Injection moulding machines for optical discs

Injection moulding machines for optical discs

Netstal optical disc systems are specifically designed for the commercial manufacture of optical audio and data carriers. The systems achieve the fast cycle times and highest possible moulding precision required to manufacture data carriers by, amongst other things, precisely regulating the mould temperatures and clamping forces. All-electric optical disc subsysteme-Jet is an all-electric injection moulding machine specifically designed for the manufacture of all optical disc formats. e-Jet is also the first Netstal machine to have an all-electric drive system.

Injection moulding machines for PET

Injection moulding machines for PET preforms PET-LINE is a state-of-the-art production system for PET preforms that is well-established in the market.
The flexible range with 3500 and 6000 kN
The two clamping forces 3500 kN and 6000 kN allow the combination of various mould and cavity sizes, resulting in high productivity and a rapid return on investments. Further information.

Systematic high performance

PET-LINE is a state-of-the-art production system for PET preforms and epitomizes the greatest possible operational efficiency and proficient production. Since its market launch, Netstal has continuously developed all of the system components and, as such, has constantly optimised the high technical standard.
Basis for the PET-LINE systems is a clearly-defined platform strategy. Consequently, the customer is able to configure each system to the desired capacity. The two clamping forces of 3500 kN and 6000 kN allow the combination of various mould and cavity sizes. A major customer benefit: minimal production costs with maximum output.

The all-electric range from netstal

The all-electric range
The ELION range, with clamping forces of 500 to 1750 kN, is all-electric and typical Netstal; forming a perfect synthesis of classic Netstal injection moulding machine features with new, innovative characteristics. Each axis is specifically designed for the all-electric drive system - numerous actual customer requirements influenced the construction of the machine.
The application profile of ELION is principally, but not exclusively, designed for so-called technical parts.Typical are medical, automotive, electrotechnical and telecommunication applications.

Innovative: the clamping unit
The clamping unit has numerous innovative design elements and is based on a 5-point toggle lever system. The toggle lever system is driven by a servo motor with gearing and reaches a top speed of over 1.5 m/s. The result is a fast, highly-dynamic process sequence with extremely short dry cycle times.
Optimally suited for the clean roomEven the basic ELION equipment provides a comprehensive equipment package that competently supports production in a clean room environment. Use of encapsulated water-cooled motors prevents particle dispersal or heat emission. An optimal clean room capability is ensured through closed-loop toggle lever lubrication and the use of oil-free linear guides for the moving platen.
Closed-loop oil lubrication systemWater-cooled and encapsulated motorsOil-free linear guides thanks to encapsulated design
Ejector with excellent movement speed As a box construction, the moving mould platen is designed to provide optimal flux of force and good flexure. A 3-point crank-operated ejector is integrated into the mould platen. The ejector drive impresses through its high breakaway torque and excellent movement speed.
Injection unit with flexible performance concept
A servo motor drives the patented injection axis. The drive technique used is a dual-toothed rack, integrated into a housing together with the metering drive.

SynErgy machines from Netstal

SynErgy machines from Netstal are characterised by five basic strengths: speed, precision, reliability, user-friendliness and operational efficiency. As a result of these performance features, the SynErgy range has firmly established itself in the global market. In particular, this user-friendly, high-performance machine displays it’s capabilities to the full when meeting complex requirements with respect to moulded parts and the injection moulding process.

The “large SynErgy machines” with clamping forces of between 5000 and 8000 kN are also now well established on the market. Being of modular construction and in two sections, a clamping unit and injection unit, the machine allows for customised machine specifications. This enables each individual user to apply the most effective machine combination in order to meet their requirements.
Netstal offers injection moulding machines with clamping forces of between 600 and 5000 kN for the manufacture of multi-coloured and/or multi-component moulded parts. SynErgy 2C from Netstal embraces all 2C processes and technologies and meets every possible requirement. The result is a creative design solution with improved moulded part functionality.
SynErgy 2C guarantees rapid movement sequences and short cycle times. SynErgy 2C is therefore the ideal solution for specific fast-injection applications, such as thin-walled packaging parts and other high output production applications. Due to its outstanding level of precision, the SynErgy 2C is also suitable for the manufacture of technically sophisticated moulded parts.

Netstal plastic injection moulding machines

Netstal offers plastic injection moulding machines (made in Switzerland) for numerous application areas. Each machine impresses with the attributes that are synonymous with the manufacturer - precision, speed, reliability, user-friendliness and operational efficiency. Through the resulting synergies, customers benefit from high-quality products that guarantee high-efficiency moulded part production.
Standard machines
SynErgyELION

