News - Engel Austria GmbH, Zentrale Verwaltung / Produktion Spritzgiessmaschinen

News - Engel Austria GmbH, Zentrale Verwaltung / Produktion Spritzgiessmaschinen

Engel Austria GmbH, Zentrale Verwaltung / Produktion Spritzgiessmaschinen

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News - Engel Austria GmbH, Zentrale Verwaltung / Produktion Spritzgiessmaschinen

Newsgrafik #35210
 09.08.2019

Engel Austria: Full process overview  (Company news)

At the K 2019 trade fair in Düsseldorf, Germany, between October 16th and 23rd, ENGEL is starting a completely new chapter in the development of intelligent assistance with its iQ process observer. To date, assistance systems have been used to optimise individual steps in the injection moulding process, such as injection and cooling. But the new iQ process observer goes several steps further, providing an overview of the entire process for the whole batch. This makes it possible to identify changes in the process at an early stage, allowing operators to determine their causes and find a solution more quickly.

The iQ process observer continually analyses several hundred process parameters across all four phases of the injection moulding process – plasticising, injection, cooling and demoulding. The results, split into the four phases, are immediately visible in an easy-to-understand overview on both the injection moulding machine’s CC300 control unit and the ENGEL e-connect customer portal.

Maximising the potential for efficiency and quality
The software automatically detects drifts by continually checking the results against the previous cycles, as well as comparing certain process parameters with a set reference condition. Furthermore, the system notifies the machine operator of counterproductive process settings and conditions, in addition to possible causes via text message. This helps the user to optimise their processes and, when necessary, to resolve errors. All the functions run automatically. The iQ process observer requires zero set-up effort to use.

“By using the iQ process observer, process technicians can maximise the potential for efficiency and quality offered by the injection moulding machine and production cell,” says Paul Kapeller, product manager for digital solutions at ENGEL AUSTRIA. “The iQ process observer is currently the only assistance system on the market based on live data, which actively indicates changes in the process and counterproductive settings, helping to improve stability throughout the process.”

Modular approach paves the way for smart factory
Permanent adaptation of quality-relevant process parameters based on real-time data is an essential feature of the smart factory. In this spirit, by offering the strictly modular approach of its inject 4.0 range, ENGEL is making it particularly easy for processors to benefit from the opportunities presented by ongoing digitalisation. Even individual solutions such as the iQ products promise considerable benefits. And it is thanks to these same solutions that the first steps towards the smart factory are being taken on many shop floors.

ENGEL at K 2019: hall 15, stand C58
(Engel Austria GmbH)

Newsgrafik #35184
 31.07.2019

Engel Austria: Success story with a bright future ahead  (Company news)

When it comes to the unparalleled success story of ENGEL’s tie-bar-less technology, the numbers speak for themselves, with more than 70,000 machines in the hands of around 10,000 customers. It was first released 30 years ago at the K show in 1989 and is currently enjoying a true resurgence. ENGEL’s tie-bar-less injection moulding machines are able, like no other machine design, to combine cost-effectiveness and efficiency with minimal resource consumption.

Photo: With perfect platen parallelism, excellent clamping force distribution and top-quality mould protection, tie-bar-less ENGEL injection moulding machines offer the highest levels of flexibility for moulding, automation and operation.

Great and enduring success was by no means assured for tie-bar-less technology. When ENGEL was the first injection moulding machine manufacturer in the world to exhibit an injection moulding machine with a tie-bar-less clamping unit in Düsseldorf, Germany, the innovation was met with both widespread astonishment and deep scepticism. There seemed to be many reasons to doubt this new method. Until then, it was regarded as an unshakable design principle that an injection moulding machine had to have four tie bars.

The idea for the new solution came from the processors themselves. Especially when using large moulds, the tie bars would curb the creative freedom of mould manufacturers. Mould mounting and dismounting through the four tie bars is rather complicated. “Even back in the 1980s, these restraints could not be reconciled with the demand for more efficiency in manufacturing,” stresses Stefan Engleder, CEO of the ENGEL Group.

As a result, the highly flexible mould area and simple mould changing offered by the tie-bar-less machine even tempted the sceptics to try out the unconventional design method – and they were impressed by the results. Interest from the industry was soon so great that the tie-bar-less machine became the predominant design at ENGEL’s main production plant in Schwertberg, Austria. Within a few years, it turned into a full machine series, which was dubbed “victory” on account of its victorious triumph.

Saving resources with smaller machines
“The market quickly recognised that this barrier-free clamping unit does more than just make mould set-up simpler,” reports Gerhard Dimmler, senior vice president of product research and development at ENGEL AUSTRIA. “Other benefits of tie-bar-less technology include improved ergonomics for all manual work in the mould area, more flexible automation solutions with the robot able to directly reach the cavities from the side, and more compact production cells with lower capital investment and operating costs.” The particularly large mould-mounting platen areas are the key to boosting productivity per unit of area. Since there are no tie bars in the way, the platens can be utilised completely up to the very edge. This means that large moulds can fit on relatively small machines. “In many cases, you can pick a machine that ranks one or two levels lower in terms of clamping force than would be necessary for the mould on a conventional machine with tie bars,” emphasises Franz Pressl, product manager for hydraulic tie-bar-less machines at ENGEL AUSTRIA. “By needing to use less energy and coolant, a smaller machine significantly helps to conserve resources. Another plus-point is the ideal utilisation of production floor space, given that shop floors often have to accommodate several machines. “It is impressive how many of our customers are using tie-bar-less technology to its full potential, giving them a substantial competitive advantage,” Engleder says.

For instance, there is particularly high potential for efficiency with multi-cavity moulds, multi-component processes with in-mould core-pulls and sliders, and ENGEL’s foammelt structural foam moulding, all of which require little clamping force for their respective mould volumes.

Even surface pressure throughout the mould mounting platen
Thanks to the consistent patent protection for tie-bar-less technology and all its improvements, it has remained a unique selling proposition for ENGEL to this day. One area in which some important milestones have been achieved is the joint on the moving mould mounting platen, which is known as the force divider in the current generation of machines. The force divider ensures that the moving platen follows the mould in a perfectly parallel manner during clamping force build-up and guarantees that the clamping force is evenly distributed across the entire platen area. This way, the parting lines of cavities at the edge experience the same surface pressure as cavities in the centre, which prevents flash, even when processing low-viscosity liquid silicone rubbers.

Efficient standards to meet specialised needs
ENGEL’s tie-bar-less technology is continually adapting to the changing needs of processors. Key milestones along the way have included the 2004 launch of the e-victory hybrid machine featuring an electric injection unit, the servohydraulic ecodrive introduced in 2008 which has since been included as a standard feature, and the current generation of injection units which has been taking the processing precision and efficiency of hydraulic machines to the next level since 2016.

ENGEL has also been offering all-electric tie-bar-less solutions since 2013. The second generation of injection moulding machines in the all-electric e-motion TL series was engineered specifically for the production of high-precision optical and electronic components. These machines have had great success establishing themselves in the consumer electronics industry, including for smartphone lenses and seals.

“We’re taking a strongly application-focused approach to the further development of all-electric tie-bar-less technology,” Dimmler reveals. “Thanks to flexible solutions for highly specific products and materials, we will be further improving cost-effectiveness, efficiency and sustainability in production through the use of tie-bar-less injection moulding machines. In this context, there is an increasing focus on smart technologies such as intelligent assistance systems.”

ENGEL at K 2019: hall 15, stand C58
(Engel Austria GmbH)

Newsgrafik #35089
 24.06.2019

Michael Traxler heads Mould Technology division of ENGEL  (Company news)

Michael Traxler (photo) has been appointed head of ENGEL’s Mould Technology division. Together with his team, the experienced toolmaker will continue to expand the consulting services internationally to further strengthen the systems business of the injection moulding machine manufacturer worldwide.

The share of integrated system solutions in ENGEL’s order volume is increasing globally. In addition to the injection moulding machine, automation and other peripheral devices, the mould is often part of the overall scope. Therefore, an in-house department at ENGEL’s headquarters in Austria has been involved in the project planning of injection moulds for more than ten years. The team of experts combines the experience and know-how gained from worldwide projects to develop a mould solution that is precisely tailor-made for the product and the production process in partnership with a mould manufacturer. In addition, ENGEL's mould technology department is contracted as a consultant, for example, when it comes to particularly demanding new product developments or feasibility studies.

Very well positioned internationally
Following the retirement of Udo Stahlschmidt, Michael Traxler has been appointed head of this strategically important division. Traxler has more than 30 years of experience in precision tool making and injection moulding. He joined ENGEL in 2015 and previously headed the Packaging business unit in North America.

“We would like to thank Udo Stahlschmidt for his many years of great commitment. With his sound expertise and keen sense of the specific requirements of the markets, he has very well positioned ENGEL’s mould technology department internationally,” says Dr. Christoph Steger, CSO of the ENGEL Group. “With Michael Traxler, we are delighted to have found a successor who has already a lot of experience in this area and who will continue the work without skipping a beat. With Mr. Traxler, we will continue to advance the decentralised development of the mould technology know-how”.

ENGEL started this process in China where a new Mould Technology department was established at its Shanghai site. “The project planning of injection moulds requires a great deal of coordination and very close cooperation between us as a system solution provider and the plastics processors. That's why it's so important to be on site and speak the native language of our customers,” says Steger.

Strong partner network
ENGEL has established a strong worldwide network of system partners, each of whom is also one of the leading providers in their field. ENGEL’s mould manufacturing partners cover a wide range, from simple moulds for standard injection moulding to sophisticated high-performance precision moulds. In the systems business, ENGEL suggests the most suitable mould manufacturer for each project and advises the customer on the choice of partner.

ENGEL’s many years of extensive experience in mould technology and its strong worldwide presence are decisive factors for many customers when commissioning ENGEL as a general contractor for the complete production cell, including the mould. As a general contractor, ENGEL assumes the overall responsibility, even if other companies are involved in the project. During project planning, commissioning and after-sales, the customer has a central point of contact, which accelerates many projects and offers the customer a higher degree of safety.
(Engel Austria GmbH)

Newsgrafik #35036
 31.05.2019

ENGEL ends fiscal year with growth  (Company news)

The ENGEL Group saw out the 2018/19 fiscal year, which closed at the end of March, with a turnover of €1.6 billion. The injection moulding machine manufacturer and systems solutions provider headquartered in Schwertberg, Austria, once again raised its sales, achieving a 6% increase over the previous year. “Asia and the German-speaking countries in Europe have been the primary factors behind our new sales growth,” reports Dr. Christoph Steger, CSO of the ENGEL Group, at the Chinaplas plastics industry trade fair in Guangzhou, China.

Throughout the fiscal year just passed, ENGEL generated 54% of its turnover in Europe, while Asia accounted for 21% and the Americas for 24%. Christoph Steger believes that ENGEL has managed to maintain its leading global position in injection moulding machines and integrated systems solutions as a result of its strong international presence, powerful ability to innovate, and consistent focus on quality and customer service. “Custom-built systems solutions, provided by ENGEL as a one-stop global supplier, have once again grown as a share of our incoming orders. As well as our expertise in automation, investment decision-makers are focusing more and more on ENGEL’s leading role in digitalisation and the networking of injection moulding processes.”

Despite robust growth rates characterising the first half of the 2018/19 fiscal year, ENGEL has noticed a worldwide decline in production since last summer in the automotive industry, its most important target sector. It is difficult to gauge the impacts of punitive tariffs and sanctions, Brexit, and the debate around regulatory limits and bans on diesel, which has resulted globally in feelings of uncertainty and a reluctance to buy. In China, the world’s largest market for cars, the automotive industry has accounted for a significant share of the decrease in economic growth since autumn 2018, according to Gero Willmeroth, president for East Asia and Oceania at ENGEL. “Overall, we’re expecting a sideways movement for Asia for the current fiscal year.”

Electric vehicles driving innovation and growth
It is no easy task to estimate how quickly the motor industry will recover and how much the decline in car sales will ultimately affect the plastics industry, especially as the sector also includes some important drivers of growth such as electric mobility. Particularly in Asia, the market share held by electric vehicles is continuing to increase substantially, which is helping to encourage innovation in this area. ENGEL, which has its own Center for Lightweight Composite Technologies, is a preferred partner and supplier to car manufacturers all over the world in the field of lightweight construction, including in China where the company is benefiting strongly from this reputation. “We have a growing number of organomelt projects with Chinese firms,” Willmeroth says. The ENGEL organomelt process makes it possible to form fibre-reinforced, semi-finished products with a thermoplastic matrix in an integrated and fully automated process, as well as functionalising these products through injection moulding. Demand for the process has been growing heavily since large-scale application began last year thanks not only to its high processing efficiency, but also, and in particular, the consistent thermoplastic approach. This makes it easier to later recycle the composite components, helping to promote a circular economy.

Alongside composite technologies, one of the key solutions in the pursuit of lower vehicle weights in Asia is to replace glass with polymeric materials; for instance, in glazing. There is also growth in the lighting sector, in which liquid silicone rubber (LSR) is increasingly being used as a lens material. At its Chinaplas booth, ENGEL is putting on a clear demonstration of the considerable potential in this application area, manufacturing LED headlight lenses from LSR in an automated process that requires no reworking.

Among trends in Asia, another encouraging development is the burgeoning demand in Vietnam. “As a result of the automotive industry establishing itself there, there are more and more suppliers – including from Korea – setting up company premises in the vicinity of car manufacturers,” says Willmeroth.

Business unit structure established successfully in Asia
In Asia, ENGEL is expecting further impetus for growth for the current fiscal year in the medical, packaging, telecommunications and electronics markets. In the latter two areas, known jointly as teletronics at ENGEL, this growth is expected to stem from both camera lenses and LSR processing for smartphone seals. The all-electric and tie-bar-less e-motion TL injection moulding machines were developed by ENGEL for this exact market segment and have had great success establishing themselves in the teletronics industry in Asia.

ENGEL was able to acquire a series of new customers in the medical and packaging sectors during the fiscal year just passed. “The introduction of the business unit structure in Asia is now well and truly bearing fruit,” says Willmeroth. “As a result, we’ve been able to build up our specialist knowledge on the local level here in Asia, which further strengthens our customers’ trust in ENGEL, especially in industries with highly specific needs and extremely rigorous standards.”

Faster decision-making
The new global sales structure is also enhancing ENGEL’s effectiveness in the individual regions. Last autumn, ENGEL grouped its 30 subsidiaries and more than 60 representative offices in seven regions around the world and appointed regional presidents, including Gero Willmeroth as the president for East Asia and Oceania. “We’ve sped up decision-making processes thanks to this new structure,” Steger emphasises. “The regional presidents take full responsibility for sales in their region and act as the local contacts for the subsidiaries and representative offices, which prevents delays caused by time differences. In addition, their close geographic and cultural proximity often makes it easier to work in partnership.”

Adam Zhang is Gero Willmeroth’s successor as Sales and Service President at ENGEL Machinery Shanghai. Zhang has worked for ENGEL in China since 2004, playing a crucial role in developing the large-scale machine plant in Shanghai and the company’s sales structure in northern and western China. He has now assumed responsibility for all ENGEL’s sales and service activities throughout China.

New investment strengthening local large-scale machine production
ENGEL has almost completed its 2020 investment programme, the largest effort of its kind since the company was founded in 1945, a fact that Christoph Steger shared on the eve of Chinaplas. Capacity has been increased at almost all production sites, while machinery has been upgraded. All in all, ENGEL has invested more than €375 million in its plants around the globe.

The expansion of its headquarters in Schwertberg was recently completed. This involved scaling up the assembly area, adding a new customer centre with a modernised training set-up and building an even larger technology centre. “By making this investment in our customer technology facilities, we are further strengthening our competitiveness,” Steger explains. “Our customers’ need for consulting services is increasing due to new expectations, especially in the context of the digital revolution. We now have greater capacity for customer trials and joint development efforts.” The large-scale machine plant in St. Valentin, Austria, will also be home to a new, larger technology centre. Construction work at the plant will be completed next year.

Shanghai was one of the first construction projects within the 2020 programme. The new building was inaugurated within a punctual time-frame on the plant’s tenth anniversary in autumn 2017.

6,900 employees around the world
As of the start of the new fiscal year, the ENGEL Group employs 960 people in Asia, including 729 in China. There are currently 6,900 staff working at the ENGEL Group’s plants and subsidiaries worldwide, 3,900 of whom are employed at the three Austrian plants.
(Engel Austria GmbH)

Newsgrafik #34980
 22.05.2019

Efficient packaging production  (Company news)

In mid-April, more than 80 attendees accepted their invitation to the 2019 ENGEL Packaging Day in Shanghai. The aim of the event was to discuss ongoing trends with guests and inform them about the latest technologies. The injection moulding machine manufacturer hosted live demonstrations to highlight innovative and intelligent solutions for efficient packaging production.

Photo: Cup with a kink: functional packaging with high-quality decoration is in great demand in China.

“In China, there are increasingly high standards expected for the quality of products and, in turn, packaging – especially in the food industry,” says Kurt Hell, Director of ENGEL’s packaging business unit in Asia. “Special designs and functional properties are in demand, as is high-quality decoration with in-mould labelling. Multi-coloured and multi-component applications for food and non-food closures are also becoming increasingly popular.” The packaging sector in China is a stable market experiencing constant growth and evolution. “Within the Chinese plastics industry, the production of packaging parts is an important segment with highly specific needs,” Hell explains.

An exciting morning saw presentations by ENGEL and its partner companies Pass Card, Wetec, Borouge and Verstraete, as well as long-standing ENGEL customer Menshen. And the show went on in the afternoon with two live demonstrations at ENGEL’s location in Shanghai, where the injection moulding machine manufacturer demonstrated how a two-compartment yoghurt cup with IML decoration from Verstraete can be produced economically and efficiently on an all-electric e-mac 180 injection moulding machine. Pass Card’s two-cavity hot runner precision mould and Wetec’s high-speed automation were both the work of Taiwan-based companies and the product of European-Asian cooperation.

Pooling knowledge and experience
ENGEL has established a global network of system partners to create a one-stop shop for its proprietary automation solutions and process technologies, along with other peripheral units and moulds. ENGEL, Pass Card and Wetec have pooled their specialist knowledge and experience around packaging solutions to tailor the relevant systems solution to the specific needs of the processors in Asia. By working with local suppliers, ENGEL can guarantee high cost efficiency even for the most demanding applications while keeping delivery times short across the whole system. “There is growing demand for integrated systems solutions in China,” Hell reports. “In particular, the automation of processes is becoming more important.”

In a second live demo, ENGEL showcased closures production on a tie-bar-less victory machine, an impressive demonstration of how the barrier-free clamping unit ensures particularly efficient production processes. This year marks the 30th anniversary of ENGEL’s tie-bar-less technology.
(Engel Austria GmbH)

Newsgrafik #34839
 09.04.2019

ENGEL opens second location in Mexico  (Company news)

Together with customers and partners, ENGEL de Mexico opened a second location in Mexico in San Pedro near Monterrey. "We are thus shortening the distance to our customers in the very important industrial region in the north of the country," emphasizes Peter Auinger, Managing Director of ENGEL in Mexico.

Photo: Two sales experts and four service technicians are the initial team: ENGEL has opened a second location in Mexico in San Pedro near Monterrey.

ENGEL de Mexico SA de CV is headquartered in Querétaro near Mexico City in the centre of the country, where numerous companies in the plastics industry are also based. There are 800 km between the two industrial regions. "This is precisely why we decided to establish a permanent ENGEL team in the north," says Auinger. Two sales experts and four service technicians are the initial team. In addition to offices, they have at their disposal a large conference room with state-of-the-art presentation technology, which is also used for customer training courses. At the inauguration of the site, Peter Auinger demonstrated the new possibilities with a live broadcast to Querétaro. Via the ENGEL service tool e-connect.24, he switched to an injection moulding machine in the technical centre of the central Mexican branch. The CC300 control surface was transferred in real time to the monitor in San Pedro and the machine was remotely controlled from there.

Machine training directly on the machine
For training courses and workshops directly on the machine, ENGEL works together with a partner in the north of the country. In its technical centre in Monterrey, this partner has machine capacities available for ENGEL customers.

"We are increasingly becoming a partner for our customers over the entire life cycle of our injection moulding machines and system solutions," explains Auinger. “The demands placed on our consulting services are increasing, and we are working more and more closely with our customers. The geographic proximity becomes even more important." In the Monterrey region, the automotive industry in particular is strongly represented. In addition, ENGEL de Mexico has many customers in the packaging, telecommunications and consumer electronics industries.

Present in Mexico for more than 20 years
Injection moulding machine manufacturer and system solutions provider ENGEL, headquartered in Austria, has had its own sales and service subsidiary in Mexico since 1996. In 2010, the premises were moved from Mexico City to Querétaro and significantly expanded. ENGEL has its own machine technology centre and spare parts warehouse in central Mexico. All in all, ENGEL employs almost 70 people in Mexico.
(Engel Austria GmbH)

Newsgrafik #34807
 05.04.2019

ENGEL signs New Plastics Economy Global Commitment  (Company news)

In mid-March 2019, the injection moulding machine manufacturer ENGEL AUSTRIA was one of the first plastic machine manufacturers to sign the New Plastics Economy Global Commitment of the Ellen MacArthur Foundation. The aim of the initiative is to create a circular economy. In cooperation with more than 350 other companies, universities and organisations, ENGEL has committed itself to actively contributing to the transfer of plastics into closed material cycles.

“As a member of the international plastics industry, we are not only responsible for our own products, but also for the products that are produced on our machines," stresses Dr Stefan Engleder, CEO of the ENGEL Group, headquartered in Schwertberg, Austria. “It is important to us to utilise our experience and knowledge to ensure that people in all regions of the world will handle plastics responsibly and that the conditions are created for plastic products to be returned to the material cycle at the end of their useful life. As an individual company, our influence is limited. This is precisely why we are involved in the New Plastics Economy Initiative. It networks the global players and makes our common concern more heard."

In concrete terms, the initiative founded in 2018 is about avoiding unnecessary packaging and ensuring that by 2025, all plastic packaging will be reused, recycled or composted. Each member company is asked to set individual goals and report regularly on its progress to the Ellen MacArthur Foundation.

Creating new applications for recycled materials
As a supplier to the plastics processing industry, ENGEL supports its customers in designing and producing packaging according to the rules of the circular economy and in opening up a wider range of applications for recycled materials. In this regard, the focus is on the following topics:
-To guarantee a high process consistency and to prevent rejects with the help of intelligent assistant systems, even when the raw material is subject to strong quality fluctuations, as is often the case with recycled materials.
-To further increase the proportion of recycled material in sandwich components with the aid of innovative processing technologies.
-Working closely with processors in the course of product development with the goal of reducing material usage and enabling the subsequent recycling of products.
-To further strengthen the consulting services in the area of upstream processes in order to optimize the processing of recycled materials for injection moulding.

