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Upgrading standard injection moulding machines (IMM) to multi-component machines – in just two short steps

22.02.2019

“The fat years are over“ (source: see footnote). During weaker economic periods investment, given sound judgement, is indispensible in order to re-establish competitiveness – to get orders through the door. Any mould maker active in the plastics processing industry will need to think twice, and carefully, before investing in a multi-component machine for special sampling operations. An automotive parts supplier may face this very question at a time when orders are thin on the ground and requirements are on an upward trend. Why not upgrade an existing single-component IMM to a multi-component IMM instead? Hence, why not make enquiries at WINDSOR, Hanau, Germany, to establish possible options?

190220-P3Over a number of years WINDSOR has retro-fitted many a IMM from single-component to multi-component units offering most attractive economic solutions. The PlugXPress® series – PxP from 42 to PxP 1780 – are autonomous injection units, basically equivalent to an IMM without a clamping unit. WINDSOR’s great strengths include the company’s special adaptations for its customer: “We offer adaptations to fit the overall configuration – exactly“. The result: Individual systems with individual  specifications where the PxP unit communicates via an interface with the IMM. There is no need for the customer to make any modifications to his IMMs, he simply needs to connect the PxP operating with a three-zone screw from 16 to 105 mm, a B&R control and a 15“ touch screen. The PlugXPress® supplementary unit for multi-component injection moulding can be connected to any machine. “One of our customers produces toothbrushes applying this solution – in three plastics materials and in four different colours.“ Rising multi-component demand and the success of the PxP are demonstrated by the number of sold units during 2017 has more than doubled compared with the previous year. “Our strengths include the individual adaptations available; our high flexibility sets us apart from our competitors. When standard solutions no longer fit the bill PXP comes to the rescue.“ As soon as the PxP unit has completed an order on one IMM it can – as soon as required – be plugged onto another IMM as a mobile unit.

The PlugXPress series takes its queue from the ‘plug and play‘ concept; the units are ready to be easily connected to the IMM. As an independent plasticizing unit the PXP communicates with the machine via a standard interface: “All processes can be handled straightforwardly – simplifying the tasks at the IMM immensely“, emphasizes Andreas Janisch, product manager at WINDSOR. The beauty of the easy application is that the PxP series is top of the class – state-of-the-art. According to Janisch a technical upgrade is in the pipeline enabling B&R control to function via Open Protocol. The injection units are not simplified, but a mobile moulding machine without a clamping system that fits any IMM – of any given type or origin – thus injects a second and/or subsequent component/s into the mould. “PxP is no scaled down variation but a fully functional unit“, explains Janisch. Highly wear-resistant materials for screws are standard. Virtually all prevalent thermoplastics as well as bespoke blends are processed, including polyamides containing fibre glass and engineering plastics. “We offer a standard three-zone screw and also special adaptations. Overall, we offer nine basic PxP units equipped with three screws each“, continues Janisch.

How does injection moulding take place at the PxP? “First of all, we require a substrate, the first shot of the IMM – in the standard process for the basic part – followed by the other components via the PxP unit“, elaborates Janisch. The machine signals the moment the substrate is ready. This indicates the go-ahead for the first of “n“ PxPs.“ During the entire process the products are logged most meticulously:  The PxP unit encompasses storage for 1000 programmes. That number can be increased significantly with the use of a USB memory device. The advantage of PxP is its variability resulting in considerable cost savings for users. Janisch: “A typical starter machine would be a standard IMM. The user manufactures parts to the completion of the order. With a new order the possibility of issues with differing moulds may occur, in particular when dealing with multi-component part production. This would necessitate investing in a multi-component machine. Not an issue with PxP: At a third of the cost of a multi-component system users could enjoy upgrading their standard IMM.“ Subsequently, orders with different requirements can now be processed flexibly. Following the financial and economic crisis during 2008/2009 such significant cost savings derived from retrofitted PxPs benefitted a number of companies in the plastics industry.