PET preform systems
PET-LINE

Optical disc subsystems
e-Jet

ferromatik electra evolution Multi Component

Multi-Component Technology
Ferromatik Milacron has nearly forty years experience in multi-component technology. In recent years numerous innovative and industry-leading solutions have been developed. A variety of injection unit combinations are available. The machine controls are fully integrated and can be set and operated in the same manner as a standard machine. ELEKTRA evolution Multi-Component
The EE-2F is available in two clamp force sizes (750 and 1550 kN)
Tie bar daylight for the mold installation area has been increased by 200mm
Three vertical injection units are available (sizes 55, 120 and 300)
Injection unit movement and nozzle holding force are created by a compact hydraulic system which can also be used optionally for core pulls
Generous travel allows for flexibility in fitting injection units with each mold
Easy mold removal is ensured by the positioning the injection unit behind the nozzle platen
The integration of fully electric turntable is easily realized
ELEKTRA evolution MSW (Monosandwich)
An EE-2F model equipped for the monosandwich process is also available The vertical injection unit is replaced by an extruder equipped with a special turning nozzle.

ferromatik elektra evolution injection machines

ELEKTRA evolution :
This fully electric machine saves energy, runs quiet and clean and, thanks to parallel movments on all axes, offers highly efficient operation. Its electric drive reduces energy consumption by 50% compared with hydraulic machines. A wide assortment of clamping- and injection unit options makes the ELEKTRA evolution a versatile system, suitable for many different applications. Medical technology, clean room and the food packaging industry are all areas where the ELEKTRA series has enjoyed success.
Clamping Unit
Regardless of which mold is used, the robust clamping unit provides the highest degrees of stability and platen parallelism. A 5-point toggle mechanism ensures the best possible combination of mold installation height and long clamp strokes with a compact design. Mold height adjustment is done automatically by a central gear ring. The clamping force is constantly monitored and automatically regulated.

Injection
The injection and plasticizing processes are executed by the latest generation of servo drives. The transfer of force is carried out by means of ball screws in combination with a belt drive. A hydro-pneumatic system – optimized for the required movements and performance – controls the movements of the injection unit. Linear bearings assure precise and smooth movements of the unit. Barrels are vertically removed for easy switching. The variety of screw diameters available ensures a high degree of flexibility.

Drive
The ELEKTRA uses a decentralized drive system which allows all axes to operate independently. The system uses high dynamic, brushless 400V AC servo-motors with permanent magnets positioned on the rotor with an attached resolver.
Advantages:
Short moments of inertia and a large control range
High reliability, complete motor protection
Compact design
High overload capacity
Low maintenance (brushless!)
High efficiency
Quiet operation

Controls
The Windows-based IQT control system is user-friendly and offers an excellent overview of the system. User-defined pages allow the operator to search setpoint values in any order and place them on three separate screen pages. Saving background data sets shortens setup times. Mold changes are easily activated by the relevant background data set. Thus production is quickly and simply changed over to new parts.
The IQT control system is also optionally available as IQT.net. This system adds an interface for OPC (OLE for Process Control) and provides a means for Internet access. This opens up a whole new world of possibilities including online diagnostics, analysis of process and production data, and process visualization with standard software applications.

ferromatik milacron injection machines MAXIMA ML

MAXIMA ML
Clamping Force Capacities: 16000, 20000 kN
The large hydro-mechanical machines are ideal for the economic production of large format injection parts. As with the MAXIMA MM, a central short stroke cylinder ensures a symmetrical distribution of the clamping force and minimum oil volume. Three injection units in international sizes ranging from 10000 to 23000 are available.
Standard Machine Designs
MAXIMA MLThe trend towards increased use of plastics in the auto parts industry is unmistakable. The ML series, designed for the the economical production of large format plastic parts, has a lot to offer in this exciting growth sector.
Clamping Unit
The compact hydro-mechanical clamping unit with its FEA optimized components allows for the highest degree of platen parallelism thanks to precisely adjustable guide rails and minimal platen deflection due to the central short stroke clamping piston. External traverse cylinders ensure rapid mold opening and closing. The generous dimensions of the mold area offer great flexibility and are well-suited to large parts such as car bumpers or car door covers. The ML series features safety mats for the mold area, a pneumatically powered safety gate, and an additional SPI ejector cross.

Injection Unit
The innovative design of the inejction unit is compact thanks to the parallel mounting of the injection cylinders and built to last with FEA optimization of all relevant parts. The whole injection unit swings out on a hydraulic mechanism for easy maintenance. A full selection of graduated screw diameters with a variety of optional screw geometries make it easy to customize production solutions for every need. Optional equipment: electrical screw drive, especially effective for independent plasticizing.

Drive
The MAXIMA ML has an energy efficient pump drive. Depending on the size of the injection unit being used, four to six constant displacement pumps – each with two regulated pumps – will be engaged.
Controls
The Windows-based IQT control system is user-friendly and offers an excellent overview of the system. User-defined pages allow the operator to search setpoint values in any order and place them on three separate screen pages. Saving background data sets shortens setup times. Mold changes are easily activated by the relevant background data set. Thus production is quickly and simply changed over to new parts.
The IQT control system is also optionally available as IQT.net. This system adds an interface for OPC (OLE for Process Control) and provides a means for Internet access. IQT.net opens up a whole new world of possibilities including online diagnostics, analysis of process and production data, and process visualization with standard software applications.

