SCHWERTBERG, AUSTRIA (Oct. 4, 1:45 p.m. EDT) — Engel Holding GmbH will use K 2007 in Dusseldorf, Germany, to launch its lower-priced all-electric press, the E-max, plus show new sizes of its Speed press range and debut a process called Exjection — which uses injection molding to make profile-type parts.
Engel will show an E-max with 110 metric tons of clamping force. Engel will price the E-max as less expensive than its current E-motion all-electric, and closer in price to hydraulic machines. Also, the E-max has tie bars, while the E-motion line is tie-barless.
Engel officials say the new all-electric has the shortest footprint in the market. Other features include a large opening stroke and generous dimensions for mold mounting. Engel also will exhibit its robots in a separate booth.
The Schwertberg-based firm continues to expand its dedicated high-speed injection press for packaging, with two larger sizes, clamping forces of 380 tonnes and 500 tonnes. The five-point, dual-toggle clamp offers good motion dynamics and smooth acceleration and braking, Engel said.
During K, being held Oct. 24-31, Engel will mold polypropylene ice cream containers a on a four-by-four cavity stack mold, to show off the new, largest Speed machine, a 500-tonne press. Another Speed, a 180-tonner, equipped with a superfast in-mold labeling system, will make decorated, round cups, also from PP, with a cycle time of less than 3.5 seconds.
An active speed setup technology guarantees smooth movements despite the fast movements of the press. After setting the opening stroke and speed, the machine automatically sets all remaining parameters.
On the Speed, the moving platen is not mounted on the tie bars, but on a moving carriage on the machine's frame. Speed presses boast an injection speed of 1,000 millimeters per second. The new in-line injection unit, the IL 3560, also can be equipped with barrier screws.
In new technology, Engel will unveil Exjection, running long thin-wall parts on one of its E-motion presses with 55 tonnes of clamping force. The wall sections are just 1.2mm thick.
The challenge of injection molding such extrusion-oriented parts, according to Engel, has been the lack of fluidity in long sections of a cooled mold. Exjection moves the mold that forms the section, in sync with the injection, at right angles to the horizontal plane of the injection press. The motion of the mold creates a moving “free” cavity volume that is continually filled by melt. That requires precise control of the melt flow, generated by the screw-forward speed, and of the moving mold cavity.
The melt is kept under pressure from the injection point, to get defined compression of the melt and get a pack and hold function and avoid shrink marks.
On the E-motion press that will demonstrate Exjection, the moving mold is driven, in synchronized fashion with the injection movement, by an electric servomotor and a ball screw. Exjection is a patented process developed by Hybrid Composite Products GmbH in cooperation with IB Steiner, both of Spielberg, Austria.
In other news, Engel announced it now has a fully electric E-Victory press that is qualified for use in clean room molding with current good manufacturing practices of the U.S. Food and Drug Administration.
A 50-tonne E-victory will make microfluid test elements under clean room conditions at K. These “labs on a chip” are sealed in plastic bags in the clean room.
Engel engineers developed a special plasticizing system that avoids the hot, gaseous plastic emissions from the nozzle area, and prevents that heat from dissipating into the clean room.
Also at K, Engel will demonstrate technologies for its Teletronics Division — or electrical, electronics and communications. Engel will mold plugs, mobile phones and precision micromolded parts. An 1,100-tonne E-max press will mold mobile phone shells. Another machine, an Engel Victory press, will mold a switch using Engel's Combimelt three-component process.
Engel also will highlight automotive molding. It will mold a car armrest on a two-component, 900-tonne Duo using the Dolphin process, which combines injection molding and foaming for soft-touch interior components.
Engel also will combine two-component molding with water-assisted injection molding to make a connecting line for use next to a car engine. That project is in cooperation with Phoenix Automation Inc. of Norcross, Ga. The part has an exterior component of glass-reinforced nylon and an interior lining of nonreinforced, PP. Water injection technology is supplied by Maximator GmbH of Zorge, Germany.