For more than seven decades, Husky has been developing plastics packaging molding technologies, from thinwall cup molds in the 1950s and stack molds in the 1960s to today’s fully integrated production platforms. The latest generation of Hylectric and Hypersync systems continues this approach, focusing on productivity, precision, process stability and material loss reduction under conditions of rising operating costs, sustainability requirements and increasing complexity of packaging applications.
Integrated approach to melt delivery
The Hylectric and Hypersync platforms are designed as fully integrated melt delivery systems, combining injection molding machines with dedicated Husky hot runners and mold controllers. Control of the entire process, from material feed to the mold cavities, is intended to ensure consistent part quality, high productivity and minimal scrap within the widest possible processing window.
On this integrated basis, each platform offers different benefits depending on the production profile. The Hylectric platform is described as a standard in packaging molding, with an emphasis on productivity, configuration flexibility and ease of operation. A key element is the three-platen clamping unit with Reflex platens, which distribute clamp force evenly across the entire molding surface. This is intended to support dimensional stability between cavities and extend mold life.
Wide tie-bar spacing and robust clamp bases allow the use of heavy, high-cavity molds that in conventional set-ups would require larger injection molding machines. At the same time, flexible integration interfaces and Industry 4.0 connectivity have been provided, allowing the machine to be treated as the central element of an integrated production system.
State-of-the-art solutions in Hylectric 6 and Hypersync platforms
Within the Hylectric line, the latest generation designated Hylectric 6 has been introduced. According to the manufacturer, it reduces non-productive time, improves energy consumption and increases system availability through the use of Advantage+Elite monitoring. Integration of monitoring is intended to enable analysis of machine and auxiliary equipment operation in real time and faster response to process deviations.
The Hypersync platform is focused on applications requiring very short cycle times and high repeatability: thinwall food packaging, lids with in-mold labelling, specialty closures and selected products for the medical and personal care sectors. The use of electric drive for mold movement and clamp locking, energy recovery systems and speed-variable servo pumps is intended to significantly lower energy consumption without limiting process dynamics and productivity.
Hylectric platform
Scope of applications in packaging molding
The Hylectric and Hypersync platforms are applied in a wide range of packaging uses, including production of thinwall containers and lids, including in-mold labelled solutions, pails, specialty closures and packaging made from renewable and recycled materials. Specialized screw geometry and suitable material selection, together with treatment of melt stream components, increase wear resistance when processing recyclates and bio-based materials.
Both platforms can be combined with stack molds, which makes it possible to nearly double production output at an unchanged footprint. This is particularly relevant for projects with very high volumes, where the possibility of expanding the machine park is limited. The use of stack molds requires a stable clamping and melt delivery system, which is taken into account in these platforms from the outset.
Hypersync platform
Advantage+Elite monitoring and support for recyclates
A factor that further enhances the capabilities of the systems is the Advantage+Elite remote monitoring integrated with the Hylectric and Hypersync platforms. This service tracks more than 70 performance parameters in real time, providing analytical data on machine and process status. The data can be used for proactive maintenance, efficiency improvements and management of system availability and load.
The manufacturer indicates that optimized screw geometry, choice of construction materials and special treatment of melt flow components support efficient processing of recyclates and bio-based feedstocks. These solutions are aimed at enabling the production of more sustainable packaging while maintaining the mechanical and visual properties required by the market.
The combination of an integrated approach to melt delivery, the ability to use stack molds and advanced digital monitoring positions the Hylectric and Hypersync platforms as solutions for demanding applications in the plastics packaging industry, including those with a growing share of recyclates and materials with an enhanced environmental profile.
