ENGEL is set to demonstrate a new approach to sustainable and space-efficient production at K 2025, focusing on the manufacture of robust technical parts from 100% post-consumer recyclate. The centrepiece of the exhibit is an all-electric e-mac 220 injection moulding machine, which produces thick-walled plastic components for the construction sector. This system is designed for maximum material savings and energy efficiency, offering a compact footprint suitable for integration into existing production environments.
The process utilises ENGEL's foammelt technology, which introduces a blowing agent into the melt, creating a finely celled foam structure. This approach, combined with a specially developed additive mix, results in components that are both lighter and more impact-resistant. In the showcased application, the system achieves around 30% weight reduction with a shot weight of 538 grams, while increasing the impact resistance by 10%. Such properties make these parts suitable for replacing heavier materials like concrete in construction applications, particularly in shafts and other infrastructure elements.
Advanced use of post-consumer recyclate and additive technology
The recyclate processed in this cell is sourced from the German “Gelber Sack” collection system, supplied by PreZero and reprocessed by EREMA. For the foaming process, an additive and blowing agent mixture developed by Moxietec is used, enhanced with the Vistamaxx additive from ExxonMobil. Precise dosing is managed by a gravimetric system from Movacolor, ensuring consistent material quality. The Moxietec formulation is particularly effective for thick-walled parts, overcoming the limitations of conventional foaming methods.
Homogeneous melt preparation is achieved with ENGEL’s standard mixing screw, specifically optimised for uniform mixing behaviour in foamed applications. The system also features a ring non-return valve with a new geometry, including crowned valve wings and a short-stroke version, which together improve reproducibility and speed up closing behaviour. This design eliminates the need for decompression after dosing, preventing sink marks and air inclusions in the finished part.
Compact solution for resource-efficient manufacturing: At K 2025, the all-electric ENGEL e-mac 220 processes
Digital assistance and process optimisation
The plasticising unit is equipped with iQ melt control, a digital assistance system that analyses the plastification process and recommends optimal parameters for screw speed, back pressure, and dosing stroke. This ensures consistently high part quality and maximises material efficiency, even with recycled materials. A cold runner system further supports the foaming process, with the cycle time for the two-cavity Moxietec mould averaging 120 seconds.
Temperature control is another critical aspect, especially for thick-walled components. ENGEL’s latest e-temp units operate with water at just 90 °C, eliminating the need for separate hot-water piping and reducing operational costs. The iQ flow control system dynamically monitors and regulates temperature, immediately correcting deviations to ensure uniform cooling, minimise warpage, and improve dimensional accuracy. This contributes to process stability and reduces energy consumption associated with temperature control by up to 85%.
The production cell is designed for compactness and automation. A servo sprue picker removes the sprue, while an ENGEL viper 12 linear robot extracts the moulded part and places it on a conveyor belt integrated within the machine’s safety guard. All automation is fully integrated with the injection moulding machine’s control system, with iQ motion control optimising movement sequences to further reduce cycle times and energy use.
With this demonstration, ENGEL highlights how sustainable production, advanced foaming technology, and intelligent cell design - supported by digital assistance systems - can be combined into a practical and economically attractive solution for the plastics industry. The system provides a stable process for demanding recycled material applications, fitting seamlessly into compact production spaces.
