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Packaging technology

Complete solutions for high performance

www.arburg.com · 01/20162

At a glance

Milk stays fresh, mineral water retains its taste and paint keeps in its con-tainer. These are just some of the appli-cations for packaging items that you can produce on our ALLROUNDERs. No problems. Reliable. And, most impor-tantly, in large unit volumes. Here, every hundredth of a second and every kilowatt-hour represent hard cash for you. That’s why we have consist-ently further developed ALLROUNDER injection moulding technology into complete energy-efficient, high-per-formance solutions. With the special “Packaging” (P) version, we guarantee you short cycle times and a high level of process reliability: around the clock, 365 days a year. In short: maximum productivity with low energy require-ments, throughout the entire volume production. From closures weigh-ing only one gram, to large-capacity containers, you can rely on our support as a partner perfectly positioned in the global market.

Special equipment for machines in packaging applications

More resilient machine base

FEM-optimised mounting platens

Individual media connections in the vicinity of the mould

Servo-electric toggle-type clamping units with energy recovery

during braking

Synchronisable servo-electric ejector with booster function

Prepared for high-speedremoval or IML system

Turnkey solutions from a single source

Servo-electric dosage drives

Highly-dynamic, position-regulated screws with active braking

Dynamic injection with either servo-electric or

hydraulic accumulator technology

“Packaging” (P) version Options

Highly wear-resistant cylinder modules with

barrier screws

High-performance drives for even higher circumferential

screw speeds

Individual bolt-type and needle shut-off nozzles

Control functions such as start-up parameters and

dosage across cycles

Example - drink bottle caps: these mass-produced plastic items are in daily use and therefore need to be produced quickly,

reliably and cost-efficiently.

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Utilising innovative technologyPackaging items require application-specific system solutions for maximum productivity. All ALLROUNDERs in the “Packaging” (P) version offer: • fast, precise, energy-saving mould move-

ments, through servo-electric toggle-type clamping units

• high plasticising capacities, through barrier screws and servo-electric dosage drives as well as

• dynamic injection flow and energy- efficient operations, through hybrid fully-electric drive concepts.

The modular drive technology means that the best possible system design can be achieved for every application. High-end injection moulding technology, such as liquid-cooled servo motors, automatic clamping force control and planetary roller screw drives are a guarantee of economical operation.

Targeted process optimizationThe freely programmable, graphic-based SELOGICA machine control system enables even complex sequences to be transparently managed. The real-time plausibility check of all entries during programming is a major advantage. Application-specific production sequences can be put together without re-quiring special programs. Special functions help operators to get the best out of all processes. Aiming for short cycle times? No problem with the cycle time diagram and synchronous sequences. Con-trolled start to production required? Easy with the right start-up parameters. Need ef-fective process control? Comprehensively possible with individual monitoring inputs Easy, reliable and fast injection moulding management – only with the SELOGICA control system.

Comprehensive service benefitsAs a system provider in the packaging sector, ARBURG is capable of offering all of its cus-tomers seamless worldwide support, from the idea to the production-ready product.Mould tests, machine comparisons and pro-cess optimisations can be implemented in the Lossburg technical centre under near series-production conditions. Expert advice on all technical issues is guaranteed by an inter-departmental packaging team. This covers customer specific, as well as machine and process technology-related issues, sup-port in mould design, conception and eval-uation of alternative solutions, as well as detailed trials and tests. The focus here is al-ways on finding the most rational technical solution for customers.

Example - flip-top caps: individual turnkey systems from ARBURG always ensure consistently high quality.

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Flow path/wall thickness ratio

Special: machine concept for maximum productivity

The requirements are complex: maxi-mum productivity allied to high energy efficiency are the key in the packaging sector. Our response consists of in-novative high-end injection moulding technology, offering high-performance, speed and top quality. These include closures with integral dosage aids, tamper-evident caps for beverages, or labelled tubs with inte-grated barrier coating for foodstuffs. In the case of packaging, functionality, convenience, material savings and the best technical properties are increas-ingly required. To be able to meet the trend for increasingly sophisticated products, you need flexible, individual injection moulding technology. In other words: ALLROUNDERs from ARBURG.

Fast cycle times – stringent requirementsThe complete production cells demanded by the packaging industry must be able to produce consistent, high-quality injection moulded parts reliably, efficiently and quickly. Whether closures/caps, containers or thin-walled items, the product to be manufactured determines the equipment used in the systems. ARBURG has the expertise in terms of machine, mould and process technology to enable individual solutions to be provided.

Flexible: modular systemThe modular ARBURG system permits indi-vidual configurations with different clamp-ing forces, distances between tie bars and injection units per machine. Moreover, the flexible combination of drives enables the ideal application-specific solution options. All movement axes can be controlled sepa-rately using servo-electric drives or hydraulic accumulator technology. Simultaneous movements mean that short cycle times can be implemented without limits.

Clamping force [kN]

Distance between tie bars [mm] Injection units according to EUROMAP

Standard

Shot weight [g PP]

Technology Thin wall

Freely combinable: injection and clamping units

as well as drive technology.

