Smart Molding International 2-2025

18 smart_molding international 2/2025 machinery Technical Moulding: Saving resources and using installation space efficiently World premiere – New generation of electric tie-bar-less machines / Automated overmoulding of fittings One of the highlights at the ENGEL stand is the world premiere of the latest generation of its electric tie- bar-less victory injection moulding machines. This new model is fast, clean, and energy-efficient, and also features a completely new technical design – delivering additional advantages for users. On the new victory electric, fittings are produced with a cycle time of just 23 seconds. The mould includes large- volume core pulls, which are optimally supported by the free access provided by the tie-bar-less design. Thanks to ENGEL tie-bar-less technology, even large moulds can be used on comparatively small machines, saving space, energy and investment. After injection moulding, the fittings are automatically equipped with seals. The production cell is equipped with two easix articulated robots to handle this step. Blocks made from recycled material with high structural stability On an all-electric e-mac 220 injection moulding machine with 2,200 kN clamping force, ENGEL is producing thick-walled, foamed construction blocks for the building industry. The material comes from yellow bag household waste, reprocessed by EREMA. Mould and foaming agent formulation are supplied by Moxietec. For optimum foam homogeneity, an optimised mixing screw is used during plasticising. The result: components with up to 30% weight reduction and 10% higher strength. This technology is particularly well suited for logistics pallets and as a substitute for concrete in construction applications. As 100% post-consumer recyclate with corresponding material fluctuations is processed, the new iQ weight control plus plays a key role. After defining just two parameters, the digital assistance system automatically adjusts the switchover point and pressure curve during every injection cycle. This reduces scrap by up to 50 %. An integrated automation solution with servo sprue picker and an integrated conveyor belt inside the machine makes the cell particularly energy-efficient and compact. Packaging: Scalable sustainability in series production Thin-walled cups with 30% rPET produced using a stack mould ENGEL is demonstrating a series- ready solution for processing rPET in thin-walled packaging on an all-electric e-motion 420 injection moulding machine with 4,200 kNclamping force. What was previously only feasible using hydraulic injection, ENGEL now achieves electrically. A 6+6-cavity stack mould from Plastisud is used to produce yoghurt cups made from 70% virgin material and 30% bottle-grade rPET. The rPET is supplied by NGR and upgraded for food contact via Liquid- State Polycondensation. This production setup delivers exce l l ent repeatab i l i t y at h i gh performance. The combination of injection compression moulding, iQ motion control, and iQ weight control plus enables the manufacture of thin- walled, precise cups with minimal material usage. The application already complies with the requirements of the Packaging and PackagingWaste Directive for 2030. Moreover, it illustrates the potential to replace thermoforming as the preferred manufacturing process, enabling producers to save on upstream steps (film production) and material (trimming waste). ENGEL thus presents a practical example of how sustainability and precision can be combined in an economically viable production environment. A high-strength bicycle handlebar is produced on the tie-bar-less ENGEL victory 180 – lightweight, automated manufacturing and continuous fibre reinforcement with fluidmelt and organomelt