1

Mold-Masters Europe

by Robert Kirkby

MasterCARE-Team, EMEA (2012-05-11)

2

Master-Series I The Flagship

12 standard gate options

6 standard nozzle sizes

Precise temperature control with

brazed heater technology and integrated T/C

3

Master-Series I Nozzle range

Hecto Femto Lite Deci Centi Pico Femto

3.5mm 5mm

6mm

5mm

7mm

6mm

8mm

8mm

11mm

12mm – 16mm

16mm – 18mm n/a

Valved

Non-Valved

4

Valved vs. Non-Valved

5

Tapered Pin

Cylindrical Pin

Types of Valve Pins

Premium valve gate solutions I Options

6

Pin must close within

‘thermal window‘

defined by gate size

and hold time.

Advantages, Tapered

Advantages, Cylindrical

Disadvantages, Tapered

Excellent gate appearance

Small gate size possible

Accurate machining of

the gate is required.

Easy to machine

Self Centering

Large gates possible

Good gate appearance

A closer look at Valve Gating

Disadvantages, Cylindrical

7

Accu-Valve I Premium valve gate solutions

Pristine cylindrical valve gating of

commodity and engineering resins

Continuous pin guiding

2 million cycle guarantee

<150 shot color changes

CX MEX EX

ACCU-VALVE CX - for Standard Resins

ACCU-VALVE MEX - for Standard Resins

ACCU-VALVE EX - for Standard Resins

8

Accu-Valve I Leak-proof protection

Additional leak-proof protection at the manifold

V-Guide System

Innovative Valve Disk design prevents leakage between the valve pin

and valve disk at the manifold area by creating a thermal barrier within

the valve disk itself

New V-Guide Valve Disk Design Previous Valve Disk Design

9

Accu-Valve I V-Guide

New V-Guide Valve Disk Design

10

Accu-Valve CX

Gate quality that always meets your expectations

Ideal for high cavitation applications, fast cycle times & fast color changes

Bi-metallic design does not rely on gate steel for pin alignment

Pin alignment through constant engagement in liner

11

Accu-Valve CX

The benefits of Accu-Valve CX over other valve gate designs:

Seal liner flow channels allow for fast color changes and no dead spots

Continual pin alignment and optimal gate temperature creates the perfect thermal condition at the gate

Resulting in minimal pin resistance and optimal gate longevity

0.0003” maximum clearance between the pin and cavity ensures that no crown flash even with very flash sensitive materials

Pin is stronger and has a simpler design

Any tolerance errors are completely eliminated as final gate/liner machining is done after assembly

Accu-Valve CX Seal/Liner

12

Accu-Valve EX

Tailored for engineering grade resins (PC, POM, etc.)

Gate quality that always meets your expectations

Ideal for high cavitation applications

13

Accu-Valve EX

The benefits of Accu-Valve EX over other valve gate designs:

Never any resistance to valve pin closure because gate temperature is always

above HDT point based on detailed FEA analysis

Results in even longer pin longevity as the pin is not exposed to additional

stress to seal/close

Double guiding mechanisms always ensure proper alignment through gate area

Gate seals and liners can be made from different materials based on the cooling

quality of the gate area in the cavity

Resulting in even more flexibility for all applications

14

Hot-Tip I Premium open gate solution

Visco-Seal™: Additional leak-proof protection

achieved with a thin plastic membrane that solidifies

at edge of seal

Seals and liners can be easily replaced in the press

Liners are made from various materials depending on

resin properties and requirements

» Thermal cycling

» Wear resistance

15

Actuation Methods (2012-08)

16

Actuator Options I Today’s Actuation Methods

Individual Actuation

Hydraulic

Pneumatic

Electric (E-VG)*

Cluster Actuator

Hydraulic

Pneumatic

Synchro-Plate

Hydraulic

Pneumatic

Electric (E-Drive)*

*For detailed information about the E-Drive or the E-VG please

refer to the corresponding product presentations and Mold-

Masters Resource Guide (MMRG).

