Oerlikon HRSflow is set to make a significant impact at K 2025 in Düsseldorf, showcasing a suite of advanced hot runner technologies that promise to redefine efficiency and quality in injection molding. With a focus on innovation, the company will present its latest developments, including the revolutionary STARgate HRS hot runner system and the patent-pending Glow HRS solution. These technologies are engineered to address the evolving needs of industries such as automotive, packaging, beauty, and personal care, offering improved process control, reduced cycle times, and enhanced product aesthetics.
STARgate HRS: A leap forward in injection molding
The STARgate HRS hot runner technology represents a radical shift in the injection molding of polypropylene (PP), polyethylene (PE), polystyrene (PS), and other amorphous thermoplastics. Unlike conventional systems, STARgate HRS eliminates the need for multiple components, streamlining production, assembly, and maintenance. This results in significantly reduced cycle times, easier color changes, and lower power consumption and pressure loss. The technology also allows for thinner back plates and shorter filling and packing times, making it highly attractive for manufacturers seeking efficiency and sustainability. Visitors to K 2025 can witness STARgate HRS in action at the BMB booth, where it will be used in the production of a bucket—a collaborative project involving BMB, Dijkstra Plastics, Oerlikon Balzers, Piovan, and R&D Plastics.
Glow HRS and FLEXflow HRS: Enhancing part aesthetics and process flexibility
Oerlikon HRSflow will also introduce the Glow HRS solution, designed for the direct injection of aesthetic parts in amorphous materials. This technology enables the production of high-quality components by avoiding halos and weld lines, thanks to precise surface temperature control and a compact design adaptable to various applications. In the automotive sector, the FLEXflow HRS servo-controlled needle valve technology will be demonstrated live at the Haitian International Germany booth. This solution enables the direct molding of premium automotive parts, such as car wheel arches, without the need for painting or extensive post-processing—even when using recycled materials. Developed in collaboration with DNP Group and Inevo, FLEXflow HRS offers rapid color changes and reduced material waste, further supporting sustainable manufacturing.
Application-specific solutions: Up Nozzle series and luxury packaging
For applications requiring compact designs and low shot weights, Oerlikon HRSflow has developed the Up Nozzle series, featuring a gate-to-gate pitch as small as 15 mm and a 12-mm nozzle cutout. This makes the series ideal for beauty, personal care, packaging, and technical applications. At the company’s booth, visitors can explore crystal-clear, eco-friendly parts produced for luxury cosmetic packaging, benefiting from significant wall thicknesses (up to 12 mm) and high process repeatability.
Live demonstrations: Advanced injection molding in action
Oerlikon HRSflow’s technologies will be featured in several live demonstrations across the K 2025 exhibition:
- At the Engel booth, a three-drop system from the Diamond Lux line will be used to produce a rear light concept, integrating decorative foil and PUR overflooding for enhanced visual design. This project is a collaboration with Zechmayer, Leonhard Kurz, Engel, and Röhm.
- At Haitian’s booth, a 16-cavity mold will produce a lightweight cable clipper from PA6.6-GF30 using the SA Series nozzles, optimized for glass fiber-reinforced plastics and ensuring excellent cavity filling and repeatability.
- At the BOY booth, a conical blood filter will be manufactured using the Multi Valve Plate (MVP) technology and a 16-drop MULTIflow HRS system, offering synchronized valve actuation and reduced drop-to-drop spacing for precision in small weight applications.
Integrated innovation: Collaboration and future outlook
The presence of Oerlikon HRSflow at K 2025, in close cooperation with its sister brand Oerlikon Balzers, underscores the group’s integrated approach to innovation. By working alongside industry partners and leveraging cross-disciplinary expertise, Oerlikon HRSflow continues to push the boundaries of hot runner technology, offering solutions that meet the demands of modern injection molding for quality, efficiency, and sustainability.