In the current economic climate producers can generate advantages by adding PxP, with a choice of nine units with three different screw diameters each – shot weights between 20 g and 4 kg – plus special units which can simply be upgraded to create a multi-component machine. For instance PxP is mounted on the fixed platen side, its tip connected to the mould via threaded connector, and the plastics material to be moulded is introduced through the mould directly into the cavity/ties. The injection unit can be fitted vertically, but also at different angles: “We are ahead of our competitors by such a flexible approach“, elaborates Janisch. PxP convinces with its streamline design; the injection units of competitors are frequently just standardized products. “Many of our customers face issues with floor space. For that reason our design gets very close to the IMM resulting in a truly flexible solution. Quoting a different scenario: with vertical presses the injection gates are positioned quite low. Therefore, hydraulics and control unit are positioned alongside the press“, according to Janisch.

Which manufacturers are already using the WINDSOR PxP series? For example, a Swiss company uses PlugXPress® Plus 4 to manufacture toothbrushes in a multi-component process. The substrate is a white PP, then soft components are followed by a concluding component. All processes involve one single machine, even including the use of four different colours! Janisch explains: “Prior to PxP manufacturers had to produce, say, one million toothbrushes in blue, followed by 1 million green, 1 million yellow and 1 million in red.“ Now, employing PxP, multi-component toothbrushes can be produced in one single cycle and straight to the packaging unit. Four differently coloured toothbrushes are manufactured in one cycle. “PxP is thus revolutionary and affords significant time and cost savings – at consistent quality“, emphasizes the WINDSOR product manager. This process involves one 350-ton IMM with four PxP42 units and 18 mm screws. For the second component the shot weights are about 30 g. The independent control system of each PlugXPress® unit allows a variety of additional functions to be added, controlled and monitored, such as core pulls, turn tables, hot runner systems as well as cascade features.

An additional PxP application: an automobile supplier manufactures wheel-house covers for German mid-range cars. The task: following the initial injection process a soft component is to be injected to the rim. Issue here is sufficient floor space. Hence, a specific integration process into the machine had to be found. Solution: one PxP 257 was mounted between the machine tie-bars and the rear safety gate. The main body was PP with a sealing lip in TPE – shot weight 40 g.

Another manufacturer produces bumpers with the help of PxP. Here, the injection unit – at a variant in 45 degree position – had to be supported on the tie-bar to enable connection with the mould. In the 45 degree variant the screw diameter can measure up to 43 mm. For another automotive product application a frame or a slide rail had to be fitted to the IMM. Therefore, the PxP aggregate can travel with the moving side of the mould.

During the project phase for a well-known Swedish company pallets with an anti-slip coating are currently being produced whereby non-slip pads are injection-moulded onto the pallets, and all this using one single mould! Here, a multi-component IMM moulds base plate and subsequent soft components  – the PxP unit is responsible for the latter. This injection unit – with a 105 mm screw – works on a 2300-ton IMM and deliver a shot weight of 3.5 kg.

Even when processing composite materials  PxP units come to the fore: for instance with vehicle interior trim. “Up to now, fibre mats had to be pressed and punched. Now, the process happens in one single phase“, explains Janisch. “The mat blanks are placed in the machine, are effectively baked, shaped to the correct form, and during the second phase – in the same machine – injection of reinforcing ribs and screw attachments takes place. We deliver the whole package: none of the presses need to be modified, the cascade valve timing device complete with hot runner temperature control are available as standard including 50/55 mm screws.“ The result: No need for this particular manufacturer to concern himself with the injection moulding process, he can just commence production without having to learn new process procedures.

One of the truly unique selling points of the PxP series, as part of plastics processors‘ armoury when preparing for particular times and specific challenges, is effectiveness and mobility – with maximum consistent quality. Due to the system’s versatile deployment and installation possibilities, the PxP is indispensable for mould makers who want to sample multi-component products and who want to produce small batches in rapid rotation without the need to invest in a large fleet of machines Why not get in touch with WINDSOR/Hanau and enquire what can be achieved?

http://www.windsor-gmbh.de

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