17

Actuator Options I Valve Actuator Section Chart*

*For detailed information please refer to the MMRG

18

Actuator Unit Minimum Pitch Type Fluid Piston Force

Competitive Design 25 mm Individual Pneumatic

Please refer to

catalogue pages MM Syncro-Plate 20 mm Multi-Pin Act. Pneumatic

MM Syncro-Plate t.b.d. Multi-Pin Act. Hydraulic

MM PN2300 44.3 mm Individual Pneumatic 596 N (@90psi)

MM HY550X 25 mm Individual Hydraulic 865 N (@ 400psi)

E-Drive* (reg. valve pin holders) 17.3 mm Multi-Pin Act. Electric STD Power Rate:

33000 N (Peak)

15000 N (Continuous)

High Power Rate:

50000 N (Peak)

24000 N (Continuous)

E-Drive* (mag. valve pin holders)

29.5 mm

Multi-Pin Act.

Electric

E-VG (55mm Solenoid) 58 mm Individual Electric

Please refer to

catalogue pages E-VG (75mm Solenoid) 78 mm Individual Electric

Small Synchro-Plate* 15 mm Multi-Pin Act. Hydr. / Pneu.

Actuator Options I Comparison Chart

19

Design Options

The HY8400/HY8500 resolves issues with applications where high injection

pressures are required by increasing the closing force of the actuator

20

Features

Similar to HY7100 / HY6500 design

Uses air or oil

HY8500 for cylindrical valve gating

HY8400 for non-cylindrical valve gating

Cylinder top

Centers air/oil flow to provide even downward pressure on the larger

piston diameter

Piston

Increases closing force without increasing supplied pressure

Wiper Seal

Reduces contamination entering actuator unit

21

Advantages

The HY8400/HY8500 has advantages over standard HY65/7100 units:

22

Components

23

E-Drive I Powerful. Precise. Clean.

Syncro plate valve pin actuation with servo motor control

Fully enclosed valve gating system with electro-mechanical actuation

Applicable for 2 up to 128 cavities

Oil-free actuation, all electrical (no oil/air power)

Suitable for clean room applications

High performance system for absolute stable production processes

Sustainable production/part quality

Cost-effective solution based on TCO

60% less energy consumption compared to hydraulic valve gate systems

>50 % reduced maintenance costs due to extended maintenance cycles

Magnetic Pin Option

24

E-Drive I System Features

Fully enclosed and all electrical (no oil/air power)

suitable for clean room applications

60% Energy savings compared to hydraulic valve gates

Applicable for 16 to 32 cavities

Higher cavitations possible with dual servos (future)

25

E-Drive I Components View

Servo and gear box

Idlers (2)

Tensioning idler

Ball Screws (2)

Valve pin

(synchro) plate

26

E-Drive I Section View

27

E-Drive I Servo Drive and Ball Screw Solution

Belt and ball screw mechanism is over 90% mechanically efficient

All movements are based on rolling

No sliding (friction) losses

Servo drive actuation

High accuracy and repeatability

Variable speed and Acceleration

High Torque

Precision Control

28

E-Drive I Features: Solid support

Synchro plate design allows pillar support from HR intermediate plate to mold

backing plate, resulting in stronger mold

29

E-Drive I Features: Freedom in Cavity Layout

Outboard location of E-drive mechanism allows substantial freedom for cavity

positioning

30

E-Drive I Ease of Use and Maintenance

Easy valve pin position and stroke set-up

automated in the controller

Modular design

Ease of access

Entire E-drive can be removed by removing top plate bolts and easing

belt tension

No o-rings

Top plate

31

E-VG I Electric valve gate solution

High energy savings

High closing force

Fast cycle times

Sequential Valve Gate Control

Simple, Easy to Use Controller

Great flexibility

75 mm

55 mm

32

E-VG I Advantages

Cleanroom Friendly

EVG is suitable for cleanroom applications

as it produces almost no particulate

pollution

Reliability

EVG is covered by a 2 year warranty and it

saves on maintenance costs as it has no

wear components

Reusability

Actuators can easily be removed and used

on future molds

33

E-VG I Advantages

Sequential Valve Gate Control

Allows for sequential opening of valve

gates in base functionality

Pin motion sensor option for sensing

whether the pin has not been able to

close

Flexibility

Individual cavities can be remotely

turned off without temperature changes

in the nozzles

Simple and easy to use controller with

touch screen interface

34

E-VG I Mold-Masters unique Solenoid Detail

Solenoid comprises of a permanent magnet holding the anchor in either one of the two

end positions.

To switch position, two electro-magnets are used; one to weaken the permanent

magnet’s magnetic field and the other to pull the anchor.

