The Rejlek Group in Vienna has commissioned Austria's first fully integrated SAM-C automation solution from Sumitomo (SHI) Demag. The new production cell is based on a fully electric IntElect 130 injection moulding machine and is used to manufacture high-precision plastic components. The plant particularly emphasises process stability, energy efficiency and precision, marking an important step towards more sustainable manufacturing.
"For us, the combination of cost-performance ratio and technical sophistication was decisive," explains Johannes Burtscher, Operations Manager for Injection Moulding and Stamping Technology at Rejlek. "The machine offers an exceptional depth of value creation, from the drive technology to the integrated robotic solution. What particularly impressed us was the seamless integration of the SAM-C robot, which significantly simplifies operation and maintenance."
At the Vienna plant, precision plastic components are produced for industrial electronics, mobility and medical technology. On the new fully electric IntElect injection moulding machine, materials with a high glass fibre content and with recycled content are processed. The machine is designed to safely process recycled materials, enabling production waste to be returned directly to the process and the material loop to be efficiently closed.
Stable process for processing recyclates
To ensure consistent product quality, even with varying feedstock parameters, the IntElect machine is equipped with activeMeltControl technology. This system automatically compensates for fluctuations in material properties, allowing a high level of process stability to be maintained with minimal scrap. The adaptive control system continuously adjusts the injection process, stabilising production conditions in real time.
This solution is particularly beneficial when using multi-cavity moulds, where uniform filling of all cavities is crucial for dimensional repeatability and surface quality. The combination of adaptive control and electric drives helps to reduce process deviations and improve overall equipment effectiveness.
Compact automation integrated with the injection moulding machine
A key component of the new production cell is the fully integrated SAM-C robot. The applied automation concept has a compact design, which saves valuable production floor space. The machine and robot are controlled from a single system, resulting in intuitive operation, simplified staff training and reduced downtimes related to changeovers and maintenance.
In the production process, the SAM-C robot is responsible for precise part removal from the mould and handling in subsequent process steps. This includes secure placement of parts and their preparation for further assembly or inspection. The integrated automation contributes to higher process reliability and consistent product quality, especially when manufacturing components with tight tolerances.
Michael Domes, Managing Director Sales Austria at Sumitomo (SHI) Demag, highlights the importance of this configuration for users of electric injection moulding machines. "With the SAM-C series, we offer a fully integrated automation solution that is perfectly matched to our fully electric machines. The combination of high dynamics, energy efficiency and ease of use provides our customers with new opportunities to manufacture more productively and sustainably."
Sustainability as part of daily practice
At Rejlek, sustainability aspects have long been embedded in day-to-day operations. In addition to the use of recycled materials, the company optimises cooling management and relies on closed water circuits, which reduces media consumption and environmental impact. The use of a fully electric drive system further helps to reduce energy consumption compared to hydraulic machines.
"Our fully electric system significantly reduces energy consumption compared to hydraulic machines," emphasises Burtscher. "At the same time, we benefit from precise, stable cycles and a very high Overall Equipment Effectiveness (OEE). The technology supports both the company's ecological and economic objectives, which is crucial for both Rejlek and Sumitomo (SHI) Demag."
Long-term cooperation and development prospects
The cooperation between Rejlek and Sumitomo (SHI) Demag has been developing over many years. Around every tenth injection moulding machine at the Vienna plant comes from this German-Japanese manufacturer. The relationship between the companies is based on trust, technical expertise and short communication paths, which facilitates the implementation of further modernisation and investment projects.
"We see great potential to further expand the partnership in the area of multi-component technology in the future," notes Burtscher, referring to possible directions for the development of the machine fleet and the scope of automation.
For Michael Domes, the installation of Austria's first SAM-C cell marks another important step in the development of the market for electric injection moulding machines. "Rejlek impressively demonstrates how precision, automation and sustainability can be harmonised. The implementation of this project confirms that fully electric production is convincing not only technologically but also economically."
Johannes Burtscher highlights the potential for further development of cooperation in the field of multi-component technology
