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Redefining the Possible at K 2019

Beck Automation and booth partners Glaroform and bfa solutions will jointly present a production cell at K 2019, aiming to redefine the limits of feasibility in injection moulding, supporting a closed-loop recycling economy.

There is no doubt that the K 2019 trade fair will take place in the shadow of the discussion about environmental protection and the correct use of plastic. The industry has a duty to present solutions and to prove that plastic can be a future-oriented, energy-efficient and sustainable raw material. Booth partners Beck Automation, GLAROFORM and bfa solutions have taken this opportunity to present a production cell that, in many respects, redefines the limits of feasibility of injection moulding and decisively supports the quest for a “closed-loop” recycling economy.

Precision and Efficiency in Thin-Walled Products

A 200 ml plastic container produced with a 4-cavity ICM (injection-compression moulding) configuration from GLAROFORM and Krauss Maffei High Performance (formerly Netstal) impresses with ground-breaking material efficiency. The unrivalled low wall thickness stretches physical limits, not only resulting in considerable material savings but also leading to a further reduction of the already highly competitive production cycle time.

The lower closing force and injection pressure required thanks to the new process reduces the forces acting on the machine. This extends the life of the production plant, thus increasing sustainability while minimising energy consumption. With this machine, GLAROFORM demonstrates its ability to innovate and is an expression of the company’s philosophy of delivering the highest precision together with a uniquely robust design.

Optimised IML from Beck Automation

Beck Automation presents compact, high-performance IML automation for wrap-around labels. The system is characterised by the dynamic process, process stability and very high availability with short cycle times. The precise interaction of the individual components of the plant, including automation systems, the injection moulding machine, the mould, label quality and the optical control system increases productivity while adding value.

The use of lightweight materials on the main arm and the deployment of high-performance linear motors enable fast, dynamic movements. The main axle has two drive motors, which improves dynamics and extends the life of both the belts and the motors. Inclined label magazines, where the labels are contained with the print image facing down, minimise label warpage. This guarantees an optimised, precise positioning of the labels.

Even with very fast cycle times, the labels are separated and transferred to the cores without disruption. The removal, transfer as well as the depositing and stacking of the products all impress with captivating levels of automation. The modified logbook which has recently been integrated into the HMI control system features user administration, parameter monitoring, simplified error analysis as well as a maintenance interval. Also, the IML system is equipped with a 10-camera vision system from Intravis. This monitors the outside of the containers through 360° while at the same time inspecting the inside of the product.

Furthermore, labels with a digital watermark from label supplier Verstraete are deployed. This new technology enables efficient sorting at recycling plants equipped to handle this technology. In addition, the digital watermarks which are invisible to the naked eye can also be used as codes, in the same way, simple bar or QR codes are used today.

Interface Ensures Efficiency

MES PiSolutions by the company bfa solutions ltd provides the interface between the production and the ERP levels in this sophisticated and pioneering application. It has the task of collating and evaluating data from the injection moulding machine, the handling process and the quality assurance system and to make this data available to different users. The various functions of the MES help to make, among other things, downtime, defective products and production progress all visible in real-time. This way, problems can be dealt with quickly, or a tool change with a preheated tool can be prepared just-in-time. Thus the utilisation and efficiency of production plant and production lines can be significantly increased. This makes it possible to save even more energy, time and money and further demonstrates the idea of plastic as an efficient and sustainable raw material.

A Sustainable Future

In the face of changing consumer demands, the plastics industry today has the opportunity to create a win-win situation for the environment as well as its stakeholders. The production plant shown here, with the significant reduction in wear and consumption in terms of materials, energy, work and the plant itself, while at the same time increasing output, stands for an even more efficient future.

We will be presenting the state-of-the-art of tomorrow’s technology at the K 2019 in Hall 12, Booth A51-03 (Swiss Pavilion).

 

Protech Automation is the UK representative for sales & service for Beck Automation. Beck Automation are specialists in ‘In-Mould Labelling’ and ‘High Speed Take out’ robots and automation for injection moulding.

 

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