The Ellen MacArthur Foundation is one of the leading global drivers of the circular economy. Since 2010, the organisation founded by British sailor Ellen MacArthur has been committed to a sustainable, resource-saving economy.
(Engel Austria GmbH)

Newsgrafik #34799
 27.03.2019

Ute Panzer takes over as Vice President Marketing and Communications at ENGEL  (Company news)

Since March 1, Ute Panzer is the new Vice President Marketing and Communication at the international ENGEL Group, headquartered in Schwertberg, Austria. She is responsible for all marketing measures, campaigns, trade fair appearances and worldwide communications, and reports to Dr. Christoph Steger, CSO of the ENGEL Group.

Ute Panzer (42) was previously head of marketing at a leading global technology company. The business administration graduate brings a total of 20 years of experience in industrial goods and technology marketing to her new position. “With Ute Panzer, we are delighted to have gained an internationally highly experienced marketing and communications expert for ENGEL who is firmly rooted in mechanical and plant engineering," says Christoph Steger.

Prior to appointing a new VP of Marketing, ENGEL restructured its global marketing activities. The Strategy and Product Management divisions were migrated into independent units. Martin Streicher, who served as Vice President Global Marketing until September 2018 and was responsible for all three areas, will head up the Strategy and Corporate Development division and continue to expand it. Katharina Hochreiter had taken over as Head of Marketing in the interim. She also remains with ENGEL, taking on the role of Project Manager in Strategy and Corporate Development.
(Engel Austria GmbH)

Newsgrafik #34759
 18.03.2019

ENGEL at Plastimagen 2019  (Company news)

The ENGEL e-cap stands for maximum efficiency combined with the best-in-class product quality. At Plastimagen 2019 from 2nd to 5th April in Mexico City, the all-electric injection moulding machine will be demonstrating its high performance under genuine production conditions. An e-cap 740/160 with 1,600 kN clamping force will be producing 28 mm PCO 1881 caps for carbonated soft drinks (CSD). Another focus of the ENGEL trade fair stand in hall D is the new opportunities that digitalisation and networking are opening up for plastics processors and how they can be easily leveraged.

Photo: Maximum output with minimum energy consumption: the all-electric e-cap injection moulding machine will be producing 28 mm caps at Plastimagen 2019.

Available with clamping forces from 1,100 to 4,200 kN, the ENGEL e-cap is the only cap machine on the market providing all-electric operation in the high clamping force range. This makes it the most energy-efficient machine in its class at the same time.

A 24-cavity mould by Austrian mould maker HTW will be used at the Plastimagen. The processed material is a PEHD by Borealis (Vienna, Austria) at a shot weight of 2 grams per cavity. The peripheral units on display will include a dry air system by Eisbär (Austria). "By precisely matching the injection moulding machine, the material, the mould and the peripheral systems from the outset, we can leverage efficiency potentials to a maximum and further reduce energy consumption," as the Managing Director of ENGEL de Mexico in Querétaro, Peter Auinger, points out. The injection moulding machine manufacturer and system solutions provider, ENGEL, headquartered in Austria, delivers fully-integrated and automated manufacturing cells from a single source, worldwide. This also increases efficiency in project planning and after-sales service. "Our customers have just one central contact," Auinger explains. "As the general contractor, we have the overall responsibility, also for system components that we implement in collaboration with partners."

Minimum cycle times, maximum quality
ENGEL has adapted the e-cap series specifically to the requirements of beverage cap production. The high-performance machine achieves particularly short cycle times for the individual cap types. At less than 2 seconds, the shortest cycle times are achieved in the manufacture of lightweight caps for still water. For CSD caps, cycle times vary depending on the cap type. At Plastimagen, the e-cap will achieve a cycle time of 3.7 seconds for 28 mm PCO 1881 caps.

In addition to energy efficiency and productivity, precision and process stability are decisive factors when selecting a cap machine. “Caps have reached their lightweighting minimum in terms of geometry," says Auinger. "This means that they place higher requirements than ever in terms of the injection moulding machine's precision and repeatability." High-performance servo direct drives are responsible for the outstanding process stability of the e-cap injection moulding machine. They ensure the required plasticising capacity and the highest possible number of good parts even when high-strength HDPE materials are used with an MFI of below 1 g/10 min.

Self-optimising machine
inject 4.0 is the second focus at the ENGEL stand in Mexico City. "Our customers are increasingly leveraging the potential of digitalisation and connectivity," as Auinger reports. There is great demand for intelligent assistance systems that enable the injection moulding machine to continuously self-optimise during the on-going process. iQ weight control, for example, analyses the pressure profile during injection and compares the measured values with a reference cycle. The injection profile, switchover point and the holding pressure profile are adjusted to the current conditions for each individual shot, which keeps the injected volume constant during the entire production run. Fluctuations in the raw material and ambient conditions are thus compensated for before rejects are produced. "iQ assistance systems are often the first step on the way to becoming a smart factory," says Auinger. "The modular structure of the inject 4.0 program makes it easy to get started with individual, smaller solutions and then build on this to further develop the digitalisation strategy in line with needs." Other assistance systems that ENGEL will be presenting in Expert Corners during the fair are iQ clamp control for automatic determination of the optimum clamping force and iQ flow control for dynamically controlled multiple-circuit temperature control.

Enhancing machine availability
The challenge in maintaining and servicing injection moulding machines is to guarantee high availability while at the same time reducing costs. And again inject 4.0 opens up new opportunities for this. The e-connect.monitor condition monitoring solution makes it possible to check the condition of process-critical machine components during operation and reliably predict their remaining service life. In this way, unplanned downtimes can be avoided and the working life of the components fully utilised. Four modules are currently available, for plasticising screws, ball screws in high-performance electric machines such as the ENGEL e-cap, fixed displacement pumps in servo-hydraulic injection moulding machines and for hydraulic oil.

All ENGEL service products – in addition to e-connect.monitor, for example, e-connect.24 for 24/7 online support – are integrated into ENGEL's e-connect customer portal. At any time and anywhere, it provides an overview of the machine status, the condition of the monitored machine components, the processing status of service and support orders and the prices and availability of spare parts. In this way, the portal simplifies and accelerates communication between processors and the supplier, ENGEL. The associated app keeps the plant operator up to date, even if they are currently at a completely different location.

MES for newcomers and advanced users
At Plastimagen, ENGEL will also be presenting smart connectivity solutions for linking injection moulding machines and production cells within the enterprise. TIG authentig, the MES (Manufacturing Execution System) by ENGEL subsidiary TIG (Rankweil, Austria) is tailored to the specific requirements of the injection moulding industry down to the last detail. It ensures transparency in order to, for example, utilise the total capacity of the machines or correlate productivity indicators and economic objectives. The new products that TIG will be presenting in Mexico include the TIG 2go dashboard solution, which is particularly suitable for entering the MES world, and the TIG big data high-performance analysis platform for networking machinery around the globe in a central cockpit.

Present in Mexico for more than 20 years
ENGEL opened its own sales and service subsidiary in Mexico in 1996. In 2010, the Mexico City facility relocated to Querétaro and was substantially extended in the process. In Central Mexico ENGEL has its own technical centre and spare parts warehouse. To further reinforce customer proximity, ENGEL is opening a second location in the Monterrey region in the north of the country at the end of February 2019. All told, ENGEL employs some 70 staff in Mexico.

ENGEL at Plastimagen 2019: hall D, stand 514
(Engel Austria GmbH)

Newsgrafik #34745
 12.03.2019

ENGEL at Plástico Brasil 2019  (Company news)

ENGEL is making its customers more competitive with reliable, flexible and efficient machines and automation from a single source. At Plástico Brasil 2019 from 25th to 29th March in São Paulo, Brazil, the injection moulding machine manufacturer and system expert headquartered in Austria will be demonstrating what this can look like in practice with two sophisticated applications from the fields of packaging and technical moulding. It will be clearly demonstrated how digitalisation, and machine and system networking can unlock even more efficiency and quality potential.

Photo: ENGEL has consistently equipped its all-electric ENGEL e-motion injection moulding machine for high-performance operation with injection speeds of more than 500 mm per second.

Packaging: Thin-wall with IML in 2.2 seconds
Flexibility and high performance play the main roles in ENGEL's packaging exhibition space at Plástico Brasil 2019. An ENGEL e-motion 440/160 will be used to produce polypropylene ice cream cups using thin-wall technology in a 4-cavity mould with a total shot weight of 14.8 grams. Thanks to in-mould labelling (IML), the cups are ready-to-fill when they leave the integrated production cell. The cycle time is 2.2 seconds.

Two main factors are responsible for the high efficiency and economy of the production process. On the one hand, in-mould labelling makes it possible to change the decor without interrupting production. Even with very small batch sizes, this guarantees the lowest unit costs. On the other hand, ENGEL has consistently geared its all-electric ENGEL e-motion injection moulding machine for high-performance operation with injection speeds of more than 500 mm per second. The closed system for the toggle lever and spindle ensures optimum and clean lubrication of all moving machine components; the e-motion thus meets the strict purity requirements not only of the food industry, but also of the cosmetics, medical technology and pharmaceutical industries.

ENGEL is implementing this exhibit together with partners. The mould is provided by SIMON from Saint-Lupicin, France. BECK automation (Oberengstringen, Switzerland) is responsible for the IML automation. The labels come from Verstraete in Maldegem, Belgium, and the polypropylene from Borealis, who are headquartered in Vienna, Austria.

30 years of ENGEL tie-bar-less technology
Compact manufacturing cells, efficient automation and fast set-up processes: with their fully usable platen areas and free access to the mould area, tie-bar-less injection moulding machines fulfil the need for high efficiency and cost-effectiveness in production in a particularly good way. To mark the start of the 30th anniversary of ENGEL tie-bar-less technology, the machine manufacturer is presenting a tie-bar-less victory 1060/220 injection moulding machine at Plástico Brasil 2019, on which technical parts are produced in a multi-cavity mould. With its tie-bar-less technology, ENGEL still has a unique selling proposition today.

Barrier-free access to the mould area makes it possible to fully utilise the mould mounting platens up to the edges. This means that large, bulky moulds can be mounted on relatively small machines. This translates into efficiency factor, especially when multi-cavity moulds are used. Multi-cavity moulds, although large, require relatively little clamping force for the precise moulding of fairly small component surfaces. Where a tie-bar-less injection machine is deployed, therefore, the machine size is determined not by mould volume, but by the clamping force required for the moulding process. Thanks to tie-bar-less technology, much smaller injection moulding machines can be used for many applications; this keeps investment and operating costs low while facilitating compact manufacturing cells.

The patented force divider in the tie-bar-less clamping unit enables the moving mould mounting platen to follow the mould exactly parallel while clamping force is building up, and ensures that the applied force is evenly distributed across the whole surface. This means both outer and inner cavities are kept closed with precisely identical force, which leads to extremely consistent wall thicknesses. Even where very low viscosity materials such as liquid silicone rubber (LSR) are used, flash is reliably prevented.

Other advantages of tie-bar-less clamping units include improved ergonomics, mould set-up time savings and highly efficient automation concepts. The robots have maximum freedom of motion and unrestricted access to the mould area from the side, thus reducing the handling times. In São Paulo ENGEL is demonstrating this with a viper linear robot.

inject 4.0: compensating for process fluctuations before rejects are produced
A third topic for ENGEL at Plástico Brasil is inject 4.0. ENGEL already offers a range of mature products and solutions for the digitalisation and connectivity of manufacturing processes, and new ones are constantly being added. The modular approach of ENGEL's inject 4.0 program makes it particularly easy for processors to take advantage of the new opportunities that industry 4.0 opens up. Even small-scale individual solutions promise considerable benefits. As an example, ENGEL will be presenting its iQ weight control assistance system in São Paulo. During the injection process, the software analyses the pressure profile in real time and compares the measured values with a reference cycle. Individually for each shot, the injection profile, switchover point and the holding pressure profile are automatically adapted to current conditions and the injected melt volume is kept consistent throughout the whole production operation. In this way, fluctuations in environmental conditions and in raw materials are automatically recognised and readjusted before even a single reject is produced.

ENGEL at Plástico Brasil 2019: stand E242
(Engel Austria GmbH)

Newsgrafik #34528
 03.01.2019

ENGEL at Interplastica 2019  (Company news)

ENGEL is making its customers more competitive with flexible and efficient machine concepts along with automation from a single source. The system expert headquartered in Schwertberg, Austria, will demonstrate what this means in practical terms at Interplastica 2019, from January 29th to February 1st in Moscow, Russia, by manufacturing lids for food containers including in-mould labelling. Another focus of the ENGEL trade fair stand in hall 2.1 is the new opportunities that digitalisation and networking are opening up for plastics processors and how they can be easily leveraged.

At Interplastica, ENGEL will be demonstrating how economical IML concepts can also be implemented for small batch sizes with one-shot production of ready-for-sale decorated lids for food packaging. To do so, ENGEL will be combining an e-motion 740/220 injection moulding machine equipped with a viper 20 linear robot with an IML uniLINE by TMA AUTOMATION. The viper robot removes the label from the IML cell, places it in the mould of the injection moulding machine, simultaneously removes the last moulded finished part and transfers it back to the uniLINE for ejection. Thanks to its standardised system concept, the compact IML cell is particularly easy to integrate. Within a very short time, the injection moulding machine can be flexibly converted for other tasks – with or without in-mould labelling. "We are thus also making IML attractive for the general purpose sector," stresses Olaf Kassek, Managing Director at OOO ENGEL in Moscow. "TMA's automation solutions can be combined just as easily with ENGEL e-mac and servo-hydraulic ENGEL victory injection moulding machines."

The ENGEL e-motion presented at Interplastica is often the first choice when it comes to producing of food packaging. With its closed system for toggle levers and spindles the injection moulding machine ensures optimum and clean lubrication of all moving machine com-ponents at all times, thus complying with the strict requirements of both the food and medical industries.

TMA AUTOMATION, based in Gdynia, Poland, is a new ENGEL partner specialising in the automation of IML and downstream processes, such as assembly, quality assurance and palletising, in the general-purpose sector for a wide range of industries. Especially in Eastern Europe, the automation expert can point to numerous well-known references. As the general contractor, ENGEL handles coordination with the automation partner for its customers and supplies the complete production cell from a single source. This also increases efficiency, as fewer interfaces often mean faster project planning.

Intelligent assistance prevents rejects
inject 4.0 is the second focus at the ENGEL stand in Moscow. "Our customers are increasingly leveraging the potential of digitalisation and connectivity," as Kassek reports. There is specific demand for intelligent assistance systems that enable the injection moulding machine to continuously self-optimise during the on-going process. iQ weight control, for ex-ample, analyses the pressure profile during injection and compares the measured values with a reference cycle. The injection profile, switchover point and the holding pressure profile are adjusted to the current conditions for each individual shot, which keeps the injected volume constant during the entire production run. Fluctuations in the raw material and ambient conditions are thus compensated for before rejects are produced. "The iQ assistance systems are often the first step on the way to becoming a smart factory," as Kassek reports. "The modular structure of the inject 4.0 program makes it easy to get started with individual, smaller solutions and then further develop the digitalisation strategy in line with needs."

Customer portal e-connect in Russian for the first time
One special highlight at Interplastica is the ENGEL customer portal e-connect, which will be presented in Russian for the first time. At any time and anywhere, it provides an overview of the machine status, the processing status of service and support orders and the prices and availability of spare parts. In this way, the portal simplifies and accelerates communications between processors and ENGEL as the supplier.

All service products from the inject 4.0 program are integrated into e-connect, including the new e-connect.monitor for condition-based predictive maintenance and e-connect.24 for 24/7 online support. "In a country as large as Russia, online support and remote maintenance are often decisive competitive factors," as Kassek emphasizes. Qualified ENGEL service technicians are available around the clock and help users to troubleshoot faults in the shortest possible time, thus minimising downtime. If so desired by the user, the machines can independently send an electronic call for help to ENGEL so that the specialists can start processing without any loss of time. The associated app keeps the plant operator up to date, even if they are at a completely different location many miles away.

MES for newcomers and advanced users
At Interplastica, ENGEL will also be presenting smart connectivity solutions for linking injection moulding machines and production cells within the company. TIG authentig, the MES (Manufacturing Execution System) by ENGEL subsidiary TIG (Rankweil, Austria) is tailored to the specific requirements of the injection moulding industry down to the last detail. It ensures transparency in order to, for example, utilise the total capacity of the machines or correlate productivity indicators and economic objectives. The new products that TIG will be presenting for the first time during the trade fair in Russia include the TIG 2go dashboard solution, which is particularly suitable for entering the MES world, and the TIG big data high-performance analysis platform for networking machinery around the globe in a central cockpit.

ENGEL at Interplastica 2019: hall 2.1, stand 1B23
(Engel Austria GmbH)

Newsgrafik #34519
 20.12.2018

ENGEL at Arabplast 2019  (Company news)

Optimum efficiency, maximum performance and consistent quality: ENGEL, the Austrian injection moulding machine manufacturer and system solution provider, will be demonstrating how tailor-made interplay between the injection moulding machine, automation, and the mould can reconcile these demands cost-effectively and sustainably at the Arabplast 2019 fair from January 5th to 8th in Dubai, United Arabic Emirates. ENGEL’s information stand in hall 6 will focus on innovative products and applications for the construction, logistics and packaging industries.

As the dynamic development of the plastics industry in the United Arab Emirates continues, it is not least Expo 2020, the upcoming world exhibition in Dubai, that is inspiring the region. The construction, logistics and packaging sectors in particular are benefiting from the preparations for several million additional visitors. "Plastics processors in these industries are increasingly investing in the modernisation and expansion of their machinery," reports Andreas Leitner, Sales Director Middle East at ENGEL in the run-up to Arabplast. "Demand is particularly high for solutions that lead to greater efficiency and further increase sustainability." As an innovation-driven company with a high level of automation and expertise in system solutions, ENGEL is one of the preferred suppliers in the region. "If we precisely tune all components of the production cell from the outset, we can fully exploit both efficiency and quality potential," says Leitner. In addition to injection moulding machines, ENGEL develops process technologies, robots and special automation solutions in-house and also collaborates with partner companies that are also leaders in their respective fields. One of these partners, Otto Hofstetter, is exhibiting along with ENGEL in Dubai. Among other capabilities, the Swiss toolmaker is one of the world's leading suppliers of thin-walled packaging. The two partners have many joint reference projects in the United Arab Emirates.

Packaging: maximum performance – minimal energy consumption
During the four days of the fair, ENGEL and Otto Hofstetter will be presenting a whole range of different thin-walled containers – from small food containers to larger paint buckets – which are manufactured using in-mould labelling (IML) at particularly low unit costs. IML makes it possible to produce highly decorated, ready-to-fill packaging in a single production step. For this purpose, a decorative film is automatically inserted into the mould and back-moulded with thermoplastic material. The high-performance machines in ENGEL's e motion series ensure that even extremely thin-walled containers are highly stable in these applications. With its closed system for toggle levers and spindles, the all-electric e-motion ensures optimum and clean lubrication of all moving machine components at all times, thus complying with the strict requirements of the food industry.

In the manufacture of caps, efficiency is also still the most important driver of innovation. The e-cap, which ENGEL developed specifically for cap production, is the only cap machine on the market providing all-electric operation with a clamping force range as high as 4,200 kN. At the same time, it is the most energy-efficient machine in its class. To manufacture 26 mm caps made of high density polyethylene in a 72-cavity mould, for example, an e-cap 2440/380 requires only 0.4 kWh of electricity per kilogram of pellets with a cycle time of less than 2 seconds. Because it is all-electric, the e-cap also saves cooling water. "The lowest possible energy and cooling water consumption values are crucial in the United Arab Emi-rates," says Leitner. "The trend in cap production is therefore clearly towards all-electric machines."

Construction: compact solutions for voluminous moulds
In the construction industry, it is mainly fittings which are produced in large quantities and place high demands on suppliers. As a rule, fitting production requires a large number of core-pulls and slide valves, thus leading to particularly large moulds. To avoid the size of the injection moulding machine being determined by the mould volume, and instead by the clamping force required for the injection moulding process, increasing numbers of fitting manufacturers are opting for tie-bar-less ENGEL victory machines. Because there are no tie bars in the way, the mould mounting platens can be fully used up to their very edges. In this way, large moulds fit on comparatively small machines, which keeps investment costs low and saves a huge amount of energy over the entire production period. The ENGEL ecodrive servo-hydraulic system, which is part of the the victory series' standard scope of supply, makes a further contribution to high energy efficiency.

Further advantages of the tie-bar-less clamping unit are faster set-up processes and more efficient automation, as the robots move close to the clamping unit and can reach the cavities without needing to work around the interfering edges. The trend towards integrating work steps downstream of the injection moulding process is leading to a further increase in the degree of automation. In the manufacture of fittings, for example, ENGEL viper linear robots automatically place seals in the component.

Logistics: reliable processing of recycled materials
The trend towards greater sustainability is particularly evident in the area of logistics. Companies in the Middle East would like to completely do without wooden pallets in the long term. Plastic pallets do not require environmentally hazardous chemicals such as pesticides and fungicides and are lighter, while offering greater stability and rigidity, making them ideal for air freight. In addition, they are neither hygroscopic nor flammable and do not splinter. "Pallets are increasingly being produced from recycled packaging waste," says Leitner, describing an important milestone. "The circular economy trend is leading to more and more high-quality applications being developed for recycled materials, which we support as machine manufacturer and system solution provider." With their very powerful plasticising units, compact, dual-platen, large-scale machines by ENGEL duo series are optimally equipped for processing recycled material.

To achieve full automation even for larger dimensions, ENGEL offers its viper robots with a nominal payload capacity of up to 120 kg. With a mould take-off stroke of 3000 mm and a reach of 3550 mm, the ENGEL viper 120 is expanding the horizon of linear robotics.

Master complex processes easily
From the standardised robot cell to the tailor-made special automation solution, ENGEL precisely meets individual handling requirements. One special feature with ENGEL is that the robot control is a component of the injection moulding machine's CC300 control. This guarantees uniform operating logic throughout the entire production cell and exploits further efficiency potential. As the machine and robot access a common database, their movements can be coordinated precisely, which cuts cycle times in many applications.

