Wittmann Battenfeld showcased a new MacroPower variant at K 2025 under the motto "Smart Choices, Smart Savings", highlighting a one-piece machine frame now available in the 400 to 600 t clamping force range. By shipping the machine as a complete unit after full factory testing, users can reduce transport complexity and accelerate on-site installation and start-up. The design follows a plug-and-play approach, limiting set-up errors associated with disassembly and reassembly. The compact construction also reduces the machine footprint on the production floor. At the fair, the company presented the machine at booth 22 in hall 15.
The injection unit on the one-piece MacroPower is pivotable and freely accessible from both the operator and non-operator sides, which simplifies and speeds screw changes. Control is provided by the Unilog B8X system with in-house developed components. A higher internal clock frequency shortens response times to sensor signals, supporting higher part-to-part reproducibility while keeping operating convenience and visualization unchanged. Drive and amplifier units are air-cooled, lowering operating costs compared to liquid cooling. A patented swivel locking system with a single cylinder is designed for low wear and fast, safe locking. In addition, a high-resolution stroke measurement system for the closing movement and pressure cans, combined with guidance of the moving platen on linear guides, enables precise mold protection and Expert functions such as coining, venting and ClampAdjust. A compact and uniform options portfolio on both nozzle and clamping sides across Wittmann machine series supports a consistent operating concept and the fast availability of retrofit and service packages for users operating mixed fleets.
Design and control features
The one-piece frame concept targets shorter installation times and easier commissioning by removing the need to split the machine for transport, then align and rejoin assemblies on site. Factory acceptance of the complete unit transfers to the customer’s floor with minimal adjustments, reducing the risk of set-up deviations. The more compact footprint facilitates cell layout in new and existing production areas.
Accessibility was a key design focus. The pivotable injection unit supports quick screw exchange from either side of the machine. The Unilog B8X control architecture integrates components developed by Wittmann Battenfeld to increase system responsiveness. The resulting faster reaction to process signals contributes to stable cycles and high reproducibility, without changing the user-facing visualization or operation. Air cooling for drives and amplifiers eliminates liquid cooling circuits, which can reduce utility complexity and operating expenses.
The locking concept is centered on a patented single-cylinder swivel mechanism intended to minimize wear while ensuring rapid, reliable clamping. Position feedback is enhanced by high-resolution stroke measurement on the closing axis and pressure cans. Together with linear guidance of the moving platen, these elements support sensitive mold protection and enable Expert features including coining, venting and ClampAdjust.
Patented swivel locking system with only one cylinder
The manufacturer emphasizes commonality of options across nozzle and clamping sides throughout its machine portfolio. For processors operating multiple Wittmann series, this uniformity can streamline operation, spare parts stocking and retrofitting through a shared concept and readily available service components.
Clamping platen support
Hydraulics and energy management
The MacroPower introduces an updated pump concept with up to four hydraulic units, configurable to the application. This allows performance scaling and parallel movements, including the core pull and ejector. A further new option is the hydraulic needle shutoff system inside the mold, which can be actuated in parallel with other functions.
Energy recovery is provided by KERS, the Kinetic Energy Recovery System patented by Wittmann Battenfeld for injection molding machines. KERS converts kinetic energy released during deceleration into electrical energy for internal use, for example barrel heating, supporting lower energy consumption.
Application at K 2025: labeled crate with thermal monitoring
At the fair, a HAIBOX crate was molded on a MacroPower 500/3400 using PP supplied by Borealis in a single-cavity mold from Haidlmair, Austria. The cell included a Wittmann IML unit inserting labels from Viappiani, Italy, on both long sides of the box. After part removal, a thermal image was taken of each shot and compared with a reference from the approval process. The images were evaluated by TD14.0 software from SKZ, Germany, assessing deviations from normal temperature differences. If temperatures were out of tolerance, the system signaled the robot to reject the part. Good parts were placed on a conveyor.
MacroPower 500/3400 with a one-piece machine frame
