Advanced hot runner solutions increase sustainability in injection moulding

Both technologies help to reduce the environmental footprint of the injection moulding process. This starts with the lower energy consumption of the servo-electric system compared to the hydraulic system and includes the ability to use smaller injection moulding machines and family moulds, reduce wall thicknesses and reduce scrap thanks to better process repeatability.

Oerlikon HRSflow has recently made the operating software for controlling the FLEXflow hot runner systems even more intuitive and convenient. With the thoroughly revised Human Machine Interface (HMI) 4.0, systems with different nozzle types can be integrated and several parameter sets can be stored per mould. Extended possibilities exist for the individual control of the respective servo motors for nozzle needle positioning and for monitoring process stability. In addition, specific user accounts for individual access authorisations can now be set up and managed. Thanks to the web connection, access to the control unit is possible regardless of location.

Turnkey Molding Solutions

In close cooperation with sister company Oerlikon Balzers, innovative coating protection for perfect molded part surfaces can also be offered. One current application is BMW's iXe all-electric SUV, which uses Oerlikon Balzer's ePD technology (embedded PVD for Design parts). This forward-looking, environmentally friendly coating process can be used wherever high-quality, metallic-looking surfaces on plastic parts with intelligent functionality are required.

Systems from Oerlikon HRSflow in action

Systems from Oerlikon HRSflow can be experienced live on the exhibition stands of Engel (Hall 15, Booth C58, door panel and smart rear panel), Tederic (Hall 15, Booth D40, 2K High Gloss B pillar), Arburg (Hall 13 / Booth A13 – B13, multi-component tool box made of PC+ABS and RECOPOUND – the recycled compound based on PET by Leonhard Kurz), Haitian (Hall 15, Booth A57, fruit box made of PE plus Tetra Pak recycled shredded flakes), Wittmann-Battenfeld (Hall 15, Booth C06, 3K coffee cup), Billion (Hall 15, Booth B24, garden tool), and Netstal (Hall 15, Booth D24 R-PP thin-wall cup).

Presentation: On the way to the digital process twin

During the show, Oerlikon HRSflow, Engel and Borealis will report at Oerlikon’s booth D10 in hall 1 on a jointly realized project which, using a family mould with three different cavities, shows how close simulation and reality can be when the partners each contribute a maximum of know-how. Instead of the usual sequential approach, the participants accompanied the development steps simultaneously and provided all relevant data of the injection molding machine, the valve gate hot runner system and the processed material for a perfect flow simulation. The parameters determined there were finally transferred to the injection moulding machine's control system. Compared to conventional sequential cooperation, the time until the initial sampling of the mould and for the commissioning itself could thus be significantly reduced.