiency gap, boosting business profits, without compromising on product quality or cycle times. Toggle joints also play a vital role in energy savings and machine durability. The Systec features a toggle clamping unit, offering a force ranging from 1,600 to 20,000 kn. In real terms, a larger hydraulic machine will have larger pipes and pumps and will use considerably more oil when opening and closing a mould, explains Nigel. Converting to a mechanical system significantly reduces the time it takes to lock the mould. For larger machines this can equate to 50% in energy savings and 30% for smaller systems. What s more, an activedrive equipped machine is almost as quiet as an allelectric. This makes for a much more pleasant working environment, claims Sumitomo s activedrive technology reduces energy consumption by up to 60% Sumitomo launches CE certification service for grey area installations Sumitomo (SHI) Demag has launched a new CE certification service for robotic injection moulding machines, relieving its customers of the burden of self-certification a time-consuming process that requires specific legal and technical knowledge. The new service has been created specifically to enable injection moulders to achieve compliance with European health, safety and environmental directives governing machines that have been modified to incorporate a robot and peripheral equipment. Since 1995, injection moulding equipment manufactured outside of the EU or imported from non-eu countries has been subject to the CE marking process when put into service in the European market. When the injection moulder incorporated a robot, it was sufficient for the robot to be accompanied by a Declaration of Incorporation, as the robot was considered to be partly completed machinery. There was no requirement, by law, for the cell in its entirety to be CE marked. With the Supply of Machinery (Safety) Regulations 2008 and amendment in 2011, it became mandatory for the complete robotic cell to carry the CE marking. The directive also stated that whoever created the final installation whether integrator or end-user was responsible for obtaining this certification. The regulation is enforced in Great Britain by the HSE (Health and Safety Executive) and any non-compliant installation can result in a fine of 5000 or up to two years in prison. However, according to Nigel Flowers, managing director of Sumitomo (SHI) Demag UK, many companies are unaware that the onus for CE marking their robotic injection moulders has shifted, and may be breaching the law. Whilst most of the larger moulding shops are well aware of their legal responsibili- 14

15 MACHINE TECHNOLOGY Sumitomo s new CE certification service ensures customer s robotic injection moulding cells are compliant, for a competitive fee. ties, a lot of smaller injection moulders aren t. There are many instances of companies who have added a robot and guarding to their injection moulding machine and think that makes it perfectly safe and legal. Even companies who are aware of the need to obtain CE certification for installations are struggling to find someone to certify their equipment and for a fair, not extortionate, fee, according to Nigel. It s straightforward enough when buying a robot and an injection moulding machine together from the same supplier, as they will usually CE certify the cell before it leaves the factory. Complications arise when, for example, the injection moulder and the robot are from different manufacturers, or a company is buying a robot to incorporate into an existing moulder. We ve heard of companies being quoted 10,000 just to get one cell CE certified. He says the issue has become more apparent as take-up of robots by the injection moulding industry has grown. More and more injection moulders are investing in robotics, and a lot of companies run the risk of not having all their safety paperwork in place when trying not to hold up an automation project, he explains. There is the option of self-certification. To achieve compliance the company must nominate a Responsible Person to undertake the conformity assessment process. This includes meeting all relevant essential health and safety requirements (EHSRs) for the product, producing comprehensive user instructions, and showing how compliance has been achieved in the technical file. However, even if companies have someone in-house with the necessary competence to undertake this responsibility, it will probably take them several days to carry out the inspections and compile the supporting documentation. Furthermore, injection moulding machines have to meet the higher safety requirements set out in the European Standard BS EN 201:2009. With this in mind, Sumitomo has come to the rescue with a full CE compliance service for a fraction of the cost of many other CE consultancy offerings. Available exclusively to Sumitomo customers from a competitive 3,000 fee, this comprehensive service gives customers peace of mind, as well as a full technical file containing all relevant information to support the CE marking of their cells. This usually includes technical drawings, bill of materials, test reports and assessments, instructions and other documents required by the directive to support the conformity of the product. European health, safety and environmental directives now mean it is mandatory for injection moulding machines with robotic or peripheral equipment to carry the CE marking. 15

16 Sumitomo (SHI) Demag Plastics Machinery (UK) Ltd Accent House Triangle Business Park Stoke Mandeville Bucks HP22 5BL Tel.: + 44 (0) Fax: + 44 (0) sales.uk@dpg.com