•ELECTROMAGNET

•PERMANENT MAGNET

•ELECTROMAGNET

35

E-VG I Mold-Masters Unique Force/Stroke Curve

3 times higher stroke forces available than competitive systems

60% more closing force compared to a pneumatic system

A 3 mm pin can close against a hold pressure of up to 23,000psi

36

E-VG I Mold-Masters Unique Force/Stroke Curve

37

Backup-Slides

38

Mold-Masters I Product & Service Portfolio

39

Patented 2-piece brazed manifold technology

Unique in the industry

Runners are carefully milled and polished,

with no sharp corners or dead spots,

promoting fast and precise color change

Endless configurations of runner routes

that drilling doesn’t allow for

Master-Series I The Manifold Technology

40

Cast-in heaters improve temperature uniformity versus pressed in heaters

Multiple melt channels for different materials can be designed in the same

manifold reducing the overall stack height by up to 22%

Master-Series I The Manifold Technology

41

NEW I IRIS I Co-Injection Technology

Unique barrier molding solution for i.e. food and

beverage containers

Barriers to protect the product and ensure

a long shelf life

Such barriers are typically created using glass, metal or

plastic, with liners or multiple layers

IRIS co-injection technology is a revolutionary

alternative to these traditional packaging methods

IRIS co-injection is achieved via the combination and

integration of Mold-Masters’ key technology elements

Single source supply of the melt distribution and

control system with global service and support

Lower capital investment with the ability to use

existing tooling and machinery

Production flexibility as the IRIS system can easily be

moved to other machines and locations

42

MasterCARE I Service offerings

System installation

System trails

System refurbishment

Retrofitting and repairs

Onsite repairs to systems

System cleaning

Trouble shooting

Dedicated Contact

Complete support management

Technical consulting for new systems

Seminars (on-site/off-site)

Technical trainings

Service and maintenance contracts

43

MasterCARE I Benefits

First customer contact for any service issue

Global field service

Dedicated team of specialists

24/7 spare parts hotline

Global spare parts services

Part centers on all continents

Immediate support

Resolution of issues in the shortest time possible

44

MasterSOLUTION I Offerings

Custom engineered solutions

Technical training and consulting

Mentoring program (co-development program)

Large program management incl. risk assessments

Trouble shooting

SAMP > Solution Assessment Management Program

CAMP > Cause Assessment Management Program

45

MasterSOLUTION I Benefits

Quick turnaround and solution finding process

Direct contact, from beginning to end

Cost effective solutions, tailored to your needs

Integrated Risk Management through project due diligence

Global pool of industry experts

Extended development capacities

Ongoing knowledge management and transfer

Worldwide Project Management

Individual, cost effective and time-to-market product solutions

46

Success in the Field - CX Customer: Major Caps and Closures Company

•Push pin mark for symmetry

47

Success in the Field - CX

Customer: Major Medical Company

System Description:

Master-Series Femto, 2 Pilot Drop Systems, 2 Production Molds 48

Drop Systems

Material: PP

Processing Temp: 232˚C; Mold Temp: 38 ˚C

Plastic Part Size: 2g

Plastic Part: Medical Parts

48

Success in the Field - CX

Customer: Major Personal Care Company

System Description:

Master-Series Pico 96 Drop System with Syncro Plate – Quantity 2

Material: PP

Processing Temp: 255˚C; Mold Temp: 35˚C

Plastic Part Size: 2.0g

49

Success in the Field - EX

Customer: Major Medical Company

System Description:

Master-Series Femto

Material: PC/ABS Blend

Processing Temp: 282˚C; Mold Temp: 99˚C

Plastic Part Size: 0.14g

Plastic Part: Medical Part

In production December, 2006

50

Success in the Field - EX

Customer: Major Medical Company

System Description:

Master-Series Femto 4 Drop

Material: PC/ABS Blend

Processing Temp: 282˚C; Mold Temp: 99˚C

Plastic Part Size: 0.14g

Successful EX implementation – could not close the gate of the Husky system

51

Success in the Field - EX

Customer: Major Medical Company

System Description:

Master-Series Centi, 12 Drop

Material: PS + K-Resin + Zinc Styrate

Processing Temp: 230˚C; Mold Temp: 30˚C

Plastic Part Size: 19.28g, 17X17X264mm