The whole process is very easily and clearly visualised via the CC300 control panel of the injection moulding machine and can be controlled centrally using the panel. With the increasing complexity of manufacturing processes, this aspect is becoming increasingly important. Control integration reduces complexity and makes it easy, even for a machine operator with little experience, to master the process reliably and produce consistently high quality. "The shortage of skilled workers in the United Arab Emirates continues to worsen," Leitner reports. "With our Simplicity approach, we are helping our customers to further boost their competiveness."

New service base in Dubai
A deep understanding of local markets and individual customer requirements is a prerequisite for developing tailor-made injection moulding solutions. To ensure close proximity to its customers worldwide, ENGEL is continuously expanding its sales and service network. In the Middle East, the service team in particular has recently been expanded. Dubai now also has its own service base. Within the ENGEL Group, ENGEL has been able to recruit a very experienced technician for the emirate.

ENGEL at Arabplast 2019: hall 6, stand C110
(Engel Austria GmbH)

Newsgrafik #34300
 12.10.2018

New safety guarding for more flexibility and safety  (Company news)

With its newly developed EN ISO 14120-compliant safety guarding, ENGEL offers a significant safety boost. In addition to this, the modular solution enables particularly easy configuration and installation. ENGEL is presenting the new development at Fakuma 2018 from 16th to 20th October in Friedrichshafen, Germany.

Photo: The new modular EN ISO 14120-compliant safety guarding improves safety in production.

EN ISO 14120 "Safety of machinery – Guards – General requirements for the design and construction of fixed and movable guards" places even higher demands on the strength of protective guards than its predecessor EN 953. Above all, the external load capacity is defined in concrete terms. In the pendulum test, the safety guarding must withstand a 90 kilogram sandbag.

Modular and highly flexible
ENGEL's goal in developing the new safety guarding was not only to reliably meet the requirements of the new standard, but also to ensure greater flexibility for users. The result is a modular design matrix with an extensive selection of protective panels and control elements such as openings, control cabinets, cable conduits, and revolving and sliding doors. Individual layouts can also be implemented in a cost-efficient way. In addition, the new solution can be adapted and extended to changing requirements at any time. In many cases, one person is all it takes to assemble the safety guarding in a short period of time.

Easier to maintain
In order to simplify maintenance and servicing, the electrotechnical area has been optimised. The electronics of the safety doors, for example, are no longer located in the door frame, but in easily accessible door connection boxes.

The new TÜV-approved safety guarding is offered as standard for both stand-alone injection moulding machines with a conveyor belt and integrated and automated production cells. It is consistently styled in the continuous and functional ENGEL design and is very easy to clean. In combination with an options package, the new safety guarding also meets requirements for clean room production.

ENGEL at Fakuma 2018: hall A5, stand 5204
(Engel Austria GmbH)

Newsgrafik #34046
 16.08.2018

Fakuma 2018: Ultra-short cycle times with maximum efficiency and quality  (Company news)

Picture: Maximum output with minimum energy consumption: ENGEL e-cap at Fakuma

At the Fakuma trade fair in Friedrichshafen, Germany, 16th to 20th October 2018, ENGEL will demonstrate a further reduction in cycle times for the production of caps. An all-electric ENGEL e-cap 2440/380 will be used to produce 26 mm caps, including tamper-proof bands made of HDPE, at a cycle time of under 2 seconds under realistic manufacturing conditions.

Optimised movement profiles allow for an increased output: The ENGEL e-cap 380 with 3,800 kN of clamping force can provide a dry cycle time of just 1.4 seconds.

The ENGEL e-cap is the only cap machine on the market providing all-electric operation with a clamping force range as high as 4,200 kN. At the same time, it is the most energy-efficient machine in its class. Despite its substantial output, the e-cap due to be showcased at Fakuma only needs around 0.4 kWh of electricity to process a kilogram of plastic granulate.

Integrated systems solution to unlock full potential
A 72-cavity mould from z-moulds (Dornbirn, Austria) will be used at the trade fair. As far as peripheral units, the exhibit will include a dry air system from Blue Air Systems (Kundl, Austria) and a camera inspection system from IMDvista (Brügg, Switzerland). As a system solutions provider, ENGEL delivers fully-integrated and automated manufacturing cells around the world from a single source. Efficiency potential is maximised and overall energy consumption kept to a minimum where the injection moulding machine, mould and peripheral systems are properly coordinated from the start of the project.

Alongside energy efficiency, the all-electric e-cap machine's features include extreme precision. This ensures the greatest possible number of good parts, even in the production of demanding lightweight caps.
ENGEL at Fakuma 2018: hall A5, stand 5204
(Engel Austria GmbH)

Newsgrafik #34032
 02.08.2018

Fakuma 2018: Flexibly produce the smallest lot sizes  (Company news)

From vehicles to electronic devices, more and more products are being offered in increasingly diverse design variations. For production, this translates to smaller lot sizes. At the Fakuma 2018, from October 16 to 20 in Friedrichshafen, Germany, using two innovative applications ENGEL AUSTRIA will demonstrate how small lot sizes can be realised with the efficiency and economy of large series.

Photo: With a clamping force of 1200 kN, the new e-motion 120 TL is the largest machine in its series.

Production of variations with fully automated switch-over
Three premieres at the same time
At the Fakuma 2018, ENGEL is celebrating three premieres at the same time with a highly integrated production cell on which two-part callipers are manufactured using ABS. A fully automated solution for the very rapid switch of mould inserts will be presented for the first time, the new size 120 of the all-electric and tie-bar-less e-motion TL series with a clamping force of 1200 kN will be introduced to the public, and thirdly, the expanded functionality of the e-flomo electronic temperature-control water manifold will be presented.

Lot sizes of less than 1,000 present a special challenge in injection moulding. In order to economically realise a large number of variations, moulds with interchangeable inserts are often used. At the Fakuma, ENGEL, together with Braunform (Bahlingen, Germany) and other system partners, is going one step further. The system solution presented there allows for a fully automated switch of the mould inserts within just one minute. To this end, the ENGEL e-motion 170/120 TL injection moulding machine is equipped with a mould that includes the fast-switch mechanism patented by Braunform.

To clearly demonstrate the potential of the new solution, the two geometrically different components of the calliper will be produced in rapid succession one after the other. After only three shots, the injection moulding machine alerts the integrated ENGEL easix articulated robot that the lot has been fulfilled and unlocks the mould inserts. The robot first removes the last produced component, then changes grippers and switches the mould inserts. From usable part to usable part, this process only takes one minute. Communication between the injection moulding machine and the periphery is conducted via authentig, the MES of ENGEL subsidiary TIG. The software provides the parts data sets to both the machine and the robot.

4.0 assistance ensures the highest measure of usable parts
One of the challenges of this application is that both components have widely varying shot weights. In order to already produce a usable part with the first shot following the setup, the injection moulding machine continuously optimises itself with the help of three intelligent assistance systems from ENGEL's inject 4.0 programme. While iQ weight control readjusts the melt volume for each individual shot, iQ clamp control calculates the optimal clamping force and sets it automatically. iQ flow control – the third assistance system on the team – automatically compensates temperature differences in the cooling water manifold circuit based on the measurements determined by e-flomo, and adjusts the pump speed in the e-temp temperature control units to the current process conditions.

The electronic temperature-control water manifold e-flomo makes another contribution to the short setup times. The automated, sequential blow-out of the manifold circuits in the mould ensures that water and possibly dirt left in the temperature-control channels is completely removed before the removal of the mould or mould insert. Upon installation, this new function guarantees an optimal ventilation of the temperature-control channels. As compared to the conventional manual blow-out, the automated process saves time and also allows for an extension of the mould's maintenance intervals. Since all channels are not evenly ventilated by pressurised air in the manual procedure, residual water may remain in the channels and lead to corrosion. This risk is eliminated by automation.

All units compactly integrated
One real eye-catcher at the Fakuma is the extremely compact layout of the production cell with the easix robot at its centre. The robot is responsible for the complete handling of the mould inserts and components, the marking of injection-moulded parts and their assembly, and the removal of the callipers from the production cell. To this end, the injection moulding machine, the station for grippers and mould inserts, the laser printer, the assembly device and the conveyor unit are arranged around the robot in a star shape.

Two factors in particular contribute to the extremely space saving arrangement of the individual components. One is the freely definable prohibited areas of the easix robot and the other is the tie-bar-less clamping unit of the e-motion TL injection moulding machine. The barrier free access to the mould area allows the robot to move very close to the clamping unit with no motion restrictions.

With the completely automated production cell, the system partners ENGEL and Braunform are addressing customers who produce articles similar to each other in small lot sizes or with a high degree of variation. Typical products are consumer goods such as writing tools, technical components in the automotive and electronic areas, but also a range of medical technology products.

Tie-bar-less and all-electric – now with up to 1200 kN clamping force
With a clamping force of 1200 kN, the new e-motion 120 TL is the largest machine in its series. This upward expansion represents ENGEL's focus on the trend towards an increased use of multi-cavity moulds. Without any tie-bars in the way, the mould mounting platens can be utilised fully, so that large and bulky moulds can be fitted on comparatively small injection moulding machines. This is also an advantage in the manufacturing of geometrically complex components that require core-pulls and sliders within the mould. Rather than the mould dimensions, now the actually required clamping force determines the size of the machine. This saves costs in new investment as well as current operations.

To ensure a long useful life of the mould and a consistently high product quality, the all-electric and tie-bar-less high performance machines by ENGEL are equipped with a highly sensitive platen parallelism adjustment. Machines from this series are often used in the production of extremely small precision parts in the electronics and medical technology industries.

One process for infinite design options
Design, structure, function in just one process step
With the evolution of its foilmelt technology, at the Fakuma ENGEL presents a roll-to-roll IMD application with a flexibility that has not existed until now. The joint development of the system partners ENGEL, Leonhard Kurz (Fürth, Germany), Schöfer (Schwertberg, Austria) und Isosport Verbundbauteile (Eisenstadt, Austria) allows for thermoforming, back-injecting, and punching out in rapid sequence the most diverse surface structures from roll to roll within the mould.

The broad spectrum of possible material combinations is remarkable. Foils functionalised using capacitive electronics, multi-layered foil systems with topcoat as well as structured, back-lightable, or open-pore systems such as wood can be processed from the roll. In addition to the typical materials such as ABS, PC or PC/ABS, PP can be used for back-injecting. To change the décor, structure and functionality, only the roll has to be switched, not the mould.

With the production of differently decorated, three-dimensionally complex sample components on a duo 1060/350 injection moulding machine with integrated viper 20 linear robot, at its exhibition booth ENGEL demonstrates the high flexibility of the series-ready technology. Among others, target groups are the manufacturers of visible parts for car interiors as well as the teletronics and white goods industries.

As of January, 2019, the production cell will be available for technology demonstrations, material tests and customer-specific developments in the new ENGEL technology centre at its headquarters in Schwertberg.

Modular and highly flexible safety guard
Another innovation presented by the foilmelt production cell at the Fakuma is the new safety guard developed by ENGEL according to EN ISO 14120, which will be available for all automated injection moulding machines and integrated system solutions as of October. Here again, the focus in development was on high flexibility in combination with a high degree of economic efficiency. The modular concept allows for an especially simple configuration and an equally easy assembly. The comprehensive selection of safety panels and functional elements such as openings, revolving doors and sliding doors allow for the cost-effective realisation even of individual layouts.

ENGEL at Fakuma 2018: Hall A5, Booth 5204
(Engel Austria GmbH)

Newsgrafik #33972
 11.07.2018

inject 4.0 Forum: The next dimension  (Company news)

Three years ago, with inject 4.0 ENGEL introduced its answer to the challenges of Industry 4.0. In the meantime, the terms smart machine, smart production and smart service have become established throughout the entire plastics industry, and in many areas, the smart factory has arrived in practice. "It is now time for the next step", announces Dr. Stefan Engleder, CEO of the ENGEL Group, at the ENGEL inject 4.0 Forum at the end of June in Linz, Austria. Marketplaces will connect companies along the value chain and generate new products and services for the injection moulding industry. "The digital transformation is guiding inject 4.0 into a new dimension", says Engleder.

At the event, to which ENGEL has invited a select circle of innovation-driven inject 4.0 users, it once again becomes clear that digitalisation is not an end unto itself. The goal of Industry 4.0 is to utilise the full potential of machines, systems and technologies in order to strengthen competitiveness, operate with more flexibility and securely manage increasing complexity. Transparency and the assistance that builds on it are the keys to more efficiency. "We have already made great strides in this direction", says Stefan Engleder. "However, it has always been clear to us that in terms of Industry 4.0, we were setting out on a long voyage. The goal is known, the way there must be continuously developed, stage by stage, in collaboration with our customers and partners. At this time, we are facing the next big step."

Horizontal networking as a goal
So far, the path to the smart factory has been focused on the function-related optimisation of individual value creation stages such as production and sales, and on indirect value creation areas such as maintenance management and quality assurance. To this end, machine and process data are collected and analysed, and the shop floor is vertically linked to the operations management level on the basis of digital twins of the machines and systems. As a rule, the classic IIoT (Industrial Internet of Things) platforms for this are proprietary solutions. In practice, however, vertical platform structures are unable to meet the requirements of processing data from various provider systems and correlating these with the data from other companies.

The goal of digital transformation is therefore the transition to horizontal platforms that bundle the know-how and offerings of various companies. An open, horizontal networking allows for the cross-functional optimisation of processes along the entire value chain. "The digital transformation is just beginning. We see a great opportunity here. We are inviting our customers and partners to continue actively developing the future of smart production in collaboration with us, and to tailor the new solutions specifically to the requirements of the plastics industry”, says Engleder. "This way, we will all derive the optimum benefit from these newly arising opportunities."

Marketplace for the entire value chain
The role model are B2C marketplaces like Amazon or Google. Instead of handling physical assets and their related value creation activities, these companies act as intermediaries between supply and demand, connecting marketplace participants with the help of digital technologies. In order to generate new services, the platforms assemble a multitude of data. The capacity to process and analyse data constitutes the foundation on which to serve customer needs better and in a more targeted fashion.

This trend is penetrating into the B2B sector, with the term marketplace also becoming established there. In future, market participants with the same, similar or complementary value streams will communicate through marketplaces, offer their products and technologies there, and include their suppliers as well as their customers in this network. The plastics processor using multiple systems from different providers will find all relevant information in a central location and can use the applications offered – so-called apps – with particular efficiency. "Horizontal networking provides the basis for new business models that supplement our current ones and offer added value to our customers", says Engleder.

ADAMOS, for example, offers an industry-specific marketplace of this kind. It is a manufacturer-agnostic, open platform that has been developed specifically for the requirements of machine engineering and its customers, and in which ENGEL also participates.

Pilot factory launching
The Austrian plastics industry is traditionally strong in innovation and is also among the pioneers in terms of digital transformation. It is no coincidence that a pilot factory for interdisciplinary, platform-based cooperation is being created at the Johannes Kepler University in Linz. Next year, the LIT Factory, in which, in addition to ENGEL, the companies Borealis, Covestro, Erema, FACC, Greiner, Leistriz, Motan, Siemens and others are participating, will commence operations.

"The LIT Factory allows us to test the new possibilities under practical conditions, gather experience together with our partners, continue researching the challenges of horizontal networking, and develop new solutions", states Engleder. One already known challenge is uninterrupted connectivity, for not all participants in the value chain are compatible with each other. "A common marketplace will accelerate the development of standards", says Engleder. "In the long term, we expect that various marketplaces will become networked with each other and allow for the exchange of data between participants."

From the production of raw materials to the recycling of plastics products that are no longer needed, the platform of the LIT Factory includes the entire value chain. In this way, horizontal networking is helping to move other urgent future topics forward. One example is the closing of value streams. The Circular Economy requires an even closer cooperation of businesses along the value chain, which can be designed especially easily and efficiently on a marketplace.
(Engel Austria GmbH)

Newsgrafik #33966
 06.07.2018

ENGEL wins Gold in Pegasus Business Award  (Company news)

ENGEL AUSTRIA is one of the lighthouses of Upper Austria's business landscape - according to the jury of the Pegasus Business Award. ENGEL was awarded Gold in the Lighthouses category during the gala night in the Brucknerhaus in Linz, Austria. The Pegasus is the most prestigious business award in the country and is awarded annually by the Oberösterreichische Nachrichten.

Photo: ENGEL wins the coveted business award in the lighthouses category. From the left: Axel Greiner (President of IV OÖ), Robert Machtlinger (FACC, Bronze), Christoph Steger (ENGEL, Gold) and Helmut Wieser (AMAG, Silver). Photo: OÖNachrichten, Weihbold

"We are very pleased about the award," says Christoph Steger, Chief Sales Officer at ENGEL, who accepted the Gold Pegasus. "This prize clearly belongs to our employees, whose daily great commitment and passion ensure that ENGEL is so successful worldwide." With production plants and branches on three continents, ENGEL is one of the world's leading manufacturers of injection moulding machines and automation solutions for plastics processing. All over the world, plastic products are being manufactured with machines and robots from the Austrian company, from toothbrushes, smartphone housings and automotive components to highly sensitive medical products. The mechanical engineering company has been on a continuous growth course for years.

Investment focus Upper Austria
ENGEL currently employs more than 6,600 people worldwide, more than half of which are based in Austria. To meet the growing demand for injection moulding machines, ENGEL hires additional employees and invests heavily in its locations. The family business is clearly committed to its roots. The largest construction projects are located in Austria. At the headquarters in Schwertberg, for example, a further production hall and a new customer technology centre are currently being built. ENGEL will invest a total of more than 375 million euros in its production facilities alone by 2020. Capacities will be increased and the machinery modernised.

"As a family business, it is particularly important to us that our employees feel at ease in the workplace. This includes a modern working environment, but above all achieving a work/life balance," explains Steger. "Together with our employees, we have implemented numerous measures in recent years that go far beyond the legal requirements." Thanks to crisis prevention, it is possible to build up a time buffer subsidised by the company which can be reduced in economically weak times. The childcare centre at the headquarters in Schwertberg was so well received that ENGEL, in cooperation with local institutions, now also supports its employees in childcare at the St. Valentin and Dietach locations.

An international outlook already during training
As a globally active company, ENGEL emphasises an international outlook already during its training. The apprentices soon work in international teams and the two best graduates of a year are allowed to spend three months in the production plant in Shanghai. In Austria alone, ENGEL trains around 200 young people in eight technical professions, and the company itself provides for the next generation of skilled workers beyond its national borders. In the plants in China, the Czech Republic and Germany, apprentices are trained according to the Austrian model of dual vocational training. The role model is the state-awarded training workshop at the headquarters, one of the most advanced in the country.

Pegasus honours Upper Austria's best companies
For the 25th time, OÖNachrichten and its partners have awarded the Pegasus. Ten companies were nominated in each of four categories - Future Hopes, Innovation Emperors, Success Stories and Lighthouses. These were evaluated by a jury consisting of representatives of Raiffeisenlandesbank, the Province of Upper Austria, KPMG, the Upper Austrian Chamber of Commerce and the Federation of Austrian Industry. ENGEL took first place in the lighthouses category. This category is awarded to companies that are successful in Europe and internationally and set an example for domestic companies.
(Engel Austria GmbH)

Newsgrafik #33881
 11.06.2018

Georg Steinbichler rewarded for services to plastics technology in Austria  (Company news)

Professor Georg Steinbichler, Senior Vice President of R&D Technologies at ENGEL AUSTRIA, has been awarded the gold badge of honour by the VÖK association of Austrian plastics processors. In conferring the award, the VÖK has acknowledged Steinbichler’s contribution to the development of plastics technology in Austria. The award was made at a celebratory presentation evening on the premises of the ÖGV Austrian Industry Association at Palais Eschenbach in Vienna.

Photo: Prizewinner Professor Georg Steinbichler (2nd left) with Senator Ernst Pöcksteiner, Chairman and Honorary President of the VÖK, VÖK President Dr. Michael Pöcksteiner and Professor Walter Friesenbichler, who presented the award (left to right).

“Georg Steinbichler is a globally recognised expert in injection moulding technology. His name has not only been associated with numerous technical and scientific innovations, he also set up the faculty of Polymer Engineering Technologies at Johannes Kepler University in Linz. Having dedicated his life’s work to injection moulding technology, he is a worthy winner of the VÖK gold badge of honour,” declared Professor Walter Friesenbichler in his laudation. Professor Friesenbichler, head of the chair of injection moulding of polymers at the University of Leoben, has worked with the prizewinner for more than 30 years.

After studying plastics engineering at Leoben, Georg Steinbichler embarked on his career in 1982 as an application engineer at injection moulding machine manufacturer ENGEL. He was soon given responsibility for process and technology development. In 2008, he completed his doctoral thesis on "Methods and processes for optimizing component development for Injection Molding” at Friedrich-Alexander Universität Erlangen-Nürnberg in Germany.

With the introduction of the polymer engineering technologies discipline at Johannes Kepler University in Linz in 2009, Steinbichler was appointed chairman of the Institute of Polymer Injection Moulding and Process Automation alongside his role at ENGEL. Since then, he has played a major role in expanding the range of university-level education for plastics engineers in Austria while strengthening university-based research in the field of plastics technology. The most recent milestone was the establishment of LIT Factory in Linz, a research factory for the production of thermoplastic lightweight composites and the digitalisation of plastics processing procedures.

Even before his appointment at the University of Linz, Georg Steinbichler was committed to education. He taught at the TGM in Vienna and lectured at technical academies in Esslingen/Stuttgart in Germany as well as Sarnen in Switzerland.

Since 1971, the VÖK has honoured personalities in the spheres of industry, business, science and public life who have made outstanding contributions to the development of plastics technology in Austria. Irene and Georg Schwarz and Dr. Peter Neumann of ENGEL also received the VÖK gold badge of honour prior to Professor Georg Steinbichler.
(Engel Austria GmbH)

Newsgrafik #33856
 25.05.2018

ENGEL at Plast 2018 with two elastomer exhibits  (Company news)

At the Plast 2018 and the integrated Rubber Show from May 29 to June 1 in Milan, Italy, the injection moulding machine manufacturer ENGEL presents its high degree of system solution competency for the elastomer industry. For the single component processing of rubber, thermoplastic elastomers, liquid or solid silicones, as well as for multi-component injection moulding in connection with thermoplastic materials, from a single source ENGEL offers fully automated and integrated system solutions for the economical production of premium elastomer products.

Image: Thanks to its barrier-free clamping unit, the tie-bar-less ENGEL victory injection moulding machine for multi-component processes using LSR represents a huge efficiency potential.

Fully automated and rework-free processing is a prerequisite for the economical production of high-tech elastomer products. With two applications, one at its own trade fair booth in Hall 24 and another with partner company Mesgo in Rubber Hall 11, in Milan ENGEL shows the wide range of use of its injection moulding machines and system solutions for elastomer applications in the automotive, teletronics, technical moulding and medical industries. This clarifies how the perfect interplay between injection moulding machine, automation and periphery makes it possible to fully utilise efficiency and quality potentials.

