Sumitomo (SHI) Demag Showcases LSR Synergy with IntElect Machines at K 2025

At K 2025, Sumitomo (SHI) Demag will highlight how strong and coordinated efforts between LSR equipment and material specialists are at the forefront of the switch to more energy-efficient electric technologies. Across three IntElect 130t LSR exhibits, Nexus, Kracht, Rico, Momentive, Wacker and Shin-Etsu will present how collaborative partnerships are taking LSR reliability and repeatability to a new level of optimised performance.

Continuous investments in the LSR manufacturing process, including more widespread implementation of all-electric technologies, is leading to a significant increase in its adoption across a wide range of industrial settings. Additionally, more OEMs are bringing manufacturing of LSR in-house to reduce lead times, support scalability and streamline supply chains, notes Sumitomo (SHI) Demag LSR specialist Jens Dickel.

Responding to these trends, Sumitomo (SHI) Demag has intentionally focused its efforts on ensuring every dosing, tooling and automation element works seamlessly together as a ‘ready to manufacture’ package. Three exhibits at K 2025 present this total synergy.

Each IntElect LSR machine includes a standardised LSR-kit, which includes a special screw, a non-return valve, a vacuum pump, and toggle technology. These features contribute to cleanliness and precise shot control required for processing LSR materials. In addition to the moulding machine, processors require optimal temperature control.

Jens Dickel expands: “This is where the mutual trust shared between specialist LSR partners leads to better outcomes for customers. Each are experts in their respective fields, including LSR tooling, dosing, automation and material specialists.”

LSR Synergy Without Compromise

On the main Sumitomo (SHI) Demag display (Hall 15, Booth D22), a compact IntElect 130t production cell is equipped with a standard 3-plate 32-cavity mould, an End of Arm Tool (EOAT) and Timeshot colddeck, all supplied by Nexus. Fully integrated to achieve the highest processing stability for tight tolerance automotive safety applications, this exhibit is manufacturing sealing frames for high voltage charging plugs. The seals are made from an LSR 2040 pre-coloured blue material from Momentive.

Integral to this LSR package is the fully automated Nexus X200 dosing system with USD colour pump, ensuring complete processing control and adherence to the OPC UA 40082-3 standard. Every 26 seconds, the IntElect machine delivers a precise shot of 42 grams of the pre-blended LSR material. The Nexus Timeshot ensures that each of the 32 cavities is perfectly balanced and filled with material.

Each seal is then demoulded by a customised Nexus robot end effector fitted onto a Sumitomo (SHI) Demag SAM-C three axis linear robot. This allows the components to be placed on a conveyor for further processing or stacked into a plexiglass silo storage container to prevent dust and other contaminants from compromising safety. Parts can then be manually or automatically sorted for inspection.

24-Hour Autonomous Medical Production

Another IntElect 130t LSR injection moulding machine features on the highly automated modular Nexus exhibit manufacturing medical valves (Hall 12, B53). Comprising intelligent robotics, precise slitting technology, optional camera inspection, and traceable packaging, this system represents the endless possibilities in 24-hour autonomous production.

In a complete cycle time of 40 seconds per shot, a 6 axis robot removes 16 moulded parts and transfers them to a slitting station. Holding them firmly in position for electric-driven slitting knives to make their cut, the next moulding cycle occurs concurrently, with the robot EOAT moving back and forth between the 16 cavity mould tool and slitting station.

Simultaneously, visual checks can be carried out by an automated camera inspection system examining the slit accuracy and outer diameter. After passing the inspection test, the robot places all 16 parts into their dedicated SLC compartment box. Ensuring total traceability.

For optimal efficiency, a tiered overhead buffer station gives the capacity to store five SLCs with no need for manual intervention for up to 24 hours. Additionally, a drawer within the modular cell segregates component samples for laboratory testing. Another separates start up parts or special batches from regular production. On-demand flow pack packaging can also be integrated, allowing each shot to be packaged, labelled, and discharged on demand using the quality control drawer.

Electric-Driven Dosing Reduces Downtime

Applying just as many years of expertise in LSR dosing, Kracht showcases its SilcoStar E-Drive series on the third IntElect electric moulding machine (Hall 11, E48). Designed specifically for LSR dosing, it offers high output (up to 10l/m), quick material changes with a dual 200L barrel exchange, and a fully enclosed design for enhanced safety and cleanliness. Suitable for cleanroom environments, Kracht claims that its servo-electric linear drive offers a service life ten times longer than dosing systems using conventional ball screw drives.

For consistently accurate colour mixing ratios without manual recalibration, integrated control technology ensures dynamic adjusting to match flow rates. Machine downtime is further minimised by the E-Drive quick-clean mixing head. Averaging five minutes, this saves valuable time and money, reports Kracht.

Equipped with a 256-cavity Rico mould tool, in a cycle time of less than 12 seconds, this IntElect LSR package manufactures 15,4-gram single wire seals with absolute precision and stability. Despite this high throughput, the IntElect machine’s energy consumption remains one of the lowest on the market, reports Dickel.

All three LSR exhibits support the OPC-UA interface, directly linking metering measurement data with the IntElect processing data to ensure a fully traceable and stable production process.

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