ferromatik milacron injection machines MAXIMA MM

MAXIMA MM
Clamping Force Capacities: 5000, 6500, 8000, 10000, 13000 kN

Standard Machine Designs Multi-Component Designs High-Performance Designs
The compact hydro-mechanical 2-platen design allows for a small footprint without sacrificing the generous mold area. Reliable and precise operation means minimum wear on the mold, which, along with the modular drive options, makes this machine an economical choice. Six injection units in international sizes ranging from 3470 to 23000 are available.
MAXIMA MMWith its hydro-mechanical clamping system the MAXIMA MM series covers mid-range clamping force requirements. Minimal clamp pressure build times guarantee short cycle times on the smallest possible floor space. The MM machines are characterized by generous mold area volumes and minimal platten deflection.
Clamping Unit
The compact hydro-mechanical clamping unit with its FEA optimized components allows for the highest degree of platen parallelism thanks to precisely adjustable guide rails and minimal platen deflection due to the central short stroke clamping piston. External traverse cylinders ensure rapid mold opening and closing. The generous dimensions of the mold area offer great flexibility and are well-suited to large parts (such as auto parts or packaging applications) or multi-cavitymolds.
Injection Unit
As with our other injection units, precision and stability have been the primary focus of our development work on high performance injection systems. Low-maintenance linear guide bearings provide excellent support and accuracy for the injection unit via eight carriers. The rigid carriage unit is height adjustable at four supporting points. Two carriage stroke cylinders and two injection cylinders with integrated screw suck-back cylinders allow for a space-saving design and minimal oil displacement. A full selection of screw diameters with a variety of optional screw geometries make it easy to customize production solutions for every need. The whole injection unit swings out for easy access and maintenance.
Optional equipment: electrical screw drive, especially effective for independent plasticizing.
Drives
Accumulator or pump? The application determines which hydraulic drive system is most appropriate. The greater the performance and dynamic range requirements of a particular task, the more sense it makes to go with a high-volume hydraulic accumulator.

The MM baseline features an energy efficient, electro-hydraulic controlled pump which adjusts its performance precisely according to the requirements of the injection function. The double-regulated pump controls oil volume and pressure according to the needs of each application.

The MM topline uses high-performance accumulator driven hydraulics with energy saving accumulator charge management via regulated pumps. This drive system provides dynamic parallel functions along all axes, and is suitable for applications which require high injection speeds.
Controls
The Windows-based IQT control system is user-friendly and offers an excellent overview of the system. User-defined pages allow the operator to search setpoint values in any order and place them on three separate screen pages. Saving background data sets shortens setup times. Mold changes are easily activated by the relevant background data set. Thus production is quickly and simply changed over to new parts.
The IQT control system is also optionally available as IQT.net. This system adds an interface for OPC (OLE for Process Control) and provides a means for Internet access. IQT.net opens up a whole new world of possibilities including online diagnostics, analysis of process and production data, and process visualization with standard software applications.

ferromatik milacron injection machines MAXIMA MV

Ferromatik milacron MAXIMA MV
Clamping Force Capacities: 2000, 2750, 3500 kNThe fully hydraulic alternative for standard applications. An extensive set of modular expansion options result in an outstanding price/performance ratio. Four injection units in international sizes ranging from 970 to 3470 are available.
MAXIMA MV With its modular design, the economical base model, along with a full set of optional equipment, is an ideal starter machine in the 2-platen series. In addition, its outer dimensions are remarkably compact.Clamping UnitFeaturing an exceptionally short 2-platen closing unit, the MAXIMA MV comes with four tie bar cylinders and two external closing cylinders for fast clamp movement with minimal oil volume. The finite-element analysis of the machine base and the clamping unit ensure a robust, well-made machine with minimum weight and minimal platen deflection. Precision linear bearings provide excellent platen parallelism for the clamping unit.
Injection UnitPrecision and stability have been the focus of our development work on injection technology. Low-maintenance linear guide bearings provide excellent support and accuracy for the injection unit via eight carriers. The rigid carriage unit is height adjustable at four supporting points. Two carriage stroke cylinders and two injection cylinders with integrated screw suck-back cylinders allow for a space-saving design and minimal oil displacement. A full selection of screw diameters with a variety of optional screw geometries make it easy to customize production solutions for every need. The whole injection unit swings out for easy access and maintenance.
Drives MV basic Electro-hydraulic regulated pumpOil volume and pressure adjusted in real time to machine requirementsMV dualDouble pump for parallel movement of core pullsand ejector with mold movementHigher injection speedsMV fast In addition to dual features described above:Electric screw drive, especially effective for independent plasticizing
ControlsThe Windows-based IQT control system is user-friendly and offers an excellent overview of the system. User-defined pages allow the operator to search setpoint values in any order and place them on three separate screen pages. Saving background data sets shortens setup times. Mold changes are easily activated by the relevant background data set. Thus production is quickly and simply changed over to new parts.The IQT control system is also optionally available as IQT.net. This system adds an interface for OPC (OLE for Process Control) and provides a means for Internet access. IQT.net opens up a whole new world of possibilities including online diagnostics, analysis of process and production data, and process visualization with standard software applications.

Contact

Ferromatik Milacron Maschinenbau GmbH

Riegeler Straße 4D-79364 Malterdingen

Phone +49 (0)7644 78-0

Fax +49 (0)7644 6885

we start injection machine blog

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