Tie-bar-less for high-precision multi-component processes with LSR
In many applications, the integrated injection moulding process is a prerequisite to bonding thermoplastics and silicone in stable layers. One example of this are coupling cushions made of PBT and LSR, which serve as windshield fasteners for rain sensors. At the ENGEL trade fair stand and using the ENGEL combimelt process, these demanding dual-component parts will be produced on a tie-bar-less victory 200H/200L/160 combi injection moulding machine with an integrated ENGEL viper 40 linear robot. The 4+4 cavity mould for the parallel processing of PBT and LSR is by Rico (Thalheim, Austria). The all-electric LSR dosing system is a new development by Dopag (Cham, Switzerland), and the LSR for this application is a product of Wacker in Burghausen, Germany.

Manufacturing two-component parts optimally leverages the efficiency potential of the tie-bar-less ENGEL victory machine. The tie-bar-less technology allows for the mounting of large, complex multi-component moulds on comparatively small machines. Automation is a second efficiency factor. The ENGEL linear robot can reach the cavities directly from the side and operate safely without having to circumvent any protruding edges. Thirdly, the extremely high process consistency constructively ensured by the tie-bar-less clamping unit factors significantly into the high degree of overall efficiency. The patented force divider enables the moving mould mounting platen to follow the mould exactly while clamping force is building up and ensures that the clamping force is evenly distributed across the platen face. Both the outer and inner cavities are therefore kept closed with exactly the same force, reducing mould wear and raising product quality.

iQ weight control is used to ensure a consistent process and consistently high parts quality in spite of fluctuations in the environmental conditions and the raw material batch. The intelligent assistance system from ENGEL's inject 4.0 programme adjusts the injection profile as well as the switchover point and the holding pressure profile for each individual shot to the respective conditions, thus compensating for external influences before a reject is produced.

ENGEL flexseal for maximum efficiency and precision
During the four days of the fair, Hall 11 is where the elastomer processors will meet. At Booth C61/D62, Mesgo (Gorlago, Italy) is presenting the fully automated production of membrane seals on an ENGEL flexseal 500/300. The especially compact and energy efficient flexseal injection moulding machine was specifically adapted to the requirements of O-ring and flat seal manufacturers. In the production of very large volumes, the servo-hydraulic machine guarantees the highest efficiency and highest precision. Mesgo will present an especially demanding application. Thermoplastic PBT inserts will be overmoulded with solid silicone and the components will be inspected by camera inline immediately following production. ENGEL is providing the completely integrated system solution for this. The parts will be handled by an ENGEL easix articulated robot, which, in this application, is being combined with an Anyfeeder for the first time. The ENGEL roto feeder will be used for the material feed. The rotating funnel with a counter-directional screw continuously transports the solid silicone, free of bubbles and at consistent pressure, thus ensuring a very high degree of process security. System partners for this application are the tool manufacturers ORP Stampi (Viadanica, Italy) and Giasini (Grassobio, Italy), as well as Proplast Plastic Innovation Pole (Rivalta Scrivia, Italy), who provided the CAD-Design.

ENGEL at Plast 2018 in Milan: Hall 24, Booth B81/C82 and at Mesgo, Hall 11, Booth C61/D62
(Engel Austria GmbH)

Newsgrafik #33751
 18.05.2018

ENGEL at PLASTPOL 2018  (Company news)

With two challenging applications on a servo-hydraulic and an all-electric injection moulding machine, ENGEL will clearly demonstrate how process consistency and quality can be combined with efficiency and economy at PLASTPOL 2018 from May 22nd to 25th in Kielce, Poland. The focus is on high-performance machines and automation as well as intelligent control technology that opens up additional optimisation potential for processors.

Photo: Thanks to its closed system for toggle levers and spindles, the all-electric e-motion injection moulding machines comply with the strict requirements of the food industry.

Power package on a small footprint
Maximum force on a comparatively small footprint – this is what ENGEL duo dual-platen injection moulding machines stand for. In terms of footprint, the ENGEL duo 500 is one of the smallest machines in this series and, with a dry cycle time of 2.6 seconds and an opening stroke of 600 mm, the fastest dual-platen machine on the market. At PLASTPOL, an ENGEL duo 3550/500 will be manufacturing engine covers from glass-fibre and mineral-fibre reinforced polypropylene in combination with an ENGEL viper 20 linear robot.

Equipped with a new-generation injection unit, the servo-hydraulic duo 500 achieves particularly high precision. Intelligent assistance systems from ENGEL’s inject 4.0 range are deployed to compensate for additional fluctuations in environmental conditions and the raw material. iQ weight control analyses the pressure profile during the injection process and compares the measured values with a reference cycle in order to adapt the injection profile, the switching point and the holding pressure profile to the current conditions for each shot. "This means that we can keep the injected melt volume constant over the entire production period and reliably prevent rejects," says Piotr Nachilo, Managing Director of ENGEL Polska based in Warsaw. "iQ weight control is already widely used by our customers and has proven itself in a wide variety of applications."

iQ for consistent processes and more efficiency
While iQ clamp control was initially only available for injection moulding machines with electrical clamping units, ENGEL is presenting the new release for use in hydraulic machines of the duo series at PLASTPOL. The software calculates mould breathing in order to determine the ideal clamping force and adapt it automatically. In the production of large-area injection moulded parts, such as engine covers, iQ clamp control opens up a great deal of potential for higher production quality. If the clamping force is too low or too high, this can lead to burn marks or flashes.

Last but not least, the third assistance system is iQ flow control. The software networks the temperature control units and the injection moulding machine and controls the rotation speed of the pumps in the temperature control units on demand. The result is significantly reduced energy consumption and the stability of the temperature control process is also enhanced. e-flomo is capable of actively controlling the temperature difference in all individual circuits and automatically setting the required flow rate for each temperature control circuit.

Together with its partner HB-Therm (St. Gallen, Switzerland), ENGEL has developed a series of particularly compact temperature control units for this new integrated temperature control solution. By linking the e-temp control units to the injection moulding machine via OPC UA, the development partners have established a milestone along the road to the smart factory. The OPC UA protocol facilitates powerful, platform-independent and above all secure communication, both at shop floor level and with superordinate control systems. For this reason, it is increasingly becoming the standard for the plastics industry.

IML integration from a single source
With a second application at PLASTPOL, ENGEL is demonstrating the great efficiency potential of integrated processes. Thanks to in-mould labelling (IML), an all-electric ENGEL e motion 440/160 injection moulding machine with integrated viper 12 linear robot, and IML automation from TMA AUTOMATION (Gdynia, Poland), produces ready-for-market decorated covers for food packaging in a single operation.

TMA AUTOMATION is a new ENGEL partner specialising in the automation of IML and downstream processes, such as assembly, quality assurance and palletising, in the general purpose segment in a wide range of industries. Based on a standardised system concept, TMA AUTOMATION implements highly compact and at the same time very flexible solutions. The Polish company has many excellent references, particularly in Eastern Europe. "In many projects, cooperation with local partner companies helps to improve cost efficiency and reduce the lead time for the entire plant," says Walter Aumayr, Head of Automation and Peripherals at the ENGEL headquarters in Austria. As the general contractor, ENGEL handles coordination with the automation partner for its customers and supplies the complete production cell from a single source. This also increases efficiency, as fewer interfaces often mean faster project planning.

ENGEL at Plastpol 2018: hall F, stand F4
(Engel Austria GmbH)

Newsgrafik #33790
 15.05.2018

ENGEL is growing  (Company news)

ENGEL is continuing to grow. For the fourth time in sequence, the injection moulding machine builder and system solution provider based in Schwertberg, Austria, was able to increase its annual revenue. At the end of March, the group of companies concluded the financial year of 2017/18 with revenues of 1.51 billion euro, an increase of 11 percent versus the previous year.

Photo: At ENGEL's company headquarters in Schwertberg, Austria, construction will continue until this autumn. The new construction will expand the northern production hall built in 2013. The new customer technology centre will be located above the assembly area.

"The production plant in Shanghai alone sold around 20 percent more machines in the 2017/18 financial year", reports Dr. Christoph Steger, CSO of the ENGEL Group, at the beginning of the Chinaplas plastics trade fair, end of April 2018 in Shanghai, where ENGEL informed the international trade press about the 17/18 financial year. Asian markets continue to have a large share in the success of the ENGEL Group, with demand especially increasing in China. "The investment climate in China is at a new high", says Steger.

In the Shanghai plant, ENGEL is building large-scale machines of the dual platen series duo, which are used in the automotive industry, among others. "The automotive industry in China continues to be the most important driver of growth and innovation", says Gero Willmeroth, President Sales and Service at ENGEL Machinery Shanghai. ENGEL in particular has grown disproportionately in the automotive lighting area. "Our customers are increasing their investment into innovative process technologies that allow them to achieve higher efficiency, productivity and quality." One example of this is the optimelt technology, which ENGEL is presenting at its trade fair booth. In the manufacturing of thick-walled LED lenses, the patented multi-layer process with external cooling significantly reduces the cycle time, at the same time ensuring a high degree of optical quality.

Whether lenses made of PMMA or polycarbonate glazing components, the substitution of materials in vehicle manufacturing aims primarily to reduce weight. Electric vehicles in China are on the rise and accompanied by innovative lightweight technologies. Until now, the focus of processors in China has been on substituting glass on the one hand and foam injection moulding on the other; composite technologies are still in the early stages. "Our customers use trade fairs such as the Chinaplas to learn about the possibilities of the wide-scale use of composite materials in automotive manufacturing, and to gauge the feasibility of new composite processes for the automotive large-scale series," states Willmeroth. "China is setting the direction and ENGEL is at the forefront here. Internationally, ENGEL is already one of the preferred partners of the automotive industry." In 2012, ENGEL established its own technology centre for lightweight composite technologies and since then has been able to achieve several significant milestones in cooperation with its development partners. At the Chinaplas 2018, ENGEL is introducing series-ready technologies for the economical production of composite components and, in addition, is providing insights into ongoing research projects.

Market position in industries further expanded
From a single source, ENGEL delivers individual injection moulding machines as well as integrated and automated system solutions, the share of which in worldwide orders continues to increase. Developing made-to-measure injection moulding solutions requires a deep understanding of both the technology and the industries, which ENGEL ensures through its Business Unit structure. ENGEL employs dedicated teams for the automotive, technical moulding, teletronics, packaging and medical industries, respectively – and this not only at the company headquarters in Austria. Last year, ENGEL also established a Business Unit structure with dedicated Business Unit managers in Asia, and has since then been continuously increasing its industry know-how locally. "With this new structure, we are continuing to expand our market position in all five business areas", reports Steger. "The feedback from our customers is very good. In many cases, we can respond even faster to requirements and requests, and support our customers in solving their very individual challenges in an even more targeted fashion."

In addition to automotive, in Asia ENGEL has increased its sales in the medical area, with health care and diagnostics being the main growth drivers, For these applications, ENGEL delivers all-electric e-motion injection moulding machines as well as hybrid machines of the e-victory series, which are produced for the Asian markets at the ENGEL plant in Korea. "In the medical area, we are seeing a trend to multi-cavity moulds, which require larger injection moulding machines to increase throughput", reports Willmeroth.

New training centre in Shanghai
ENGEL is also increasing its personnel in Asia. The ENGEL Group is currently employing a total of 950 people in its Asian production plants and subsidiaries, which is more than 20 percent more than last year. ENGEL Machinery Shanghai currently has a headcount of 490 employees. In the previous financial year, new employees were added primarily in the Business Units, service and training. For the 18/19 financial year, ENGEL has posted additional vacancies in Shanghai as well as all of Asia.

In the context of the plant expansion that was completed in September 2017, ENGEL constructed a new, larger training centre and hired a dedicated training manager. Together with his team of experienced trainers, Boris Wen is continuing to expand the seminar and workshop offering for customers in China.

6,600 employees worldwide
At the beginning of the new financial year 2018/19, the ENGEL Group is employing 6,600 people worldwide – more than ever before. More than half of these (3,700) are working in the three Austrian plants.

As compared to the previous year, there has been a slight shift in the distribution of the 1.51 billion euro in worldwide revenue. America has increased by 2 percent, to 26 percent. With currently 53 percent, Europe still represents the lion's share. Asia is at 20 percent.

From the worldwide perspective, North America – USA, Canada and Mexico – and Asia are the primary growth drivers for ENGEL, with South America also picking up speed. In Europe, Germany remains the strongest sales market and also the most important driver of innovation.

From the perspective of the industries, the strongest growth worldwide is in the packaging area, followed by technical moulding.

More capacity in the machine plants
With the largest investment programme in the company's history, ENGEL is ensuring that the growth of the company extends into all regions of the world. For a total of more than 375 million euro, by 2020 production plants worldwide will be modernised and their capacities expanded.

The expansion of ENGEL Machinery Shanghai was completed in time for the ten-year anniversary of the plant in September 2017. First of all, the existing office building was lengthened to add another 1,000 square metres of usable space. In addition, a new production hall was constructed, complementing large machine production by 1,600 square metres. The training workshop is also being newly constructed. For the apprentice workshop alone, ENGEL invested just under 1 million euro. It is equipped with state-of-the-art machines to optimally prepare the apprentices for their future profession, and it is also significantly larger than the previous one because since the beginning of ENGEL's apprenticeship programme in China, the number of apprentices has increased considerably. Currently in Shanghai, 51 young people are being trained as mechatronics engineers, CNC technicians and plastics technicians. In the summer of last year, the first apprentices of ENGEL Machinery Shanghai completed their final examinations with good results across the board and were hired as permanent employees.

The largest construction projects are taking place in Austria. At company headquarters in Schwertberg, by the autumn of this year the northern production hall there, which was constructed in 2013, will be expanded by 11,500 square metres. In addition, a new, significantly larger customer technology centre is being built.

With an investment volume of 160 million euro, the expansion of the large machine plant in St. Valentin, Austria, is by far the largest construction project. In the first stage, last year an additional hall bay was constructed that contains several offices and is otherwise dedicated to machine assembly. A few weeks ago, construction began on the new administration building and the additional expansion of the assembly area, including the tecnology centre. In the course of this work, more space will also be created for the Center for Lightweight Composite Technologies.
(Engel Austria GmbH)

Newsgrafik #33773
 04.05.2018

A self-optimising production process  (Company news)

ENGEL is set to welcome visitors to the smart factory at Elmia Polymer 2018, Scandinavia’s biggest trade fair for plastics and rubber processing, which takes place from May 15th to 18th in Jönköping, Sweden. The injection moulding machine manufacturer and system solutions provider will present both new and firmly established products from its inject 4.0 range. Innovative process technologies for greater efficiency and quality and the new hydraulic injection units that ENGEL will be bringing to a Scandinavian trade show for the first time will also be featured over the four days of the event.

Image: iQ weight control compensates for process fluctuations before rejects are produced. The intelligent assistance system is available for electric and hydraulic injection moulding machines.

The ENGEL stand will revolve around the self-optimising injection moulding machine. The production of inject 4.0 logos will clearly demonstrate how the potential for efficiency and quality that Industry 4.0 offers can be maximised with minimal effort. For this purpose, the e-motion 80 TL machine is equipped and networked with intelligent assistance systems. The networking of production systems, the systematic use of machine, process and production data and the deployment of intelligent assistance systems is enhancing the productivity, efficiency, and quality of production operations. At the same time, processors can respond to requirements – which are changing ever more quickly – with maximum flexibility.

At the trade fair, the injection moulding machine’s CC300 control unit will simulate fluctuations in the raw material and ambient conditions. Visitors to the event will be able to watch live as the machine identifies deviations and automatically readjusts the parameters before even a single reject moulding is produced.

Compensating for fluctuations before rejects are produced
Three assistance systems from ENGEL’s iQ product range will be on show at the trade event. iQ weight control analyses the pressure profile during the injection process and compares measured values by means of a reference cycle. The injection profile, switchover point and the holding pressure profile are adjusted to the current conditions for every shot, which keeps the injected volume constant during the entire production run. At the same time, iQ clamp control calculates mould breathing in order to determine the ideal clamping force and adapt it automatically.

iQ flow control is the latest iQ assistance system that ENGEL will be unveiling to a Scandinavian audience at Elmia Polymer. By connecting the temperature control units to the injection moulding machine, the software can regulate the rotational speed of the pumps in the temperature control units on demand. The result is much lower energy consumption and the stability of the temperature control process is also enhanced. e flomo is capable of actively controlling the temperature difference in all individual circuits and automatically setting the required flow rate for each temperature control circuit.

Together with its partner HB-Therm (St. Gallen, Switzerland), ENGEL has developed a series of particularly compact temperature control units for the new integrated temperature control solution. By linking the e-temp control units to the injection moulding machine via OPC UA, the development partners have established a milestone along the road to the smart factory. The OPC UA protocol facilitates powerful, platform-independent and above all secure communication, both at shop floor level and with superordinate control systems. For this reason, it is increasingly becoming the standard for the plastics industry.

Scandinavian launch for new e-connect customer portal
The modularity of the inject 4.0 concept makes it easy for plastics processing firms to harness the opportunities presented by Industry 4.0. Even individual stand-alone solutions such as iQ assistance systems offer considerable benefits. In Jönköping, ENGEL will also present easy-to-implement solutions for networking machine parks and entire production sites as well as online support, remote maintenance and predictive maintenance products.

There will be a Scandinavian launch for ENGEL’s e-connect customer platform at Elmia Polymer. Now comprehensively revised, the portal is ideally equipped to handle all current and future requirements of the smart factory. At any time and anywhere, it provides an overview of the machine status, the processing status of service and support orders and the prices and availability of spare parts. In this way, the portal simplifies and accelerates communications between processors and ENGEL as the supplier.

All service products in the inject 4.0 range have been integrated with e-connect, including the new e-connect.monitor for predictive maintenance. For the first time, e-connect.monitor makes it possible to monitor the condition of critical components in injection moulding machines during current operations, and calculate their residual life. The aim is to prevent unplanned system shutdowns and minimise downtimes in the case of planned work such as the installation of spare parts. Two modules of this solution have already been introduced to the market: one for plasticising screws and the other for spindles in electrical high-performance applications.

Very deep vertical data integration
At the Expert Corner for smart production on the ENGEL stand, the focus will be on the authentig MES from the ENGEL subsidiary T.I.G. Tailored to the specific requirements of the injection moulding industry, the manufacturing execution system offers particularly deep vertical data integration to the level of individual cavities. The software ensures transparency in order to, for example, utilise the total available capacity of a machine park or correlate productivity indicators and economic objectives. Thanks to its modular structure, authentig can be adapted to the precise individual needs of processors; as it is not dependent on a specific interface, injection moulding machines of different brands can be incorporated.

New injection units for even greater efficiency, precision and performance
The new injection units will enable the ENGEL victory and ENGEL duo injection moulding machines to achieve even more impressive performance, precision and efficiency. At Elmia Polymer, ENGEL will be presenting its new generation of hydraulic injection units at a Scandinavian trade fair for the first time.

Based on its many years of experience in the different fields of use of its injection moulding machines, ENGEL has restructured the sizes of the units and optimised their performance data, such as injection pressure, injection speed and plasticising capacity, for current and future requirements. This makes it possible to address the specific needs of users even more exactly in the machine design. All in all, the new units enable more precise injection and higher process stability. Control of temperature and pressure in the barrel contribute to this in equal measure. Temperature control of the feed throat was one focus of development work. The temperature control range was enlarged to safely rule out clumping in the feed zone and absorption of moisture across a wider range of materials. The new concept minimises energy losses both during heating and cooling of the feed through. The main contributor to better controllability of the pressures is the revised piston design.

Furthermore, the long established ENGEL ecodrive servohydraulic has now become a standard feature of the victory and duo machines.

Producing high-quality surfaces with efficiency
Visitors will also be attracted to the stand by a large video wall on which ENGEL will present new developments in the area of process technologies. One focus will be on technologies capable of producing high-quality surfaces with great efficiency. The clearmelt process, for example, uses in-mould coating to produce ready-to-install trim components with very high-quality yet robust surfaces in a single work step. Polyurethane is used for surface finishing since it allows for fast changes between different colours.

The integrated and fully automated DecoJect process, which combines in-mould graining and injection moulding, also cuts down on work steps. Since colour, structure and haptics are achieved through the foil, DecoJect represents an extremely cost effective way to visually enhance injection moulded parts and harmonise surfaces in vehicle interiors – even in the case of small batch sizes.

The application examples on show will clearly demonstrate how innovative process technologies and integrated system solutions can meet even the most stringent quality demands while keeping unit costs competitive.

ENGEL at Elmia Polymer 2018: Hall C, stand 4:20
(Engel Austria GmbH)

Newsgrafik #33725
 13.04.2018

Frank Schuster is the new Vice President of Packaging at ENGEL  (Company news)

As of April 1, 2018, Frank Schuster (Bild) has taken over as the Vice President of the Business Unit Packaging at the injection moulding machine manufacturer and system solution provider ENGEL, headquartered in Schwertberg, Austria. He succeeds Michael Feltes, who is transitioning to China within the group of companies.

Frank Schuster has been with ENGEL for two years and, as the Sales Manager of Packaging, has made significant contributions during this time to the very successful development of the division and the continued strengthening of the ENGEL brand in the worldwide packaging industry. Prior to his time with ENGEL, Schuster was already active in leading sales positions in the field of plastic machinery manufacturing with a focus on packaging. We are happy to be able to fill this position with a very experienced packaging expert, and in-house, more¬over", says Dr. Christoph Steger, CSO of the ENGEL Group. "This ensures our customers of a high level of continuity."

Michael Feltes, the previous Vice President of the Business Unit Packaging, is transitioning within the ENGEL Group of companies, becoming President Sales & Service for the WINTEC subsidiary in Changzhou, China.
(Engel Austria GmbH)

Newsgrafik #33641
 03.04.2018

ENGEL automation on show at Chinaplas 2018  (Company news)

At Chinaplas 2018, which takes place in Shanghai from April 24th to 27th, ENGEL will showcase its expertise in automation at a special Expert Corner. On show will be the compact e-pic B and e-pic Z robots – integrated, with expanded software functions –, the new viper 20 speed for high-speed applications and the new 10-inch hand-held unit, which will be making its first appearance in front of an Asian audience.

Photo: 30 percent faster than the conventional viper: the new viper 20 speed offers removal times of well under 1 second.