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Basis: adapted designThe reliability of injection moulding machines over their entire service life depends not least on their design. The special “Packaging” (P) ALLROUNDER versions ensure:• permanent process reliability, thanks to

their stable machine bases• low mould wear, thanks to precisely

guided clamping units with symmetric force application

• minimal mould breathing, thanks to FEM-optimised mounting platens

In addition there are generously dimen-sioned clamping ranges with plenty of free space for complex moulds.

Efficient: servo-electric toggle systemThe servo-electric toggle-type clamping units of the hybrid HIDRIVE-P and electric ALLDRIVE-P machines save a lot of time and energy in comparison with the hydraulic clamping units, also making them more cost-efficient. The cycle times can be re-duced thanks to extremely fast mould move-ments. Features such as energy recovery during braking ensure that the energy ap-plied is used more efficiently. Energy savings totalling up to 30% can thus be achieved with specific articles. Greater precision in the positioning of the servo electric clamping unit also leads to more reliable removal.

Important: high plasticising capacityCorrespondingly high plasticising capacity is often crucial in the production of packag-ing. So-called barrier screws, in which the compression zone has been replaced with a barrier zone, ensure homogeneous melt preparation. The cylinder modules are highly wear-resistant and thus ensure a long service life. The servo-electric direct drive permits dosage across cycles, precise dosage volumes and energy-efficient opera-tion. High-performance drives with high screw circumferential speeds permit mini-mal dosage times.

Fast, precise, and energy efficient: servo-electric

toggle-type clamping unit.

High-performing: barrier screws for

homogeneous melt preparation.

Stable: machine bases for permanent

process reliability.

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Highly dynamic: servo valves arranged near the

point of application.

Application-oriented: variety of technical details

A collection of technical components only becomes a fully functional produc-tion system when you are supported by a reliable partner throughout the entire value-added chain. A partner like us: as system provider, we always maintain the overview. We combine the injection moulding machine, mould and automa-tion, as well as competent service.Whether in-mould-labelling or multi-component technology, machine configuration or turnkey projects: we offer you a broad range of technical details for specific applications that will satisfy every demand. In this way, we can always provide you with a suitable production solution.

Fast, dynamic injectionHighly dynamic filling during injection moulding is decisive for thin-walled items. This is the only way to achieve the shortest injection times on a reproducible basis. As well as high acceleration, active braking is also important. This is assured by the unsur-passed, position-regulated screw from ARBURG. This is achieved by means of hy-draulic servo valves and servo-electrically powered planetary roller screw drives for correspondingly fast movements.

Synchronous, powerful ejectionFast cycles are also influenced to a signifi-cant extent by a fast, reliable ejector. ARBURG also has practical solutions on

offer for this important detail. The combination of servo-electric toggle-type clamping unit and servo-electric ejector is extremely powerful and results in short opening and clos-ing times thanks to the precise, reproducible dropping of moulded parts. The hydraulic booster function means that even shrunk-on closures can be demoulded with ease. Force is applied evenly in all mould cavi-ties through the use of ejector platens with several eccentric ejector pins.

High precision: servo-electric ejectors with

booster function.

Fast actuation: valve clusters with large cross

sections for pneumatic functions.

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Tailored expansionsLarge valve clusters help with the fast actuation of pneumatic func-tions in the mould. Mould cool-

ing can be optimised through customer-specific cooling wa-ter distributors with feed lines measuring up to two inches. A dry air device above the clamping unit prevents the formation of condensation.

System solutions for packagingAs system service provider, ARBURG also handles the project planning of complete systems, commissioning at the customer’s premises, CE labelling, as well as training and support. This is made possible through close cooperation with leading manufactur-ers of moulds, automation systems and peripheral devices.

Highly customised: media connections in the

vicinity of the mould.

Effective cooling: supply lines with large

cross-sections.

www.arburg.com · 01/20168

Freely programmable: SELOGICA control system

1 Flexible sequence management

The SELOGICA can be configured ideally to suit the specific production application se-quence, with no need for special programs. Synchronisation of movements is individu-ally adjustable, depending on the paths or forces. Equally unique: all signals can be monitored for optimum process and quality control, as well as process reliability. The production sequence is controllable, de-pending on machine, mould and peripheral

signals. Follow-up functions can be individ-ually selected. Example: production will only start if compressed air is available. Only the SELOGICA offers operators so much free-dom when configuring ALLROUNDERs.

Firmly under control: synchronous entry of the

high-speed removal systems.

Maintaining control over sophisticated machine, mould and robotic technol-ogy is the domain of SELOGICA. With this setting and monitoring system, you can quickly set up both simple and complex injection moulding processes, operate them intuitively and perform reliable optimisation. In other words: central management. All technical fea-tures of the SELOGICA control system, such as the graphic sequence editor, are also ideally suited for the production of packaging items and aimed at mak-ing operation faster, more reliable and more convenient. Here too, ARBURG provides you with decisive application advantages: because we have already integrated all the necessary functions for high-quality and cost-effective part production in the SELOGICA system.

