Boy saving energy at the press, in its factory

Düsseldorf, Germany — Dr. Boy GmbH & Co. KG has a next-generation press that improves energy efficiency, a reformatted control system to advance Industry 4.0, and it has gone solar at its injection molding press manufacturing factory to offset steeply rising electrical spending.

Sustainability, automation and cost control are at the forefront for the family-owned company and its customers that manufacture PET preforms, rubber goods, liquid silicone rubber products, devices in clean rooms and more.

Founded in 1968, Dr. Boy has delivered more than 50,000 presses worldwide with clamping forces up to 125 tons.

At K 2022, the Neustadt-Fernthal, Germany-based company launched a next-generation press called Boy XS E — the Boy XS was released 13 years ago — with a more efficient servo-motor pump drive.

"In addition to the energy benefits provided by the drive technology of the E-series, the servo drive of the new BOY XS E also scores with its high dynamics and an extremely smooth running," according to Martin Kaiser, head of technology at Boy.

The modified machine also offers a more ergonomic design and better accessibility. An extractable drawer was integrated into the front side of the machine frame for service and cleaning purposes.

At K 2022, Boy showed two of the midsized presses with one producing polypropylene mounting bolts in a 15.6-second cycle time and the other dishing out NAS 30 material egg cups in a 28-second cycle time. The egg cups are removed from the mold by a robot and placed on a conveyor belt.

The Boy XS E is available with two different clamping platen configurations: a standard design for conventional mold sizes up to 160 millimeters as well as a special holder for micromolds.

The new press also is equipped with the next-gen Alpha 6 control system, which has a larger screen and multitouch technology. Target quantities and tolerances can be set, displayed and monitored.

In addition to a wider screen, the controller is flexible and attractive, according to Marko Koorneef, president of Boy Machines Inc.

"The Alpha 6 is more compatible for Industry 4.0 and provides more communication with chillers, TCUs [temperature control units] and dryers," Koorneef said.

In the future, a new cooling water distribution system also will be standard to digitally record set flow rates on the machine display.

The Boy XS E will replace the Boy XS in 2023.

At another exhibit, K 2022 attendees can select two tool bits to be placed into a T-grip made of PA 6 with 10 percent carbon fiber on a Boy 35 E W. The bits are then inserted into the T-handle by Boy's own LR5 pick-and-place robot.

"This is an example of what Boy can do with parts in automation," Koorneef said, adding labor shortages also are addressed. "The automotive factories have been automated for years. It took jobs in the beginning, but not anymore because there aren't enough people."

The LR5 robot, launched a couple of years ago, Koorneef said, and has been resonating with processors wanting to operate lights-out with full automation.

In the demonstration, the gripper of the Boy LR5 removes a bit holder from a feed unit and inserts it in the open mold. After it has been closed, 42.5 grams of PA6 CF10 is injected by hot runner. The metal part then is overmolded with the handle and removed by the robot and placed on a cooling station.

The cooled down T-handle then is transferred by robot to an automatic pick-and-place system. The bits ordered by attendees then are inserted into openings of the handle and given to the person via a conveyor belt.

The application combines insert molding and automation in a compact footprint, Koorneef said.

In another exhibit, a Boy 35 E equipped with an electric stuffer developed by the machine builder takes one-component silicone, puts it in a cannister and then pushes it into the barrel and makes a dental device.

"It's one of a kind. It's completely integrated into the controller so there's not two separate controls, just one controller," Koorneef said. "I've sold two of them, and this is No. 3."

The electric stuffer is suitable for any market, he added, with manufacturers of automotive, aircraft and connector components among the buyers.

To reduce its own electrical costs and be more sustainable, Boy has installed solar panels at the production part of its headquarters site.

"It was a big investment, but you've got to move in this direction," Koorneef said. "Everything is so unpredictable. When can you get steel? When can you get this and that? Right now, electricity is through the roof. The expectation is that as soon the winter starts hitting, there might be companies that aren't going to survive. If that happens to one of your suppliers, you're going to have to find another. Everybody is a little on edge about what's going to happen."

The solar power for the production plant is just one of the provisions Boy has made. The company also has secured the oil and gas it expects to use through the winter.

"They're ready," Koorneef said. "Whatever happens, they are good to go, but that doesn't mean our suppliers have done the same thing. That's what makes everything so unsure, but we have tried to prepare as best we can."