For many years, robots have been relied on in China to provide process stability, fast cycles and high efficiency. From standardised robot cells to customised, integrated system solutions, ENGEL meets the specific automation needs of injection moulding businesses to the letter. It achieves this through a comprehensive portfolio of robots, high levels of special automation expertise and local expertise. At its large-scale machine manufacturing plant in Shanghai, ENGEL runs an automation centre for clients in China.

“On many projects, success depends on short distances, which means fast project planning and commissioning,” says Gero Willmeroth, Sales and Service President at ENGEL Machinery Shanghai. “That’s why we have invested so heavily in local expertise over the past few years. Now we are ideally placed to handle the increasingly complex demands of our customers. Feedback from the market has been excellent. We have been able to strengthen the trust that our customers have in us.”

At Chinaplas, ENGEL’s entire automation team in Asia will be on hand to speak to customers. They will use four technically sophisticated applications to demonstrate live the full spectrum of ENGEL’s automation experience. ENGEL will also present all new robot-related developments in a special Expert Corner.

Integrated e-pic robots
Small e-pic robots, the latest products in ENGEL’s automation range, are offered in two versions: as linear pick-and-place robots (e-pic Z) and servo sprue pickers (e-pic B). The main feature of the e-pic series is the robots’ lightweight swivel arm in place of a conventional x-axis. This new kind of kinematic system – a USP of ENGEL – significantly increases dynamism and energy efficiency while facilitating a highly space-saving installation on the injection moulding machine. The swivel arm requires less space than a linear axis when moving towards both the injection and clamping sides.

In a new development, ENGEL will be equipping its e-pic robots with efficiency control. This further improves energy efficiency as the robots adapt the speed of their movements to the cycle of the injection moulding process with the aid of software. Efficiency control has been an established feature of viper linear robots for years.

At Chinaplas, ENGEL will present the integrated version of its e-pic robots, clearly illustrating how efficiency potential can be maximised by combining injection moulding machines and robots. Within the integrated solutions, the CC300 control unit for ENGEL injection moulding machines becomes the main operating panel for the whole manufacturing cell; this means uniform parts data and alarm management as well as a unified look and feel. Consistent operating logic significantly simplifies activation and programming as well as control of robots and the manufacturing cell as a whole. Of course, robots can be connected subsequently to injection moulding machines by means of a EUROMAP 67 interface, regardless of machine brand.

viper 20: now even faster
There will also be an Asian premiere for viper linear robots at Chinaplas. The new viper 20 speed offers removal times of well under 1 second. The enhanced servo-electric drive technology and the reduced weight of the robot’s axes are responsible for the step up in performance. Developed for applications with total cycle times of around 4 seconds, the viper 20 speed is mainly used in the medical and packaging sectors, areas in which top-entry robots tend to offer very high flexibility.

The viper 20 speed will demonstrate its impressive performance by handling cups at the trade fair. It will work in tandem with an ENGEL easix articulated robot that will take the cups from a moving conveyor belt and stack them in a magazine. In this application both robots – the viper linear and the easix articulated robot – are integrated into a CC300 control unit. It makes no difference whether the CC300 is controlling linear or rotary axes. The additional movement instructions for the multi-axis robot integrate seamlessly with the graphical interface, which simplifies operation significantly. To allow for simple and fast parameterisation despite the complexity of the overall system, the control unit provides different user levels, from a simple view to a fully object-oriented visualisation of the sequence.

10” for easier operation
Another highlight of ENGEL’s Expert Corner on automation will be the new C10 10-inch hand-held unit for robots in the ENGEL series; this will replace the 7-inch units in the C70 series over the course of the year. Visitors to Chinaplas will gain a foretaste of the easier operation of the new hand-held unit, which provides a clearer overview.

ENGEL at Chinaplas 2018: Hall 5.1, stand E71
(Engel Austria GmbH)

Newsgrafik #33596
 09.03.2018

Customer portal e-connect goes live in North America  (Company news)

ENGEL's new e-connect customer portal will be launched in North America in time for NPE2018: e-connect will simplify and speed up communication between processors and ENGEL while providing an overview of the machinery, the processing status of service and support orders and the price and availability of spare parts – any time, anywhere. From May 7 through 11, 2018, the Austria-based injection molding machine manufacturer and system solution provider will be demonstrating at its trade show booth W3303 in Orlando, Florida, how the new version of the customer portal is also ideally suited to meet the requirements of Industry 4.0.

Photo: Fastest link to the world of ENGEL: the new version of the e-connect customer portal is even clearer.

e-connect facilitates entry into the world of ENGEL and opens up new opportunities for injection molders to produce even more efficiently. “With the new software, we can now provide customers with more specific information at any time and independently of their location, establish contact with them even faster, and provide the best possible support to meet the challenges of Industry 4.0,” as Wolfgang Degwerth, Vice President Sales and Service at ENGEL Machinery Inc. in York, Pennsylvania, explains. "From now on, e-connect will be an important hub in the cooperation with our customers."

From the first order, all machines and system solutions supplied by ENGEL are stored in the system, with the current status also shown. For the best possible overview, users can reproduce the structure of their individual machinery in the system and even assign production lines to different halls or departments online.

No time to waste in support and service cases
Making support and service enquiries online is not only convenient for users, but also speeds up order processing significantly. As soon as a customer makes a request, it is automatically forwarded to the service team so that they can start looking at it immediately. Since customers and service technicians use the same data, they have the same knowledge base at all times. In many cases, the system history this contains makes it easier to find a solution. This is also why each new service call is fully documented in e-connect. The portal makes all details relating to the service call transparent for the user, and store the service report. With sites on three continents, ENGEL ensures qualified service technicians from its internal workforce are available around the clock.

In particular, e-connect facilitates the procurement of spare parts. As price and availability are stored on the system, the customer can directly request and download a quotation from the platform. Customers can also track the spare part online up to its arrival at their plant.

Condition-based, predictive maintenance included
e-connect supports all service products in ENGEL's inject 4.0 program. In addition to online support and remote maintenance, this includes e-connect.monitor for predictive, condition-based maintenance. The aim is to utilize the full lifespan of machine components while avoiding unscheduled system downtimes. To ensure this, sensors monitor the condition of components and residual life is calculated on the basis of mathematical models. While the condition of plasticising screws is determined in the course of regular servicing, spindles are subject to automatic online monitoring; in both cases, the results of the evaluation are stored in e-connect; they can be called up and processed by the customer at any time.

ENGEL will also be integrating future service products for the smart factory into its customer portal. “We have structured the platform so that we can quickly implement further demands of advancing digitalization,” says Wolfgang Degwerth.

More clarity, simpler navigation
In addition to new functions, e-connect now offers greater clarity and transparency and even simpler navigation. The platform provides users with a constant wealth of information, from product descriptions and event news to latest reports from the world of ENGEL and the details of contact persons. A calendar contains the dates of trade fairs and booked seminars, while ENGEL’s e-learning platform is just one click away via e-connect.

ENGEL at NPE2018: West Hall, Booth W3303
(Engel Austria GmbH)

Newsgrafik #33570
 01.03.2018

Fewer rejects and greater energy efficiency  (Company news)

At the launch in North America, ENGEL will be demonstrating iQ flow control live at NPE2018, from May 7th to 11th in Orlando, Florida. The integrated temperature-control solution improves the stability of injection molding processes, reduces rejects and boosts energy efficiency.

Photo: Thanks to the e-temp temperature control units, ENGEL has become a system solutions provider in the field of temperature control of injection molding processes.

"Most rejects in injection molding are the result of temperature control errors," says Joachim Kragl, Director of Advanced Molding Systems and Processing at ENGEL Machinery Inc. in York, Pennsylvania. "This explains why the processors' focus is increasingly shifting to mold temperature control." With flomo, ENGEL laid the groundwork for more transparency and consistency in the temperature control process as one of the pioneers in this field back at K 2010. ENGEL flomo, an electronic temperature control water manifold system, replaces the maintenance-intensive cooling water distributors and even the basic version can individually monitor and document all cooling and temperature control circuits. The next generation e-flomo is further able to actively control either the flow rates or the temperature difference (ΔT) in all individual circuits. The advantage of ΔT control is the automatic setting of the individually required flow rate for each temperature control circuit.

On-demand pump control
iQ flow control sees ENGEL taking the next step. The software networks the temperature control units and the injection molding machine to create a single unit and, based on the measured values determined by e-flomo, controls the pump speed in the temperature control units on demand. While e-flomo increases the process stability which consequently reduces the risk of rejects, automatic speed adjustment ensures that temperature control requires substantially less energy.

Since the pump operates on-demand rather than at maximum output all the time, stress on moving parts is reduced and temperature control units have a longer service life, which makes it possible to extend the maintenance cycles. This allows for further substantial savings. In conventional operations, regular maintenance of the temperature control units, including the downtime associated with it, is a major cost factor.

As an integrated solution, the entire temperature control process can be set up, monitored and centrally logged at the CC300 machine control display while the ideal operating point for the particular temperature control unit is determined and set automatically. This allows injection molding shops to fully leverage their injection molding machines' potential without the system operators needing special training.

Self-optimizing machine
To integrate the temperature control units with the CC300 control unit on the injection molding machine, ENGEL collaborated with temperature control unit manufacturer HB-Therm (St. Gallen, Switzerland), to develop the temperature control unit series known as e-temp. The extremely compact devices are networked with the injection molding machine via OPC UA (Open Platform Communication Unified Architecture). With its service-oriented, platform-independent and freely scalable structure, this communications model offers great flexibility. A high degree of data security is guaranteed by the technical safety features that are an integral part of the architecture.

OPC UA is becoming increasingly popular in the plastics industry for networking injection molding machines, peripherals, sensors and applications and is an important component of the inject 4.0 platform by ENGEL. Thanks to inject 4.0, ENGEL is helping clients pave the way to the smart factory, with continuously self-optimizing production processes. Self-regulating systems such as iQ flow control play a key role in creatring smart machines.

ENGEL at NPE2018: Hall West, Stand W3303
(Engel Austria GmbH)

Newsgrafik #33552
 16.02.2018

ENGEL to present innovative process technologies at Chinaplas 2018  (Company news)

“Innovation is key to the future” – this is the motto of Chinaplas 2018 from 24 to 27 April in Shanghai. At its booth, ENGEL will be presenting many exciting applications and technology solutions to demonstrate how innovative injection moulding technologies can help build competitive advantage and secure future viability. When it comes to challenging plastic products, the injection moulding machine producer and systems solution provider based in Austria is among the preferred suppliers of the plastics processors in Asia.

Photo: Thanks to its free accessible clamping unit, the tie-bar-less e-victory injection moulding machine unlocks major potential for high-efficiency LSR processing.

Chinaplas 2018 is all about growth. “The investment climate in China is on a new high,” reports Gero Willmeroth, President Sales and Service of ENGEL Machinery Shanghai, in the run-up to Asia’s most important plastics trade show. “Chinaplas will give a further boost to this trend.” Growing competition among the local producers of plastic components is another factor contributing to this positive development. Investment is being made in modernising machinery and new technologies that help to raise production efficiency and product quality.

Economical injection moulding of thick-walled lenses
The exhibition space dedicated to Automotive at the ENGEL booth reflects the trend towards the use of innovative process technologies. This is the first time that ENGEL is presenting a complex multi-component process with interlinked injection moulding machines at Chinaplas. Two duo injection moulding machines will produce LED lenses made of PMMA with a thickness of 22 mm for vehicle headlamps.

Plastic is increasingly being used to produce high-quality optical components. The polymer materials are lighter than glass and offer product designers more freedom. The challenge, however, is to combine high optical quality with highly efficient production. The optimelt multilayer technology developed and patented by ENGEL with external cooling meets precisely that challenge.

Initially, a preform is produced and further layers of the same material added to it in subsequent stages. Overmoulding compensates for any sink marks in the surface of the previous layer and achieves high optical quality. Optical tests have shown that the boundary between the layers has no influence on the performance and function of the lighting optics.

Because the cooling time in injection moulding increases with the square of the wall thickness, the multilayer technology significantly improves efficiency especially in the production of thick-walled components. Several thin layers cool in total faster than one thick layer. If, in addition, the base body of the lens is removed from the mould to cool, the cycle time is shortened further. Cooling in the air takes longer than in the mould, but it does not affect the cycle time.

During Chinaplas, the lens base bodies will be produced on a duo 1060/400 injection moulding machine in a 4-cavity mould. An easix articulated robot is integrated in the production cell and removes the four parts and passes them to an external cooling station. From there the robot takes four already sufficiently cooled preforms at a time and transfers them to the 4+4-cavity mould of the duo 600H/600H/500 combi multi-component machine with rotary table. There, two more PMMA layers are applied successively before easix removes the finished lenses. The cycle time is significantly lower than 3 minutes, although the preforms take around 30 minutes to cool. The cooling time can be controlled via the number of cooling positions in the external cooling station.

The combination of a standard injection moulding machine and a two-component machine is synonymous with very high production flexibility. Both machines can also be utilised independently of the other with different moulds.

ENGEL is presenting the exhibit jointly with system partners including Skymould (Ningbo/China), HRSflow (San Polo di Piave/Italy), Innolite (Aachen/Germany), Opsira (Weingarten, Germany) and Gimatic (Shanghai, China). In order to integrate other peripheral units and moulds alongside its own robots and process technologies, ENGEL has established a worldwide network of system partners. “We have very strong partners locally in China who, like us, are very familiar with the demands of local processors and translate them into optimal solutions,” explains Willmeroth. “By working with local suppliers, we can also guarantee high cost efficiency for challenging applications and keep the delivery time short for the complete plant.”

Innovative lightweight concepts from a single source
Material substitution to reduce component weight is an important trend in the automotive industry, also in China, where electric vehicles are very much on the increase. There are four main areas the processors in Asia are looking at here: LED lenses made of PMMA, glazing systems made of polycarbonate, foam injection moulding, and composite technologies.

ENGEL is dedicating an Expert Corner of its booth to composite technologies. At its Center for Lightweight Composite Technologies in Austria, the machine manufacturer works with partner companies and universities to develop especially economical processes that will help composite technologies become established in automotive series production faster. From HP-RTM and SMC, through processing of thermoplastic semi-finished products such as organic sheets and tapes, to reactive thermoplastic technologies such as in-situ polymerisation (T-RTM), ENGEL’s developers are exploring all the current cutting-edge technologies and have already achieved several internationally significant milestones. A central success factor in that process has been ENGEL’s expertise in automation and systems solutions. At the same time, ENGEL also offers in its v-duo a machine series that is specifically developed for the demands of the composites industry.

Processing liquid silicone rubber, no reworking required
Electric mobility relies not only on new processing technologies but also new design solutions. For example, electric vehicles require a greater variety of grommets to lead wires safely from the engine compartment into the vehicle interior than those with a combustion engine. During Chinaplas, ENGEL is producing wire grommets made of liquid silicone rubber (LSR) for individual wires with a corresponding fine structure. A tie-bar-less e-victory 50/80 injection moulding machine with electric injection unit is used to process the extremely low-viscosity LSR with high precision and high efficiency. On the ENGEL tie-bar-less injection moulding machines, the patented force-divider ensures that the moving mould mounting platen follows the mould exactly while the clamping force is building up distributing the clamping force evenly across the platen face. This keeps all the cavities closed with exactly the same force, which ensures consistent compression of the mould and consistently high product quality. “Burr-free manufacturing with no reworking required is the only way high-tech components can be produced economically from LSR in injection moulding,” Willmeroth stresses. LSR is used increasingly in China. Besides seals for diverse applications, a growing number of microcomponents, for example for mobile phones or medical technology, are also made from LSR on tie-bar-less ENGEL machines.

ENGEL is presenting LSR processing with its partner Elmet Elastomere Produktions- und Dienstleistungs GmbH (Oftering, Austria). In this application, the 4-cavity mould and the LSR dosing system, which can be integrated in the CC300 control of the e-victory machine, come from Elmet.

A cleanroom solution with a tiny footprint
Another premiere is in Medical, where ENGEL is presenting a highly integrated production cell for manufacturing pipette tips under cleanroom conditions. This exhibit too, is the result of cooperation between Europe and China. ENGEL, Waldorf Technik (Engen, Germany) and Wellmei Mold (Dongguan, China) have combined their know-how and experience with medical precision parts and tailored the system solution exactly to the specific requirements of the Chinese processors.

Because the pipette tips are used in fully automated analytical systems in medical diagnosis, reproducible product quality is the highest priority. As mass-produced parts, however, they are also under especially high cost pressure. To achieve a stable process and high economic efficiency, the system partners integrate a tie-bar-less e-victory injection moulding machine from ENGEL with a 32-cavity hot runner precision mould from Wellmei and high-speed automation from Waldorf Technik in an extremely compact space. The free accessibility of the mould area makes it possible to move the automation particularly close to the clamping unit of the e-victory injection moulding machine.

The electric injection unit on the hybrid machine ensures very high precision when injecting the plastic melt. To additionally compensate for fluctuations in the ambient conditions and raw material, iQ weight control is also used. The assistance system from the ENGEL inject 4.0 programme analyses the pressure in real time during the injection process and compares the measured data with a reference cycle. For every shot, the injection profile, the switchover point and the holding pressure are automatically adjusted to the current conditions and the injected melt volume kept constant throughout production. This is a proactive way of preventing rejects.

The automation is another key to constantly high product quality in this application. The automation solution developed by Waldorf Technik removes 32 pipette tips from the mould in sync with the injection moulding process and loads groups of 96 pipette tips, sorted by cavity, into racks. Every 18 seconds, 96 pipette tips are discharged from the production cell, which is enclosed to create a cleanroom environment.

In practice, subsequent steps such as quality control or packaging are increasingly taking place immediately after the injection moulding stage. In place of the many different downstream processes, during Chinaplas a Sawyer collaborative robot from Rethink Robotics (Boston, USA) retrieves the loaded racks at the end of the production process. A special feature of collaborative robots is that they require no protective enclosure and can operate safely hand in hand with employees.

inject 4.0: consistent quality without specialist knowledge
With intelligent assistance systems such as iQ weight control, ENGEL makes it especially easy for its customers to ensure consistently high product quality, even without specialist knowledge. The iQ systems continually analyse critical process parameters and readjust them automatically, shot for shot. The result is a self-optimising injection moulding machine.

The growing intelligence of the machine control is a key feature of the smart factory, the goal of Industry 4.0. Networking of production systems and systematic use of machine, process and production data additionally help to raise the productivity, quality and flexibility of manufacturing. Under the name of inject 4.0, ENGEL already offers a series of mature products and solutions for digitalising and networking injection moulding production that have proven themselves in practice many times. These generate considerable benefits both in isolation and as part of a digitalisation strategy encompassing the entire production operation. “Step by step towards the smart factory, that is our customers’ strategy,” Willmeroth says.

ENGEL is demonstrating the great potential of the inject 4.0 solutions in the production of inject 4.0 logos on a tie-bar-less and fully electric e-motion 80 TL injection moulding machine. The CC300 machine control is capable of simulating process fluctuations so that the automatic readjustments by the intelligent assistance systems can be tracked on the display. While iQ weight control maintains consistent injected melt volume throughout the injection moulding process, iQ clamp control monitors the mould breathing in order to calculate and automatically adjust the optimal clamping force. “With the self-optimising injection moulding machine, we are making it especially easy for processors to exploit the full efficiency and quality potential of the machines and technologies,” says Gero Willmeroth. “The first machines with iQ are already in operation in China.”

ENGEL at Chinaplas 2018: Hall 5.1, Booth E71
(Engel Austria GmbH)

Newsgrafik #33527
 06.02.2018

ENGEL at the Plastics & Rubber Vietnam 2018  (Company news)

The packaging industry is one of the fastest growing sectors in Southeast Asia, and a key driver of innovation. The pressure on costs is greater in this sector than almost any other. Competitive production is only possible when maximum throughput, a stable process and a high degree of process integration all come together. At Plastics & Rubber Vietnam, which takes place from March 20th to 22nd, 2018 in Ho Chi Minh City, ENGEL will manufacture food containers to demonstrate how these demands can be met in practical situations.

Photo: iQ weight control compensates for process fluctuations before rejects are produced.

The injection moulding machine manufacturer, based in Austria and with a wholly-owned subsidiary in Vietnam, enables customers to overcome their specific challenges and secure competitive advantages by means of custom-made system solutions – and supplying system solutions from a single source plays a part in this. “It is only possible to maximise efficiency and quality potential where all components in a manufacturing cell are perfectly coordinated from the start,” points out Nguyen Hieu, Head of ENGEL VN in Ho Chi Minh City. Injection moulding machines, automation and process technologies are developed and manufactured in-house. To integrate other peripheral units and moulds, ENGEL has established a global network of system partners. “In Asia we have very strong partners who can implement ideal solutions because they also understand the needs of local processing firms intimately,” says Kurt Hell, Manager of ENGEL’s Packaging and Medical Business Units in Asia. “By working with Asian suppliers, we guarantee high cost efficiency even for most demanding applications while keeping delivery times short across the whole system.” Last year, ENGEL appointed dedicated business unit managers for Asia based in Shanghai, China. With this new structure, ENGEL can support its customers in various industries even more targeted in solving their very individual challenges.

All-electric e-mac: stable and efficient in continuous use
At the Plastics & Rubber Vietnam event, ENGEL will use an e-mac 440/180 injection moulding machine on its stand to produce oval bowls typically used for ready meals. Thanks to in-mould labelling (IML), ready-to-use packaging leaves the production cell. “IML makes high quality decoration affordable while facilitating the efficient production of small batch sizes,” says Hieu. The two system partners involved with the exhibit are based in Taiwan. IML automation is provided by JET Engine Automation, while the 4-cavity mould is provided by CNN Plastic System.

Since high productivity requires a dependable, high performance injection moulding machine, the all-electric e-mac is solely equipped with very powerful servomotors. The ejection and clamping are also handled servo-electrically. This guarantees the best possible precision and process stability while maximising the effectiveness of the machine as a whole. In continuous use, the highly energy efficient machine guarantees stable production around the clock.

With the CC300 control unit, the e-mac offers full flexibility for the integration of robots and other peripherals as well as the deployment of intelligent assistance systems from ENGEL’s inject 4.0 range.

Self-optimising injection moulding machine
inject 4.0 is ENGEL’s answer to the challenges of the fourth industrial revolution, also referred to as Industry 4.0. The aim is to realise the smart factory, in which production processes continually self-optimise through the networking of production systems; the systematic usage of machine, process and production data; and the deployment of intelligent assistance systems. In this way processing firms can increase the productivity and quality of their production operations while responding to demands – which are changing ever more quickly – with maximum flexibility.