Further information: SELOGICA control system brochure

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Reliable start-up

2 Reliable start-up

A controlled production start ensures maxi-mum process reliability and efficiency through the one-off definition of start-up parameters and cycles. Production parame-ters no longer need to be ad-justed. All values are stored in the data record – start-up is al-ways performed automatically at the start of production.

3 Ultimate process optimisation

From simultaneous injection as the mould closes (injection on the fly) to robotic system advancement as the mould opens, the SELOGICA offers almost unlimited options for getting the very best out of

every process. Movements remain harmo-nious and reliable, even at maximum speeds. This is ensured through freely configurable ramps.

Highlights

• Control centre for the entire injection moulding technology

• Convenient sequence programming with graphic symbols

• Immediate plausibility checks• Free programmability of production

sequences • Common data record for the entire

production unit• Water-cooling for continuous temper-

ature control in the control cabinet

Ultimate process optimisation

Flexible sequence management 1

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Application examples

Injection moulded plastic packaging is on the advance, offering universal design options, for example. In order to ensure that optimum performance is achieved in your business on a daily basis using multi-cavity moulds, speed, a high degree of reliability and qual-ity are essential. These are precisely the features that characterise our ALLROUNDER technology. As a system service provider, our concern is with complete solutions from a single source with machine technology that is pre-cisely tailored to the specific individual application. Professional advice, from the planning stage and installation on site through to service, round off our offer. This ensures that you are al - ways on the safe side when it comes to packaging.

1 Complex two-component

bottle capsARBURG cooperates with established experts to develop perfectly harmonised complete solutions. The best example of this is the combination of innovative mould technol-ogy with a two-component ALLROUNDER to produce water bottle caps. The machine technology can be adapted individually to the mould, e.g. through corresponding flex-ible arrangement options for injection units. ARBURG handles the complete integration of the mould functions, such as servo-elec-tric turning, in the machine.

2 In-mould closing of flip-top cap

The integration of functions is always an important issue in the packaging sector with its high requirements in terms of cost efficiency. In the case of flip-top caps for shampoo bottles, the open cap can actually be closed inside the mould, for example. The flexible SELOGICA machine control sys-tem offers significant advantages here. Thanks to the detailed, configurable se-quence management feature, the produc-tion sequence can always be ideally adapted to the relevant application. The intuitive hu-man/machine dialogue lends transparency to complex sequences and makes the pro-duction process easy to control.

Efficient: fully integrated mould technology impresses with its reliable processes and

short cycle times.

High-quality: flip-top caps are closed directly

in the mould.

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3 72 screw caps in 3 seconds

Multi-cavity moulds that produce large unit volumes in a matter of seconds are the dominant technology when it comes to the production of screw caps. In addition to a correspondingly l arge plasticising capacity implemented with barrier screws and high-performance drives for the shortest possible dosage times, there is a particular require-ment for powerful servo-electric ejection that can be synchronised with the mould movements. All other components of the system, such as cooling sections and visual part inspections are also coordinated in ac-cordance with the application. This is the only way in which production can run quickly, reliably and to a high quality.

4 Reliable label insertion

Those wanting to produce containers in large unit volumes in a single process step with the appropriate labels using the in-mould labelling process (IML), can rely on us to provide a complete turnkey solution. As a systems supplier, ARBURG designs and configures such systems individually, in line with requirements. Speed, functional relia-bility and cost efficiency are important key-words here. This is provided mainly by the servo-electric toggle-type clamping unit with its extremely short dry cycle times, energy recovery during braking and high positioning accuracy.

5 Long cartridges

Owing to the long flow channels, many packaging applications, such as cartridges for silicone compounds, require the shortest injection times and thus dynamic move-ments and high speeds. Here, the position-regulated screws of the ALLROUNDER can fully demonstrate their great advantages in combination with hydraulic accumulator technology and servo valves positioned close to the consumers.

Dynamic: achieve long flow paths with short

injection times.

Productive: production of mass-produced

items in a matter of seconds.

Time-saving: simultaneous insertion of

labels and removal of containers.

Distances between tie bars of 920 x 920 mm | Clamping forces up to 4,600 kN | Injection units up to size 4600 (according to EUROMAP)

ARBURG GmbH + Co KG

Postfach 11 09 · 72286 Lossburg · Tel.: +49(0)7446 33-0 · Fax: +49(0)7446 33-3365 · www.arburg.com · e-mail: contact@arburg.com

With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia,

Spain, Czech Republic, Turkey, Hungary | Asia: People’s Republic of China, Indonesia, Malaysia, Singapore, Thailand, United Arab Emirates | America: Brazil, Mexico, USA

For more information, please go to www.arburg.com.

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© 2016 ARBURG GmbH + Co KGThe brochure is protected by copyright. Any utilisation, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG.

All data and technical information have been compiled with great care. However we accept no responsibility for correctness. Individual illustrations and information may deviate from the actual delivery condition of the machine. The relevant valid operating instructions are applicable for the installation and operation of the machine.

ARBURG GmbH + Co KG

DIN EN ISO 9001 + 14001 + 50001 certified

Film