Upgrading standard injection moulding machines to multi-component machines

In the current economic climate producers can generate advantages by adding PxP, with a choice of nine units with three different screw diameters each - shot weights between 20 g and 4 kg - plus special units which can simply be upgraded to create a multi-component machine. For instance PxP is mounted on the fixed platen side, its tip connected to the mould via threaded connector, and the plastics material to be moulded is introduced through the mould directly into the cavity/ties. The injection unit can be fitted vertically, but also at different angles: “We are ahead of our competitors by such a flexible approach“, elaborates Janisch. PxP convinces with its streamline design; the injection units of competitors are frequently just standardized products. “Many of our customers face issues with floor space. For that reason our design gets very close to the IMM resulting in a truly flexible solution. Quoting a different scenario: with vertical presses the injection gates are positioned quite low. Therefore, hydraulics and control unit are positioned alongside the press“, according to Janisch.

Which manufacturers are already using the Windsor PxP series? For example, a Swiss company uses PlugXPress Plus 4 to manufacture toothbrushes in a multi-component process. The substrate is a white PP, then soft components are followed by a concluding component. All processes involve one single machine, even including the use of four different colours! Janisch explains: “Prior to PxP manufacturers had to produce, say, one million toothbrushes in blue, followed by 1 million green, 1 million yellow and 1 million in red.“ Now, employing PxP, multi-component toothbrushes can be pro-duced in one single cycle and straight to the packaging unit. Four differently coloured toothbrushes are manufactured in one cycle. “PxP is thus revolutionary and affords significant time and cost savings - at consistent quality“, emphasizes the Windsor product manager. This process involves one 350-ton IMM with four PxP42 units and 18 mm screws. For the second component the shot weights are about 30 g. The independent control system of each PlugXPress unit allows a variety of additional functions to be added, controlled and monitored, such as core pulls, turntables, hot runner systems as well as cascade features.

An additional PxP application: an automobile supplier manufactures wheel-house covers for German mid-range cars. The task: following the initial injection process a soft component is to be injected to the rim. Issue here is sufficient floor space. Hence, a specific integration process into the machine had to be found. Solution: one PxP 257 was mounted between the machine tie-bars and the rear safety gate. The main body was PP with a sealing lip in TPE - shot weight 40 g.

Another manufacturer produces bumpers with the help of PxP. Here, the injection unit - at a variant in 45 degree position - had to be supported on the tie-bar to enable connection with the mould. In the 45 degree variant the screw diameter can measure up to 43 mm. For another automotive product application a frame or a slide rail had to be fitted to the IMM. Therefore, the PxP aggregate can travel with the moving side of the mould.

During the project phase for a well-known Swedish company pallets with an anti-slip coating are currently being produced whereby non-slip pads are injection-moulded onto the pallets, and all this using one single mould! Here, a multi-component IMM moulds base plate and subsequent soft components - the PxP unit is responsible for the latter. This injection unit - with a 105 mm screw - works on a 2300-ton IMM and deliver a shot weight of 3.5 kg.

Even when processing composite materials  PxP units come to the fore: for instance with vehicle interior trim. "Up to now, fibre mats had to be pressed and punched. Now, the process happens in one single phase", explains Janisch. "The mat blanks are placed in the machine, are effectively baked, shaped to the correct form, and during the second phase - in the same machine - injection of reinforcing ribs and screw attachments takes place. We deliver the whole package: none of the presses need to be modified, the cascade valve timing device complete with hot runner temperature control are available as standard including 50/55 mm screws." The result: No need for this particular manufacturer to concern himself with the injection moulding process, he can just commence production without having to learn new process procedures.

One of the truly unique selling points of the PxP series, as part of plastics processors‘ armoury when preparing for particular times and specific challenges, is effectiveness and mobility - with maximum consistent quality. Due to the system’s versatile deployment and installation possibilities, the PxP is indispensable for mould makers who want to sample multi-component products and who want to produce small batches in rapid rotation without the need to invest in a large fleet of machines Why not get in touch with Windsor/Hanau and enquire what can be achieved?