ENGEL is already offering a whole series of advanced and proven products for digitalisation and networking, and continues to develop the range. The modularity of the inject 4.0 concept makes it easy for plastics processing firms to harness the opportunities presented by Industry 4.0. Even individual solutions promise considerable benefits.

At the trade event, the e-mac injection moulding machine will underline this point. Equipped with the iQ weight control assistance system, the machine identifies fluctuations in environmental conditions and the raw material, automatically compensating for these shot for shot. Throughout the process, it keeps the injected melt volume constant and thereby stops rejects being produced.

ENGEL will be taking another assistance system to Ho Chi Minh City: iQ clamp control software, which calculates mould breathing in order to determine ideal clamping force and adapt it automatically.

Launch for new e-connect customer portal
ENGEL is introducing its new e-connect customer portal to Asia: it will be available in Vietnam from April 2018. “The aim in this development was to provide customers with more specific information, establish contact with them even faster and provide the best possible support to meet the challenges of Industry 4.0,” says Hieu.

From the first order onwards, all machines and system solutions supplied by ENGEL are stored in the system, with the current status also shown. For the best possible overview, users can reproduce the structure of their individual machinery in the system and even assign production lines to different halls or departments online. Making support and service enquiries online is not only convenient for users, but also speeds up order processing. As soon as a customer makes a request, it is automatically forwarded to the service team so that they can start looking for the cause immediately.

The new customer portal assists with online support and remote maintenance as well as further service products in ENGEL’s inject 4.0 range, including e-connect.monitor for condition-based, pre-emptive maintenance.

ENGEL at Plastics & Rubber Vietnam 2018: Hall A, stand M1
(Engel Austria GmbH)

Newsgrafik #33368
 04.01.2018

ENGEL at Interplastica 2018  (Company news)

ENGEL is making its customers more competitive with flexible and efficient machine concepts along with automation from a single source. The system expert based in Schwertberg, Austria, will demonstrate what this means in practical terms by presenting two technically sophisticated applications at Interplastica 2018, which takes place from January 23 to 26 in Moscow, Russia. At the same time, the company will highlight the new opportunities that digitalisation and networking are opening up for plastics processing firms.

Photo: authentig creates transparency of machinery. With its “Energy” module the MES reliably caps peaks in the power demand.

In many cases, wristwatches require sales packaging that is not just high quality, but original – in the form of globes, for instance. Over the four days of the trade event, ENGEL will use a mould supplied by its customer Betar to produce base bodies for globes on an ENGEL victory injection moulding machine. Hemispheres that can be put together will be moulded. Based in Chistopol (midway between Moscow and the Urals), Betar manufactures numerous products for gas and water metering and a great many plastic articles for customers. Flexibility is an essential characteristic of the company’s production equipment, which is why the company mainly invests in tie-bar-less injection moulding machines from ENGEL’s victory range. “Free access to the mould area makes it much quicker to install and remove moulds,” stresses Olaf Kassek, Managing Director of OOO ENGEL in Moscow. “Thereby, tie-bar-less technology significantly improves the availability of injection moulding machines when producing small batch sizes.” Tie-bar-less technology also enables compact manufacturing cells, which is especially advantageous when producing complex, three dimensional parts and using multi-cavity or multi-component moulds. In such cases, the moulds have a large volume and the injection moulding process tends to require relatively small clamping force thanks to rather short flow paths. Tie-bar-less technology makes it possible to choose the machine size on the basis of the clamping force actually required, rather than the mould size. Given that mould fixing platens can be used to the hilt, even small injection moulding machines can be fitted with large moulds.

Consistent processes despite variable pellet quality
The victory machine on show in Moscow will have a new generation injection unit. On the basis of its extensive experience across the many different application areas for its injection moulding machines, ENGEL has restructured the sizes of the hydraulic injection units and further optimised performance data such as injection pressure, injection speed and plasticising performance. The long established ENGEL servohydraulic ecodrive is standard equipment in the new machine models. Depending on the type and size of machine and the application, this cuts the energy requirement by 30 to 70 percent. Key to this is needs-based pump capacity. When a machine is idle (for example, during cooling phases), the engines also close down and consume zero idling energy. As positive side-effects, the machine runs much quieter and the hydraulic oil is not heated as much, which reduces the amount of energy needed for oil cooling.

Visitors to the trade fair will also be able to track the workings of iQ weight control live on the control panel of the victory machine. During the injection process, the software analyses the pressure profile in real time and compares measured values by means of a reference cycle. For every shot, the injection profile, switchover point and the holding pressure profile are automatically adapted to current conditions and the injected melt volume is kept consistent throughout the production operation. This compensates for fluctuations in environmental conditions or moulding compound before rejects can be produced.

ENGEL uses the iQ prefix to denote the expanding number of intelligent assistance systems in its inject 4.0 range. These enhance the quality and efficiency of production without requiring machine operators to acquire specialist knowledge. Five years ago, iQ weight control became the first iQ system to be launched; since then, more than 1,500 of the systems have been sold worldwide. Initially, the software was limited to use with injection moulding machines with electric injection units; now iQ weight control is also suitable for hydraulic machines. “Feedback from the market has been excellent,” says Kassek. “iQ weight control significantly increases reproducibility in hydraulic victory machines.”

Maximum integration with a minimal footprint
ENGEL will bring a second exhibit to Moscow to demonstrate how to maximise the efficiency potential of tie-bar-less technology in the field of medical technologies as well. Compact manufacturing cells are particularly beneficial in the cleanroom environment. Two years ago, ENGEL developed a stainless steel pipe distributor for the cavity-specific handling of small injection moulded parts; this will be presented at Interplastica with a totally new and more compact design. Thanks to tie-bar-less technology, it is situated next to the clamping unit of the ENGEL e-victory 80 injection moulding machine and completely fits into the machine’s widened safety gate.

At the trade event, the highly compact manufacturing cell will produce needle holders for 1ml safety syringes using a 16-cavity mould. An ENGEL viper 12 linear robot will remove the delicate polystyrene parts from the mould and transfer them to the distributor system. To ensure batch traceability to the level of individual cavities, the injection moulded parts will be packed in cavity-specific bags. For this purpose, 16 bags will hang in a cart directly beneath the pipe distributor. Individual shots can be extracted for quality control purposes.

For unmanned cleanroom operation – for example, during night shifts – two carts can be alternated in sequence, with a buffer system enabling the fully automated exchange. The entire periphery for this is integrated into the CC300 control unit of the injection moulding machine. Thanks to shared data storage, the CC300 can precisely coordinate the movements of the machine and the robot with each other, thus optimising overall efficiency. The total cycle time for this application is just six seconds.

The delicate needle holders, which have a shot weight of just 0.08g and varying wall thicknesses, require extremely precise process control. ENGEL guarantees this through the electric injection unit of the hybrid e-victory machine and iQ weight control.

Immediate response, 24/7
The two machines at the ENGEL stand will be linked so that machine statuses and process data can be tracked in real time via a central computer. In this way, ENGEL will be able to showcase other products from its inject 4.0 range in Moscow. For example, e-connect.24 enables remote maintenance of injection moulding machines and production cells, even at distant production locations. Qualified ENGEL service engineers can be contacted directly 24 hours a day, seven days a week. As soon as they receive a service request, they use a secure remote connection to start troubleshooting and providing specific online support. “In many cases, faults can be resolved over the internet,” says Olaf Kassek. “Users benefit from the fact that they don’t need to call out a service technician, which is expensive and time-consuming, and from the greater availability of their production system.”

Keeping an eye on production
At its stand, ENGEL is dedicating an individual expert corner to the MES authentig. The Manufacturing Execution System was developed by T.I.G. Technische Informationssysteme GmbH, which has been part of the ENGEL Group for one year. With the integration of T.I.G. into the ENGEL Group, both companies have combined their MES know-how and their many years of experience with MES projects worldwide, thereby achieving innovation at an even faster pace.

Tailored to the specific requirements of the injection moulding industry, authentig offers particularly deep vertical data integration, down to the level of individual cavities. The software creates transparency in order, for example, to optimally utilise the available capacity of a machine park, or to correlate productivity ratios with economic goals. The MES has a modular structure and can be precisely adapted to the individual requirements of the processor.

"Energy" is the most recent authentig module. Not only does it make the energy consumption of individual consumers in the injection moulding operation transparent, but it also reliably caps peaks in the power demand. This is made possible by defining situational consumption limits for each individual consumer, and then dynamically allocating the pre-defined power amounts to the consumers. This intelligent hall management can thus help to significantly reduce the energy costs for the machine pool.

ENGEL at Interplastica 2018: Hall 2 (level 1), stand B23
(Engel Austria GmbH)

Newsgrafik #33349
 20.12.2017

ENGEL at the Saudi PPPP 2018 in Riyadh  (Company news)

Optimum efficiency, maximum performance and consistent quality: ENGEL, the Austrian injection moulding machine manufacturer and system expert, will demonstrate how flawless interplay between injection moulding machine, automation, mould and application technology can reconcile these demands cost effectively and sustainably at Saudi Plastics & Petrochem. The event takes place in Riyadh, Saudi Arabia, from 21 to 24 January 2018, in conjunction with Saudi Print & Pack. ENGEL’s information stand will focus on innovative products and applications for the construction, logistics and packaging sectors.

Photo: In Saudi Arabia, the trend is towards sustainable plastic pallets.

The injection moulding industry of Saudi Arabia is making a strong comeback for Saudi PPPP 2018 thanks to some innovative products and applications. Investment was halted in many areas following the collapse of the oil price in 2014. However, new orders and fresh growth are emerging as the year comes to a close. “The worst is over,” says Andreas Leitner, Sales Director Middle East at ENGEL. “We are holding more discussions with customers over new product ideas that will actively assist with local value creation and stimulate the economy. Saudi PPPP 2018 will give this development greater impetus.” Three areas in particular will benefit from the upturn: the construction industry, logistics and the packaging sector.

New products driving infrastructure projects
In the construction industry, for example, electrofusion fittings for use in gas and water networks are among the innovative products driving sales for processing firms. Typical of this fitting type are integrated heating elements; after being installed in a pipeline system, they are temporarily charged with electricity to materially bond the pipe ends. This results in highly secure and durable connections that do not require seals.

To manufacture electrofusion fittings, heating elements are overmoulded with thermoplastics, which generally requires two injection moulding steps. This means inserts and pre-moulded parts must be handled carefully; moreover, the moulds are very large owing to the complex component geometry. To facilitate highly efficient and cost-effective production despite this, tie-bar-less injection moulding machines of the victory series are preferred for such applications. Even in high clamping force classes up to 5,000 kN, ENGEL designs its victory machines with tie-bar-less clamping units.

Since the mould mounting platens of tie-bar-less machines can be used to the hilt, it is possible to fit very large and complex moulds on relatively compact machines, which minimises both investment and operating costs. A second efficiency factor is automation as robots can access the cavities directly from the side without having to negotiate obstacles; thirdly, the high process stability which is ensured by the tie-bar-less clamping unit design helps to maximise overall efficiency. The patented force divider enables the moving mould mounting platen to follow the mould exactly parallel while clamping force is building up and ensures that the clamping force is evenly distributed across the platen face.

ENGEL victory machines are fitted with the ecodrive servohydraulic as standard. This cuts the energy requirement by 30 to 70 percent in comparison with conventional hydraulic injection moulding machines, depending on the machine size and application.

Plastic pallets for greater sustainability
The trend towards sustainable products and manufacturing concepts is especially clear in the logistics field, where plastics and petrochemicals companies have redoubled their efforts to dispense entirely with wooden pallets in the region. According to current surveys, raw materials manufacturers alone in Saudi Arabia require 14 million pallets annually. To produce these from wood, 700,000 trees would be needed, which Saudi Arabia does not have; however, polymer pellets are produced locally. Companies cannot reconcile importing large quantities of wood with their environmental protection commitments, especially when this would also involve treating wood pallets with pesticides and fungicides. By contrast, plastic pallets require no environmentally harmful chemicals; they are neither hygroscopic nor flammable, have no sharp edges and cannot splinter, which makes for simplified customs clearance in many countries.

To make these pallets lighter than wooden pallets – as well as more stable and rigid – ENGEL draws on a wide spectrum of technologies and materials together with system partners and raw materials producers. For injection moulding machines, the low MFI values of the materials used present a particular challenge. With their very high box power output and high quality screws, compact ENGEL duo double-platen machines are ideally equipped to meet this. As a producer of system solutions, ENGEL has the ideal robots for pallet production in its range. With its demoulding stroke of 3,000 mm and range of 3,550 mm, the viper 120 has a load-bearing capacity of 120 kg.

Ultimate efficiency for caps and closures production
The packaging sector was least affected by Saudi Arabia’s economic crisis, yet new technologies are accelerating market developments in this area as well. The focus is on continued optimisation of production efficiency in the manufacture of beverage caps as well as thin-wall packaging for the food industry.

At its stand, ENGEL will use sample parts and videos to illustrate the strong potential of integrated system solutions. For example, an e-cap 380 injection moulding machine with a 96-cavity mould is used to produce 26 mm caps of HDPE, including tamper band, in a cycle time of under 2.5 seconds and with total energy consumption of less than 0.7 kWh/kg. Alongside the all-electric injection moulding machine, peripherals deliver an important contribution to such outstanding overall efficiency: the new TWIN flying closure system is used, for example, enabling IMDvista to meet another challenge in the manufacture of beverage caps. Newly produced caps generally undergo camera inspection on a conveyor belt, which means the top side of the cap cannot be recognised by the cameras. The new technology lifts the caps by means of an air current, enabling them to be inspected from above and below without extending the processing time.

The e-cap injection moulding machine, which ENGEL has tailored to the needs of caps production, accounts for just 0.42 kWh/kg of the total energy consumption of 0.7 kWh/kg. “Now that beverage caps have reached their lightweighting minimum in terms of geometry, they are placing greater demands than ever on the precision and repeatability of injection moulding machines,” points out Leitner. High-performance servo direct drives are responsible for the outstanding precision and process stability of e-cap machines, ensuring the required plasticising capacity and the highest possible number of usable parts even when high-strength HDPE materials are used with an MFI of well below 2 or even 1 g/10 min. Additionally, its increased ejector force and clamping force ensure very fast cycle times. Despite such impressive performance, the e-cap requires very little energy and cooling water, even in high speed operation. “As far as caps production is concerned, there is a definite trend towards all-electric machines,” says Leitner. “The e-cap machine is now firmly established in Saudi Arabia.”

Enhanced quality and cost effectiveness for thin-wall packaging
More and more food packaging is being locally produced in Saudi Arabia. Lightweight food containers are driving the trend, which stems from a desire to be more independent of imports.

Manufacturers of thin-wall containers are increasingly turning to integrated system solutions to ensure high levels of both quality and cost effectiveness. These solutions are often based on the all-electric ENGEL e-motion injection moulding machine, which offers cycle times of well under 3 seconds and injection speeds in excess of 500 mm per second. The closed system for toggle lever and spindle guarantees optimal, clean lubrication of moving machine components at all times and meets the stringent hygiene standards of the food industry.

One focus of the ENGEL information stand will be the integration of IML solutions: with in-mould labelling, it is possible to produce highly decorative and ready-to-use packaging in a single injection moulding step. New automation concepts of the kind developed by ENGEL partner BECK automation promise ample flexibility in the production of small batch sizes.

Integrated system solutions enhance competitiveness
“Our top priority is to give our customers a competitive edge,” stresses Andreas Leitner – and expertise in automation and system solutions is key to this. “We can only exploit the maximum quality and efficiency potential by coordinating all the components in a manufacturing cell from the outset while taking account of the individual requirements of the customer.” In addition to injection moulding machines and automation, ENGEL system solutions can include upstream and downstream process steps, moulds, quality assurance systems and software solutions for digitalisation and networking. As the general contractor, ENGEL has the overall responsibility for the system, and this includes components that are implemented in collaboration with partners. This reduces the number of interfaces and can speed up project planning and the commissioning of new production solutions in many cases.

ENGEL joins with partners in Riyadh
Around the world, ENGEL works with partner companies that are also leaders in their fields. Three of these partners will be making a joint presentation with ENGEL in Riyadh. The Swiss mould maker Otto Hofstetter specialises in meeting the needs of the packaging industry; the company is one of the world’s leading suppliers of moulds for thin-wall container production. BECK automation, also from Switzerland, makes fast extraction robots and automation devices for high performance applications in the injection moulding industry; the company is also a pioneer in the IML area. The third partner, IMDvista, is another Swiss high-tech business with a focus on testing systems. IMDvista solutions are deployed around the world for the inline quality control of caps and bottles, for example.

ENGEL, Otto Hofstetter, BECK automation and IMDvista have successfully completed several projects in partnership and possess a wealth of experience in Saudi Arabia. Throughout the trade event, experts from the four companies will be on hand to field specific enquiries and provide initial appraisals of new projects on the spot.

ENGEL at Saudi PPPP 2018: Hall 2, stand 504.2
(Engel Austria GmbH)

Newsgrafik #33310
 28.11.2017

ENGEL at Plast Eurasia 2017  (Company news)

'Experience the smart factory' will be ENGEL's slogan for Plast Eurasia 2017, which takes place in Istanbul, Turkey, from December 6th to 9th. In Hall 12 (stand 1216), the injection moulding machine manufacturer and system solutions provider with headquarters in Austria will demonstrate the opportunities that digitalisation and networking present for the plastics processing industry, and how these can be applied to maximum effect with inject 4.0.

Photo: Thanks to its lightweight swivel arm, the e-pic Z pick-and-place robot delivers high dynamism and requires minimal space.

inject 4.0 is ENGEL’s answer to the challenges of the fourth industrial revolution. The aim is to realise the smart factory, in which production processes continually self-optimise through the networking of production systems; the systematic usage of machine, process and production data; and the deployment of intelligent assistance systems. In this way processing firms can increase the productivity and quality of their production operations while responding to demands – which are changing ever more quickly – with maximum flexibility.

At a very early stage, ENGEL focused on the trend towards networking and digitalising production processes by developing an integrated digitalisation strategy for its own production as well as its customers. "Many of our inject 4.0 products and solutions have already been successfully deployed at customer sites for many years," reports Abdulkadir Topucar, Managing Director of ENGEL Enjeksiyon Makineleri in Istanbul. "At the same time, we are consistently working to develop the range. We are inviting trade fair visitors to experience both established and new products and solutions at our stand, and try them out first hand." In particular, it is the modularity of ENGEL's inject 4.0 approach that makes it extremely easy for plastics processors to start working towards the smart factory step by step. Even individual stand-alone solutions can add great value.

Compensating for process fluctuations before rejects are produced
As integration and automation make injection moulding processes ever more complex, managing and controlling them also needs to be simpler and more intuitive. Self-adapting, intelligent assistance systems make a major contribution towards this objective as they boost process capability and quality without requiring operators to acquire special skills. To clearly demonstrate the way these assistance systems work, ENGEL will be producing inject 4.0 logos at its stand over the four days of the fair using an all-electric and tie-bar-less ENGEL e motion 80 TL injection moulding machine. Fluctuating process conditions will be simulated in the machine's CC300 control unit, giving trade fair visitors the opportunity to track the automatic readjustment by the intelligent assistance systems live on the machine's display. While iQ weight control keeps the injected melt volume consistent throughout the injection moulding process, iQ clamp control determines mould breathing in order to set the correct clamping force for good mould venting. This means that fluctuations in ambient conditions and raw materials are automatically detected and compensated for in a single shot, before rejects can be produced.

Efficient, precise and space-saving
The design of the e-motion 80 TL also meets the strictest efficiency and precision requirements. The model range combines the benefits of ENGEL tie-bar-less technology, such as fast tooling processes, efficient automation solutions and compact production cells with all-electric drive technology. Thanks to these qualities, the e motion 80 TL can be used, for example, to manufacture precision parts and premium optical components in the electronics industry.

At Plast Eurasia, an integrated e-pic Z robot will remove the parts from the mould. The innovative kinematic system of the pick-and-place robot in the ENGEL product portfolio combines linear movements with a swivel arm, and thus requires minimal space. The swivel arm comprises a tailor-made, lightweight, thermoplastic composite material which also raises energy efficiency and dynamism.

Managing multi-component processes with LSR
ENGEL will also underline the efficiency potential of its tie-bar-less technology with its second trade fair exhibit. Over the four days of the event, ENGEL will use a victory 200H/200L/160 combi injection moulding machine with integrated viper 40 linear robot to produce two-component pressure accumulator membranes used in pressure compensation containers. In a single workstep, the machine will process PBT and LSR simultaneously in a two-component mould. The integrated injection process in this application makes it possible to bond thermoplastics and silicone in stable layers.

Because the tie-bar-less clamping unit fully uses the mould mounting platen to the edge, the bulky two-component mould for the pressure accumulator membranes can be installed on a relatively compact 160-ton machine, thus keeping down both the investment costs and the operating expenses. Moreover, the linear robot can access the cavities directly from the side, without having to negotiate obstacles, and operate safely in that area. The third efficiency factor is the very high level of process consistency ensured by the tie-bar-less design of the clamping unit. The patented force divider enables the moving mould mounting platen to follow the mould in a precisely parallel manner while clamping force is building up and ensures that the clamping force is evenly distributed across the platen. This way, both the outer and inner cavities are kept closed with exactly the same force, which reduces mould wear and raises product quality. “To manufacture high-tech products of liquid silicone in a cost-effective way, you need burr-free, waste-free, fully automated processing of LSR with no reworking required,” says Topucar.

Keeping an eye on production
The two injection moulding machines at the ENGEL trade fair stand are linked to each other. Machine states and process data can be tracked in real time using a central computer. In this way, ENGEL will showcase further products from its inject 4.0 range at the Istanbul fair. For example, e-connect.24 enables remote maintenance of injection moulding machines and production cells, even at distant production locations. Qualified ENGEL service engineers can be contacted directly 24 hours a day, seven days a week. As soon as they receive a service request, they use a secure remote connection to start troubleshooting and providing specific online support. In many cases, the problem can be resolved directly via the internet, thus saving the user a time-consuming and expensive on-site call by a service engineer while increasing the production line's availability.

One special highlight of the ENGEL trade fair stand will be the presentation of the new e connect customer portal, the future platform for communication between ENGEL and its customers. The fully revised version supports the optimum use of inject 4.0 products while providing an overview of the machine park, the processing status of service and support orders and the prices and availability of spare parts – any time and anywhere. "We are offering visitors to the trade fair an exclusive preview of the amazingly clear design, intuitive navigation and the new features of our customer portal," says Abdulkadir Topucar in the run-up to Plast Eurasia. As of April 2018, e-connect will be available in Turkey.

ENGEL at Plast Eurasia 2017: Hall 12, stand 1216.
(Engel Austria GmbH)

Newsgrafik #33288
 20.11.2017

The Fakuma 2017 was a great success for ENGEL  (Company news)

The Fakuma 2017 was a great success for ENGEL. The good investment climate continues, many orders for injection moulding machines, robots and integrated system solutions were closed at the fair, with others being announced. Almost all of the new projects have one thing in common: They include at least one product from ENGEL’s comprehensive inject 4.0 programme. The topics of digitalisation and networking have arrived in the industry – that became very clear at the Fakuma 2017.

Photo: From the first day of the fair on, the ENGEL booth was consistently very well-visited.

Trade fair visitors thrilled by new customer portal e-connect
The conversations at Fakuma confirmed that Industry 4.0 has arrived in the majority of companies. "The inquiries are becoming more and more specific", reports Paul Kapeller, Product Manager of Digital Solutions at ENGEL. "By now, most of our customers have a distinct idea of the advantages brought to them by digitalisation and networking, and are inquiring about specific products and solutions."

In several Expert Corners, ENGEL presented its entire inject 4.0 programme. Numerous products, such as the intelligent assistance systems of the iQ series, have by now proven themselves in practice over many years in several thousand installations throughout various sectors. They generated as much attention as the new products that were presented at a fair for the first time in Friedrichshafen. e-connect, the ENGEL customer portal which was launched in a completely revised version at the Fakuma, turned out to be a genuine visitor magnet. "In future, the customer portal will be an important linchpin in the cooperation with our customers", says Kapeller. "The new version supports our inject 4.0 products and accompanies our customers on the path to the smart factory." Trade fair visitors were especially impressed by the possibilities to clearly virtualise the machine park, including all machine conditions. "e-connect allows taking an easy first step towards a networked production", states Kapeller.

Premiere for innovative applications, machines and technologies
In addition to inject 4.0, the live demonstrations in five highly integrated production cells contributed to ENGEL's success at the Fakuma 2017. They included several world premieres. For example, in the automotive exhibition area ENGEL produced the first exterior component worldwide in clearmelt technology. This also represented an immense leap in development as compared to the previous presentation. With the new Colourline System by the ENGEL partner Hennecke from St. Augustin in Germany, PUR colour systems can now also be used in the clearmelt process. ENGEL demonstrated how quickly the colour change is performed in live operation. The components – both in high gloss – were alternately produced in black and in grey.

Until now, the subject of clearmelt revolved around decorative elements and electronic functional components for the vehicle interior, however, with the technology developed by ENGEL with Hennecke and other partners, there is an increasing focus on the exterior. In addition to the high efficiency of the integrated process, the reason for this is the enormous scratch resistance and high surface quality of the resulting components. Not only the automotively inclined among the trade fair visitors stopped at the clearmelt exhibit. For example, the technology also opens up new possibilities for manufacturers of control elements in various industries. Decorative as well as capacitive foils can be efficiently overmoulded. Functional elements thus vanish beneath a continuous, closed surface.

New e-mac 280 is the shortest machine on the market
Also part of the ENGEL line-up at Fakuma was a new machine. With the e-mac 280, ENGEL has extended its machine series for all-electric applications in the teletronics and technical moulding areas at the top, taking into account the trend towards the increased use of multi-cavity moulds in the production of highly precise volume components. In addition, the new injection moulding machine provides an important contribution to an increase in area productivity. Thanks to optimised toggle-lever geometry, with its length of 6.20 metres the e-mac 280 is the shortest all-electric injection moulding machine in this clamping force class on the market, and that in spite of retaining its very large opening stroke of 600 mm.

Ongoing good economy in the plastics industry
In order to continue meeting the rising demand in future, at the Fakuma ENGEL announced comprehensive investments into its worldwide production sites, the continued expansion of its sales and service teams, and the reinforcement of local application-technical, automation and industry expertise. "The very positive mood in Friedrichshafen is an important indicator, both in Europe and worldwide, for the ongoing good economy in the plastics industry", says Steger.
(Engel Austria GmbH)

Newsgrafik #33244
 20.10.2017

ENGEL getting ready for continued growth  (Company news)

At the Fakuma trade fair in Friedrichshafen, Germany, ENGEL AUSTRIA is presenting itself in a good mood. The injection moulding machine manufacturer and system solution provider based in Schwertberg, Austria, continues to be on course in the current financial year. Production capacities and the number of employees worldwide are being continuously increased.

"We are very happy with the development of the business", states Dr Stefan Engleder, CEO of the ENGEL Group. "In the current financial year, we are expecting revenues of approximately 1.5 billion euros." This is a significant increase as compared to the previous year's revenue of 1.36 billion euros. The machine manufacturer is optimistic regarding the upcoming months.

ENGEL has been disproportionately benefiting from the robust, uninterrupted growth of the plastics industry for almost ten years. "We have continued to achieve growth in all regions and all relevant industries", says Engleder. At 55 percent, Europe represents the lion's share of revenue. At this time, ENGEL is achieving 24 percent of its revenue in America and 20 percent in Asia.

ENGEL in Germany strengthening application technology and inject 4.0 competence
Germany continues to be one of the highest revenue markets of the ENGEL Group. Over the last five years, ENGEL was able to increase its sales here by 50 percent. As explained by ENGEL's Managing Directors, there are two factors that play a major role in this. "Germany continues to be the most technologically advanced market and the greatest driver of innovation", emphasises Dr Christoph Steger, CSO of the ENGEL Group. "In addition, German companies are continuing to advance their global expansion."

ENGEL currently employs more than 300 people in Germany, and the trend is rising. The ENGEL Deutschland Technologieforum Stuttgart – the youngest of the four German subsidiaries – has more than doubled its amount of personnel since opening in April of 2013. Most recently, new employees have been added in the areas of service, project management, and application technology. Application technology plays an especially important role in the technology centre in Stuttgart, which is significantly larger than most other technology centres within the ENGEL group. Since September of this year, the location includes a MuCell competence centre. A large foam injection moulding cell is now permanently available in Stuttgart for customer tests, development work and training. In the competence centre, ENGEL in Stuttgart employs an in-house MuCell technology expert.

In the current financial year, the main focus of investment in Germany is the Hannover location – with 80 employees, it is one of the largest ENGEL sales and service subsidiaries worldwide. The significantly expanded and modernised branch was opened in May. ENGEL has invested about 5 million euros into its northernmost German location. The customers in Hannover are benefiting from the doubling of the usable area, especially because of the significantly larger technology centre and the expanded event and seminar area. The new interactive technology centre also accommodates large machines with clamping forces up to 7000 kN. In addition to varying showpieces, the topics of lightweight construction and inject 4.0 are two permanent main exhibit areas.

In parallel to Hannover, ENGEL has also opened an inject 4.0 hotspot in its technology and automation centre in Hagen, Germany. The goal is to very clearly communicate the new opportunities of digitalisation and networking, and to offer live demos of all ENGEL inject 4.0 products.

ENGEL creating new jobs worldwide
Industry 4.0 is one of the strongest growth drivers worldwide, which is clearly reflected in the presentations at Fakuma 2017. These are not only about changes in production processes, but rather new forms of collaboration, as Stefan Engleder clarifies: "More and more, we are accompanying our customers throughout the entire life cycle of injection moulding machines and production cells. Among other things, this involves even more intense consulting in planning production solutions, new possibilities in after-sales service such as predictive maintenance, continuous process optimisation and the flexible adaptation of production solutions to changing tasks. In order to fulfil these requirements to our customers' complete satisfaction, we will require even more highly qualified and committed employees in future than we do today."

The direction in which ENGEL's collaboration with its customers is growing explains why in particular the areas of service and application technology are growing in terms of personnel. Furthermore, ENGEL is increasingly employing people in the area of information technology. Specifically, 120 additional positions are advertised for the three Austrian locations, with another 20 advertised for Germany. By the end of the financial year in March 2018, ENGEL expects to employ 6,400 people worldwide.

Demand for integrated systems solutions continues to increase
Other technological growth drivers are the advancing material substitution in high-tech applications such as automobile construction or medical technology, as well as lightweight construction in the automotive and teletronics industries.

The technological trends go hand in hand with a continuously increasing degree of process integration and automation, which in turn leads to an increased demand for integrated solutions from a single source. "The increasing complexity of processes is one of the biggest challenges facing plastics processors. As the complexity increases, It is our job to provide more transparency and clarity and to ensure that even complex processes can be easily managed and controlled", clarifies Christoph Steger. "With its extremely advanced system solutions expertise and its own comprehensive automation, peripheral, technology and Industry 4.0 programme, ENGEL is optimally equipped for this trend. The share of integrated system solutions in the order book is continuing to grow, and this is clearly a worldwide trend." For example, the system solutions business is allowing ENGEL to grow in Asia, while many providers that are focused entirely on machines are seeing a decrease of sales in that region.

Production capacities being expanded
To meet the worldwide increase in demand, more than three years ago ENGEL began the most comprehensive investment programme in the history of the company. Altogether, over 375 million euros will be invested into the production facilities alone by 2020. "The first projects with a total volume of close to 120 million euros have been completed", says Engleder. "We are working at full speed to rapidly drive the expansion forward, and are continuously readjusting plans and priorities to the actual conditions."

The largest ongoing construction project is the expansion of the large machine plant in St. Valentin, Austria. In the summer of this year, a milestone was achieved and an additional production hall was put into operation. This expands the production area by more than 4,000 square metres and also provides additional office space. In the next step, a new administrative building and a new customer technology centre will be built at the site, starting in spring 2018. In the source of this expansion step, the centre for lightweight composite technologies located in St. Valentin will also be expanded.

In the ranking of the biggest construction projects in the ENGEL Group, the company headquarters are right behind St. Valentin. Since the summer, there has been a large construction site next to the main entrance. By autumn of 2018, the northern production hall there, which was constructed in 2013, will be expanded by 11,500 square metres. In addition a new, significantly larger customer technology centre is being built. ENGEL just completed the expansion of the technology centre at the southern end of the plant premises in the spring of this year. An additional area of 10,000 square metres for office space, the apprentice workshop and a daycare centre was added there. The in-house daycare centre for small children is a new offering by ENGEL, which has been met with such a huge positive response by employees that by now, a second daycare group has been started. In June, the editorial staff of Woman magazine named ENGEL as one of the most family-friendly companies in Austria.

In parallel to the large machine factory in St. Valentin, capacities were also expanded in Shanghai. In time for the 10-year anniversary of the plant, this September ENGEL was able to open the new building complex with a grand festive ceremony. In Shanghai, the existing office building was lengthened to add another 1,000 square metres of usable space. In addition, a new production hall was constructed, expanding large machine production by 1,600 square metres. The apprentice workshop is also being newly constructed. It is considerably larger than the previous one, because since beginning the ENGEL apprenticeship programme in China four years ago, the amount of trainees has increased significantly. Currently in Shanghai, 45 young people are being trained in three technical professions.

New round of Sales Trainee programme starting in 2018
With in-house training and continuous investments into its apprentice workshops, ENGEL is securing its long-term demand for trained workers. At all locations, the hiring rate is over 98 percent. Besides Austria and China, ENGEL has training programmes for technical professions in Germany and the Czech Republic.

Finding qualified and committed employees and binding them to the company does not only pose a challenge for production. "We also need to break new ground in sales", emphasises Christoph Steger. To that end, ENGEL started an international sales trainee programme in September 2016. Seven young men and one woman from the US, China, Korea and Austria, respectively, are the pioneers on this training track. By now, they have successfully completed the introductory phase and their first assignments abroad. By the end of the two year training, they will have become familiar with ENGEL plants and subsidiaries on three continents. "Especially in sales, our employees operate in internationally networked teams", says Steger. "A basic skill that this requires is thinking beyond the limits of one's own language and culture. That is exactly what we intend to train." ENGEL plans to offer new sales trainee positions for the coming year.
(Engel Austria GmbH)

Newsgrafik #33217
 17.10.2017

New customer portal e-connect goes live at Fakuma  (Company news)

e-connect, the new customer portal of ENGEL, is due to be launched at Fakuma 2017. The portal will simplify and speed up communication between processors and ENGEL while providing an overview of the machinery, the processing status of service and support orders and the prices and availability of spare parts – any time, anywhere. The new version of the customer portal will also meet the current and future requirements of Industry 4.0.

Picture: The fastest link to the world of ENGEL: the new version of the e-connect customer portal is even clearer. The platform supports all service products in ENGEL's inject 4.0 programme.

e-connect provides fast access to the world of ENGEL. Between 17th and 21st October in Friedrichshafen, Germany, the injection moulding machine manufacturer and system solutions provider will demonstrate the new possibilities at its stand in hall A5. “In developing the new software, the aim was to provide customers with more specific information, establish contact with them even faster and provide the best possible support to meet the challenges of Industry 4.0,” points out Verena Paradeis, product manager for e-connect. “The customer portal will be the lynchpin for our partnerships with customers.”

From the first order onwards, all machines and system solutions supplied by ENGEL are stored in the system, with the current status also shown. For the best possible overview, users can reproduce the structure of their individual machinery in the system and even assign production lines to different halls or departments online.

No time to waste in support and service cases
Making support and service enquiries online is not only convenient for users, but also speeds up order processing significantly. As soon as a customer makes a request, it is automatically forwarded to the service team so that they can start looking for the cause immediately. Since customers and service technicians use the same database, they have the same level of knowledge at all times. In many cases, the system history this contains makes it easier to find a solution. This is also why all new service orders are fully documented in e-connect. With sites on three continents, ENGEL ensures qualified service technicians from its regular workforce are available around the clock.

Condition-based, predictive maintenance included
In addition to online support and remote maintenance, the new version of e-connect supports predictive, condition-based maintenance. Under the name e-connect.monitor, ENGEL offers solutions for monitoring the condition of plasticising screws and spindles. The aim is to utilise the full lifespan of machine components while avoiding unscheduled system downtimes. To ensure this, sensors monitor the condition of components and residual life is calculated on the basis of mathematical models. While the condition of plasticising screws is determined in the course of regular servicing, spindles are subject to automatic online monitoring; in both cases, the results of the evaluation are stored in e-connect; they can be called up and processed by the customer at any time. In the long term, continual condition monitoring serves to optimise the moulding process while making it easier to identify causes of wear.

e-connect.monitor is part of the inject 4.0 programme, which ENGEL uses to help clients meet the challenges of Industry 4.0 head-on. ENGEL will also integrate future service products for the smart factory into the customer portal. “We have structured the platform so that we can quickly implement further demands of advancing digitalisation,” says Paradeis.

More clarity, simpler navigation
In addition to new functions, e-connect now offers greater clarity and transparency and even simpler navigation. It provides users with a wealth of information, from product descriptions and event news to latest reports from the world of ENGEL and the details of contact persons. A calendar contains the dates of trade fairs and booked seminars, while ENGEL’s e-learning platform is just one click away via e-connect.

The new e-connect version will be available for all customers in Germany, Austria, Switzerland and the United Kingdom from Fakuma 2017 onwards; it will be then extended to other countries in Europe and the USA.

ENGEL at Fakuma 2017: hall A5, stand 5204
(Engel Austria GmbH)

Newsgrafik #33193
 16.10.2017

ENGEL automation on show at Fakuma 2017  (Company news)

At Fakuma 2017, which takes place in Friedrichshafen, Germany, from October 17th to 21st, ENGEL will showcase its expertise in automation at a special Expert Corner. On show, among others, will be the small e-pic B and e-pic Z robots – integrated and with expanded software functions –, the new viper 20 speed for high-speed medical and packaging applications and the new 10” hand-held touch terminal, which makes its exclusive world premiere at the Fakuma event.

Picture: 30 percent faster than the conventional viper: the new viper 20 speed offers removal times of well under 1 second.

Integrated e-pic robots
At Fakuma 2017, ENGEL will present the integrated version of its e-pic robots for the first time, clearly illustrating how efficiency potential can be maximised by combining injection moulding machines and robots. Within the integrated solutions, the CC300 control unit for ENGEL injection moulding machines becomes the main operating panel of the whole manufacturing cell; this means uniform parts data and alarm management as well as a unified look and feel. Consistent operating logic significantly simplifies activation and programming as well as control of robots and the manufacturing cell as a whole.

Integration is a key feature of ENGEL solutions. Since ENGEL supplies injection moulding machines and robots from a single source, the individual components of the manufacturing cell are seamless from a process control and mechanical viewpoint. Injection moulding machines, robots and other peripherals, such as conveyor belts, sprue chutes and protective covers, are coordinated in the design and arranged to be as space-saving as possible. Integrated manufacturing cells also ensure maximum security. A CE certificate will be obtained for the overall solution.

Of course, all ENGEL robots can be integrated subsequently to injection moulding machines via the EUROMAP 67 interface, regardless of the machine brand. No modifications to the injection moulding machine are required to connect the e-pic robots.

Efficiency control reduces energy consumption and wear
e-pic robots, the latest products in ENGEL’s automation range, are offered in two versions: as linear pick-and-place robots (e-pic Z) and servo sprue pickers (e-pic B). The main feature of the e-pic series is the robots’ lightweight swivel arm in place of a conventional x-axis. This completely new kind of kinematic system – a USP of ENGEL – significantly increases the dynamism and energy efficiency, reduces maintenance effort and enables a highly space-saving installation on the injection moulding machine. The swivel arm requires less space than a linear axis when moving towards both the injection and clamping sides; it also works around obstacles, such as core pulls or slides, quickly and easily. Operating the e-pic robot is therefore no more complicated than operating a linear robot. The control unit converts rotary movements into linear movements.

In a new development for Fakuma 2017, ENGEL will be equipping its e-pic robots with efficiency control. The robots use the software to adapt the speed of their movements to the injection moulding process, thereby reducing energy consumption and raising the lifespan of mechanical components. Efficiency control has been an established feature of viper linear robots for years.

viper 20: now even faster
There will also be a premiere for viper linear robots at Fakuma. The new viper 20 speed offers removal times of well under 1 second. The enhanced servo-electric drive technology and the reduced weight of the robot’s axes are responsible for the step up in performance. Developed for applications with total cycle times of around 4 seconds, the viper 20 speed is mainly used in the medical and packaging sectors, areas in which top-entry robots tend to offer very high flexibility.

The new ENGEL viper 20 speed will demonstrate its impressive performance by handling cups at the Fakuma event. It will work in tandem with an ENGEL easix multi-axis robot that will take the cups from a moving conveyor belt and stack them.

In this application, both robots – the viper linear and the easix multi-axis robot – are integrated into a CC300 control unit. It makes no difference whether the CC300 is controlling linear or rotary axes. The additional movement instructions for the multi-axis robot integrate seamlessly with the graphical interface, which simplifies operation significantly. To allow for simple and fast parameterisation despite the complexity of the overall system, the control unit provides different user levels, from a simple view to a fully object-oriented visualisation of the sequence.

10” for easier operation
Another highlight of ENGEL’s Automation Expert Corner will be the new 10” hand-held terminal C10 for robots in the ENGEL series; this will replace the 7” units in the C70 series in the year ahead. Visitors to Fakuma 2017 can look forward to an exclusive preview. The new hand-held terminal will provide a much clearer layout, simplifying operation considerably.

ENGEL automation still growing strongly
Injection moulding production is facing increasingly complex challenges owing to the pace of market development. Around the world, ENGEL is offering customers solutions that address the required degree of automation precisely, from standardised robot cells to made-to-measure system solutions. A consistent robot portfolio and the automation expertise of ENGEL specialists supply the basis for the high degree of flexibility. “In an ongoing project, we are integrating nine robots of different types,” says Walter Aumayr, head of the Automation and Peripherals division at ENGEL AUSTRIA. “Demand is rising for very complex automation cells to be used in highly integrated production processes.”

To meet the individual requirements of processors and address the particular characteristics of its various national markets, ENGEL has its own automation centres in Austria and Germany as well as China, Korea and the USA. Of the 6,000 ENGEL employees around the world, more than 500 are devoted to automation technology – a number that will continue to rise. “We are hiring a lot of new employees for automation,” confirms Aumayr.

Over the past five years ENGEL has doubled its turnover from automation projects; the area of special automation was developing especially strongly with growth rates of 30 percent on average. “The trend shows no sign of slowing down,” says Aumayr. “ENGEL automation will continue to achieve strong, double-digit growth rates.”
ENGEL at Fakuma 2017: hall A5, stand 5204
(Engel Austria GmbH)

Newsgrafik #33125
 05.10.2017

MuCell proficiency strengthened in the southwest  (Company news)

Picture: The ENGEL Technology Centre in Stuttgart is one of the largest in the company. The new duo 350 injection moulding machine with MuCell technology package is permanently available for ENGEL customers

Structural foam moulding is one of the most important lightweight technologies available today and continues strong growth worldwide. The injection moulding machine manufacturer and provider of system solutions ENGEL, headquartered in Schwertberg, Austria, is responding to this trend by strengthening its application technology globally. One area of focus is Germany. In September, ENGEL Deutschland Technologieforum Stuttgart opened a MuCell Competence Centre.

“As a Competence Centre, we are even better able to support our customers to more fully exploit the potential offered by the physical foaming process,” says Claus Wilde, Managing Director at ENGEL Deutschland in Stuttgart. “We already have a number of major customers here in southwestern Germany who use the MuCell process in their factories worldwide.”

Therefore, a large manufacturing cell has been installed in the ENGEL Technology Centre in Stuttgart for customer trials, development work, application-specific consulting, training and small-lot production – for example, for initial sampling. Equipped with an ENGEL duo 350 injection moulding machine with a clamping force of 3500 kN, an integrated ENGEL easix multi-axis robot and a T-200 MuCell unit from the company’s technology partner Trexel, the cell covers a broad spectrum of applications.

Long before the Competence Centre was opened, ENGEL had appointed a MuCell Technology Expert for the site. Over the past months, Lukas Neunzig has successfully completed numerous MuCell projects with customers from around the world at ENGEL’s headquarters in Schwertberg and at the large-scale machine plant in St. Valentin, and he is bringing this experience to Stuttgart.

To celebrate the inauguration of the Competence Centre, ENGEL hosted a MuCell technology event in mid-September, which was fully booked several weeks in advance with over 120 participants. “The great success of our event confirms the huge potential and strong demand here in the southwest,” Wilde emphasises. The technology event underlined a further trend: MuCell is not just for car manufacturers. “We are receiving a growing number of inquiries from other industries as well, such as technical injection moulding and medical technology,” says Wilde.

Less weight, better component properties
There are two main factors that are key to the great success of MuCell technology. First is the general lightweight trend and, second, the high quality of the components produced in the structural foam moulding process.

Physical foaming involves the injection and homogeneous distribution of a blowing agent into the plastic melt during plastification. After injection into the mould, the gas separates from the melt and creates a fine-cell foam structure. In this way, significantly less material is needed to fill the cavities compared to standard injection moulding and the component weight decreases. At the same time, components produced by MuCell have proven to have high dimensional stability. Since foaming enhances the flow properties of the melt, even challenging geometries with undercuts are completely filled.

MuCell is a brand owned by the company Trexel, located in Wilmington, MA, USA. As a system supplier, ENGEL imports the MuCell systems for its customers and manages the integration of the controls and safety aspects into the injection moulding machine, making it very easy to implement the technology.

Apart from Stuttgart, ENGEL also offers customers its MuCell know-how and machine capabilities in Austria, the USA and China.
(Engel Austria GmbH)

Newsgrafik #33039
 26.09.2017

Engel at Plastimagen 2017: For higher productivity and quality   (Company news)

inject 4.0 – this is ENGEL's answer to the challenges of the fourth industrial revolution. At Plastimagen 2017, from November 7 to 10 in Mexico City, ENGEL will demonstrate how these new opportunities – tailored to the requirements of the respective country and industry – can be optimally utilised. In addition, the exhibition booth of the Austrian-based injection moulding machine manufacturer and systems solution provider will be presenting MuCell foam injection moulding for the automotive industry, as well as the extremely precise and very economical processing of liquid silicone.

Photo: At Plastimagen, ENGEL will produce coasters on a tie-bar-less victory machine using liquid silicone.

"We invite fair visitors to get to know our smart factory products at our booth and to see for themselves what a huge impact even smaller individual solutions can have", announces Walter Jungwirth, Managing Director of ENGEL de Mexico in Querétaro. By networking production systems, the systematic use of machine, process and production data, and the use of intelligent assistance systems, the manufacturing processes in a smart factory can continuously optimise themselves. As a result, the productivity and quality of production increase, and at the same time processors can react with great flexibility to rapidly changing requirements.

ENGEL committed to this trend early on, and today, under the name inject 4.0, offers numerous sophisticated products and services for all areas of the smart factory – smart machine, smart service and smart production. All of the products provide a tremendous benefit, individually as well as in the context of a high-level digitalisation strategy. With this modular approach, ENGEL is making the entry into digitalisation and networking especially easy.

Self-optimising machine
With production cells becoming more and more complex due to increasing process integration and automation, steering and controlling them must become that much more simple and intuitive. Self-adapting assistance systems play a decisive role in this. They increase process consistency and quality without requiring the machine operator to acquire special expertise.

To clearly demonstrate the functionality of these solutions, during the four days of the exhibition ENGEL will produce inject 4.0 logos on an e-motion 80 TL injection moulding machine at its booth. The CC300 machine control is capable of simulating process fluctuations; the automatic readjustments by the intelligent assistance systems can then be tracked live on the display of the machine. While iQ weight control maintains consistent injected melt volume throughout the entire injection moulding process, iQ clamp control monitors the mould breathing in order to calculate and automatically adjust the optimal clamping force. Fluctuations from the target values are automatically detected and compensated for within the same shot, thus preventing rejects.

iQ flow control, the third assistance system presented at the Plastimagen, will connect the injection moulding machine, which is equipped with an e-flomo electronic temperature control water distributor, to the temperature control unit, enabling the pump speed to automatically adjust to the actual requirement. This results in higher energy efficiency. Together with its partner HB-Therm, ENGEL has developed its own line of temperature control units called e-temp.

Capping costly energy peaks
In several Expert Corners, visitors can dive even deeper into the subject of inject 4.0. Some of the topics included will be the online-support and remote maintenance tool e-connect.24 and the MES authentig. This manufacturing execution system was developed for the specific requirements of the injection moulding industry and therefore achieves an especially greater depth of vertical data integration, down to the level of individual cavities. authentig creates transparency, for example to optimise the utilisation of a machine pool's total capacity, or to correlate key productivity indicators with economic objectives.

The MES has a modular structure and can be precisely adapted to the individual requirements of the processor. "Energy" is the most recent of the authentig modules. Not only does it make the energy consumption of individual consumers in the injection moulding operation transparent, but it also reliably caps peaks in the power demand. This is made possible by defining situational consumption limits for each individual consumer, and then dynamically allocating the pre-defined power amounts to the consumers. This intelligent hall management can help to significantly reduce the energy costs for the machine pool.

Less weight, better component properties
MuCell injection foam moulding will be the main focus of the automotive exhibition area at the ENGEL booth. "MuCell offers the opportunity of combining resource-efficient lightweight design with a high degree of cost efficiency and excellent component properties," emphasises Jungwirth. "This combination means that the process is continuing to rapidly gain significance." During the trade fair, ENGEL will produce passenger car cooling radiator components on an ENGEL duo 2460/500 injection moulding machine using the MuCell process.

During physical foaming, nitrogen is injected into the plastic melt as a propellant and homogeneously distributed. Following the injection into the form, the gas separates from the melt again, forming a fine-cell foam structure. In comparison to the standard injection moulding process, this method reduces the raw material consumption and the weight of the component. At the same time, MuCell-produced components do not display any distortion or shrinkage.

MuCell is a brand of the Trexel company, based in Wilmington, MA, USA. As a systems provider, ENGEL imports MuCell systems for its customers, also managing the integration of the controls and safety measures into the injection moulding machine, making it particularly easy to implement the technology.

Tie-bar-less for consistently high quality
Burr-free, zero-waste, rework-free, and fully automated – these are the key elements in the economic injection moulding manufacturing of sophisticated components from liquid silicone. At the Plastimagen, ENGEL will demonstrate how this can be put into practice by manufacturing coasters in a 4-cavity mould on a hydraulic victory 200/120 injection moulding machine. Due to its tie-bar-less clamping unit, the victory provides advantages for many liquid silicone applications. For example, the patented Force-Divider allows the moving mould mounting platen to follow the mould precisely while clamping force is building up, and ensures that the clamping force is evenly distributed across the platen face. This allows both the outer and inner cavities to be kept closed with exactly the same force, ensuring consistent compression of the mould and a consistently high product quality.

Further advantages of the barrier-free clamping unit are fast changes to the mould set-up, optimal automation concepts and particularly compact production cells. Without any tie-bars in the way, the mould mounting platens can be utilised fully, right up to the edge of the platen, so that even large and bulky moulds can be fitted on comparatively small injection moulding machines. This reduces the system footprint, for example, in the case of multi-component applications or multi-cavity moulds.

ENGEL at Plastimagen 2017: Hall D, Booth 514
(Engel Austria GmbH)

Newsgrafik #33035
 19.09.2017

Bringing process monitoring to the next level  (Company news)

Cyclically determined performance indicators are used to monitor and optimise injection moulding processes. In the past, the focus was on axle movements and the forces and times that these required. Today, iQ weight monitor goes one big step further. ENGEL's monitoring software generates performance indicators that provide direct information on the component quality to be expected. As of Fakuma 2017, iQ weight monitor will be one of the standard features on all ENGEL injection moulding machines.

Photo: The respectively current performance indicators are clearly presented on the display of the CC300 control of the injection moulding machine. Traffic light colours indicate which values are within and which are outside of tolerance.

In the development of iQ weight monitor, ENGEL's particular focus was on the filling of cavities. For the screw movement in the speed-regulated filling phase, the machine operator enters a starting position, a speed profile and a switchover point as target values. The machine control uses these to calculate a target value specification, which the injection regulator then fulfils as best as possible. In addition to the speed, the resulting injection pressure curve depends on the amount of melt in the screw vestibule, the flow properties of the material and the flow resistance along the jet, hot runner and cavity. Due to the many influencing factors, the injection pressure curve is characteristic to the respective application – and therefore unique. Fluctuations in one or several influencing factors that occur in practice affect the part quality as well as the pressure curve. Therefore, the pressure-time curve is suitable as an indirect quality monitor.

Meaningful performance indicators

iQ weight monitor provides three performance indicators for each shot: the injection volume, the change in viscosity of the melt and the congruence between the pressure curve and the reference curve.

Since it is directly connected to the actual shot weight, injection volume is the key performance indicator. It takes into account that differences in the closing behaviour of the non-return valve result in more or less material being conveyed into the cavity.

Change in viscosity, the second performance indicator, is meaningful because the viscosity determines the flow capacity of the melt, which in turn determines the injection volume. Viscosity changes can result from, for example, fluctuations in the batches of material, the percentage of recycled material content, the moisture content or changes in temperature.

Thirdly, the congruence of the pressure curve provides valuable indications of the existence of other disrupting factors during injection moulding. For example, an extremely fluctuating value may indicate that the process is poorly adjusted or that a cold plug has formed in the nozzle.

Small effort, huge benefit

At the Fakuma 2017, from October 17 to 21 in Friedrichshafen, Germany, ENGEL will demonstrate how easy it is to fully utilise the potential of iQ weight monitor. At first, the operator optimises the process to the desired component quality as usual, and then starts the reference measurement with the push of a button. During the running process, the continuously calculated performance indicators can be monitored directly on the display of the CC300 control of the injection moulding, or, independent of location, through an MES.

As iQ weight monitor already calculates the performance indicators in the course of injection, in case of deviation from the target values the system provides the opportunity to make corrections within the same cycle, thus proactively preventing rejects. ENGEL has also developed a software for this in-line regulation. iQ weight control adjusts the switchover point and the holding pressure profile to the respective state in each cycle, thus maintaining a consistent injection volume.

How well iQ weight control can improve reproducibility depends on several factors. Naturally, processes that are already very stable in and of themselves can only be optimised to a lesser extent. In order to evaluate the additional effect that iQ weight control may have, iQ weight monitor provides the injection moulder with a very smart feature: it calculates the improvement potential achievable through iQ weight control.

ENGEL at Fakuma 2017 Hall A5, booth 5204
(Engel Austria GmbH)

Newsgrafik #33044
 15.09.2017

ENGEL at T-Plas 2017 in Bangkok  (Company news)

Low costs per unit and high quality – the packaging industry has particularly high demands and must also adapt flexibly to the various requirements of the individual national markets. With the help of tailored system solutions, ENGEL supports its customers in mastering these challenges and securing competitive advantages. At the T-Plas 2017, September 20 to 23 in Bangkok, Thailand, the Austria-based injection moulding machine builder and systems solution provider will demonstrate what this can look like in practice. One important building block in achieving high efficiency is the digitalisation and networking of production processes, for which ENGEL already has several mature solutions to offer.

Photo: Thanks to in-mould-labelling technology, food containers come out of the ENGEL e-mac 180 injection moulding machine ready-to-fill.

"The packaging industry is one of the especially fast-growing sectors in South East Asia, and is one of the innovation drivers at the same time", states Romain Reyre, President South East Asia for ENGEL. "There is hardly another sector in which the per unit cost is under higher pressure than in the packaging industry." Competitive production is only possible when the highest throughputs, a stable process and a high degree of process integration come together. To allow, for example, ready-to-fill food containers to come directly out of the injection moulding machine, an increasing number of processors are turning to in-mould labelling technology (IML). IML makes high-quality decoration economical and also allows for the efficient production of smaller batch sizes. In order to take full advantage of the efficiency potential of IML integration, the injection moulding machine, the mould and the handling of the labels and finished products must be perfectly coordinated with each other. To this end, ENGEL has developed a worldwide network of partner companies.

For the production of oval bowls – used, for example, for convenience meals –, the e-mac 440/180 injection moulding machine presented at the T-Plas works with Asian partners who are also well familiar with the requirements of local producers and translate these into optimally tailored solutions. The 4-cavity mould comes from CNN Plastic System, based in New Taipei City, Taiwan. The IML-automation is implemented by JET Engine Automation – also based in New Taipei City. "The collaboration with local partners makes it possible for us to guarantee high cost-efficiency for our customers, even for very sophisticated, innovative technologies, and to also keep the delivery times for the complete production cell short," emphasises Reyre.

High productivity requires a reliable and high-performing injection moulding machine. The all-electric e-mac is exclusively equipped with especially powerful servo drives. Ejection and pressing is also handled servo-electrically. This guarantees the best possible precision and process stability while maximising the effectiveness of the machine as a whole. The highly energy-efficient machine ensures a stable production, even at continuous, round-the-clock operation.

Self-optimising injection moulding machine
With the CC300 control, the e-mac provides full flexibility for the integration of robots and other peripherals, as well as the use of intelligent assistance systems from the inject 4.0 programme of ENGEL.

inject 4.0 – this is the response of ENGEL to the challenges of the fourth industrial revolution, for which the name Industry 4.0 has become established. The goal is a smart factory in which production processes continuously self-optimise through the networking of production systems, the systematic use of machine, process and production data, and the utilisation of intelligent assistance systems. Producers can thus increase the productivity and quality of their production and respond very flexibly to ever more rapidly changing requirements.

ENGEL already offers an entire range of mature products for digitalisation and networking that have been proven in practice again and again, and is continuously expanding its line-up. The modularity of the inject 4.0 approach makes it especially easy for plastics processors to take advantage of the opportunities offered by Industry 4.0. Even small isolated solutions provide huge benefits.

In Bangkok, the e-mac injection moulding machine makes this impressively clear. Equipped with the iQ weight control system, it detects fluctuations in the environmental conditions and in the raw material, and automatically compensates for these shot by shot. Throughout the entire process, it maintains a consistent melt volume, thereby preventing the production of rejects.

ENGEL is presenting two more assistance systems in Bangkok: iQ clamp control and iQ flow control. While iQ clamp control calculates the mould breathing in order to determine the optimal clamping force and automatically adjust it, iQ flow control optimises the mould temperature control. To achieve this, the software connects the electronic temperature control water manifold e-flomo with the temperature control unit, and is thereby able to continuously adjust the pump speed to the actual requirement. This results in even higher energy efficiency.

Minimising downtime
In order to increase the availability of machines and productions cells, inject 4.0 relies on online support, remote maintenance, and predictive, condition-based maintenance. e connect.24 is the online support and remote maintenance tool through which ENGEL customers can send an emergency call for help to their machine builder partner at any time of the day or night. Via a remote connection, the ENGEL specialists immediately begin to look for the cause. In many cases, they can help directly over the internet, saving the processor a time-intensive and possibly expensive on-site visit by a service-technician. In this way, down times are minimised.

With e-connect.monitor, ENGEL even makes it possible to inspect the condition of process-critical components such as plasticising screws during operation and to establish a reliable prognosis of their remaining useful life. With this condition-based, predictive maintenance, the useful life of machine components can be fully utilised without entailing the risk of unplanned system downtime.

Capacity increased for South East Asia
In order to be able to fulfil the specific requirements of plastics processors in the extremely dynamic developing markets of South East Asia in an even more targeted fashion, in the autumn of last year ENGEL further developed its sales structure in South East Asia. The responsibility for the individual subsidiaries and representative offices was combined, and Romain Reyre was appointed as President South East Asia. At the same time, the service team was reinforced and a regional hub for the supply of spare parts was opened. For the first time, ENGEL South East Asia now has its own service manager with cross-national responsibility, who is based in Bangkok. "The new structure is showing results", reports Reyre. "Over the past months, we were able to further strengthen our position in South East Asia."

On the whole, ENGEL's growth in Asia is especially robust. Among other factors, the machine builder has the consistent investments into its regional sales and service subsidiaries and production plants to thank for this continued success. ENGEL is the only European injection moulding machine builder producing injection moulding machines at three locations in Asia – in China and Korea – and can therefore guarantee its customers short delivery times, fast service, and the flexible adjustment of products and system solutions to regional requirements. The e-mac injection moulding machine presented at the T-Plas was also produced in Asia, at the plant for small and medium-sized machines in Pyungtaek City, Korea.

Since it was founded in 1945, ENGEL has been 100 percent family-owned and independent of external investors, thus guaranteeing both customers and employees stability and a long-term perspective. In the 2016/2017 financial year, ENGEL achieved sales of more than 1.36 bn Euros. ENGEL employs more than 6,000 people worldwide.

ENGEL at T-Plas 2017: Hall 102, booth T01
(Engel Austria GmbH)

Newsgrafik #32962
 05.09.2017

Interplas 2017: Smart solutions for more productivity, quality and flexibility  (Company news)

Picture: The assistance systems from ENGEL's inject 4.0 programme that are integrated into the CC300 of the injection moulding machine ensure that process fluctuations are adjusted before rejects occur

Experience the smart factory – this is ENGEL's focus at the Interplas 2017, from September 26 to September 28 in Birmingham, United Kingdom. At its trade-fair booth, the injection moulding machine builder and system expert, headquartered in Schwertberg, Austria, will demonstrate the opportunities created by digitalisation and networking, and how inject 4.0 can help to take advantage of these in a simple fashion. From the perspective of technologies, the focus of ENGEL will be on the highly precise processing of LSR and extremely economic process integration.

inject 4.0 is ENGEL's answer to the challenges of the fourth industrial revolution. The goal is the smart factory in which production processes continuously self-optimise through the networking of production systems, the systematic use of machine, process and production data, and the utilization of decentralised, intelligent assistance systems. During the three days of the trade fair, ENGEL will demonstrate how plastics processors can increase the productivity and quality of their production and respond flexibly to ever more rapidly changing requirements with the production of inject 4.0 logos on an all-electric and tie-bar-less ENGEL e motion 170/80 TL injection moulding machine.

Self-optimising injection moulding process
The CC300 control is capable of simulating process fluctuations; the automatic readjustments by the intelligent assistance systems can then be tracked on the display of the machine. Three assistance systems from the inject 4.0 programme of ENGEL will be used. While iQ weight control maintains consistent injected melt volume throughout the entire injection moulding process, iQ clamp control monitors the mould breathing in order to calculate and automatically adjust the optimal clamping force. Thirdly, iQ flow control will connect the injection moulding machine, which is equipped with the e-flomo electronic temperature control water distributor, to the temperature control unit, enabling the pump speed to automatically adjust to the actual requirement. This results in higher energy efficiency. ENGEL, together with its partner HB-Therm, has developed a new line of temperature control units called e-temp. The machine is connected via OPC UA, thus pointing the way for further applications. Together with its market partners, ENGEL is actively committed to establishing OPC UA as the standard for communication models in injection moulding applications. OPC UA enables platform-independent, high-performance, and above all secures communication, both within the shop-floor level and with higher level control systems such as MES and ERP.

Hydraulic precision for sophisticated LSR
Burr-free, zero-waste, rework-free, and fully automated – these are the key elements in the economic manufacturing of high-tech products from liquid silicone. At the Interplas, ENGEL will demonstrate how this can be put into practice with the production of venting valves for beverage bottles on a hydraulic ENGEL victory 860/160 injection moulding machine. This application optimally utilises the efficiency potential of the tie-bar-less machine. For example, the patented Force-Divider allows the moving mould mounting platen to follow the mould precisely while clamping force is building up, and ensures that the clamping force is evenly distributed across the platen face. This allows both the outer and inner cavities to be kept closed with exactly the same force, ensuring consistent compression of the mould and a consistently high product quality. iQ weight control provides a further contribution to high process consistency and reproducibility. Initially, the software was only available for injection moulding machines with electrical injection units; ENGEL has expanded the area of application with a version for hydraulic machines.

ENGEL is presenting the processing of LSR together with its partner Elmet Elastomere Produktions- und Dienstleistungs GmbH (Oftering, Austria). In this application, Elmet is providing a model TOP 5000 P LSR dosage system, a 16-cavity mould with a cold runner and a demoulding unit. Parts are handled by a viper 40 robot from ENGEL's linear robot programme. The conveyor belt is integrated into the safety gate of the injection moulding machine, keeping the entire system compact.

One-shot process reduces costs per unit
The healthcare application presented at Interplas also impresses with an extremely high degree of integration. Interdental brushes of the type "scrub!" will be produced on a clean-room version of the all-electric ENGEL e-motion 170/110 T injection moulding machine. Together with the grip surface and core, up to 500 bristles can be formed in a single-component injection mould. Extremely delicate in the bristle area, the high-performance precision 8-cavity mould comes from Hack Formenbau (Kirchheim unter Teck, Germany), with Hekuma from Eching, Germany, providing the automation. A highly integrated, automated production cell, built in the modularised HEKUflex design, will be presented by Hekuma. Immediately after injection moulding, the parts will be inspected by camera and the usable parts will be automatically packed in retail bags, 16 parts to each. A bag leaves the production cell every four seconds.

The high degree of process integration and the single-component design of the interdental brush, developed by pheneo in Bremen, Germany, significantly increases production efficiency in comparison to the products and processes established on the market. Interdental brushes are generally made up of three components, which are usually produced in separate processes: The grip surface, a wire-mesh, and the filaments. However, the technology of the system partners ENGEL, Hack and Hekuma has made single-component injection moulding production possible.

With a total shot weight of only 1.93 grammes, completely filling eight cavities with up to 500 bristles places extremely high demands on the mould as well as the injection moulding machine. The all-electric drive technology ensures the highest precision in machine movements. In addition, iQ weight control and iQ clamp control help to prevent rejects.

The application potential of the integrated process is huge. It ranges from medical applications to cosmetics. For example, besides interdental brushes, mascara brushes are needed in very large quantities and at low unit costs.

All-electric for maximum performance
At the Interplas, the booth next to ENGEL (Booth H71) is also dedicated to the very highest performance. Campetella from Montecassiano in Italy is presenting a highly integrated production cell for the manufacturing of thin-walled containers, including in-mould labelling. The cups will be injected in a 2-cavity mould on an all-electric ENGEL e-motion 440/160 T injection moulding machine. On the basis of this application, Campetella presents a side-entry automation of the MINI MODULA series. The entire system operates with a cycle time of 2.8 seconds and accordingly produces 2,571 cups per hour.
ENGEL at Interplas 2017: Hall 4, stands F70 and G70
(Engel Austria GmbH)

Newsgrafik #32950
 04.09.2017

Industry Competence in Action  (Company news)

At the Fakuma 2017 from October 17 - October 21 in Friedrichshafen, Germany, ENGEL will be opening up new horizons for the injection moulding industry. The highly integrated manufacturing solutions at the ENGEL exhibition booth in Hall A5 achieve an even higher degree of quality, efficiency and profitability – respectively tailored to the specific requirements of the various application industries. Also there: the all-electric e-mac injection moulding machine in a new clamping force class, the first clearmelt exterior component, the new compact pipe distributor for the cleanroom, and an even higher degree of precision for LSR processing.

Photo: On an ENGEL victory 860/160, ENGEL will produce venting valves for beverage bottles during the Fakuma.

Automotive: Extremely scratch-proof in a single step
At the Fakuma, ENGEL and its clearmelt technology will be opening the door to a new application area. The focus so far has been on decorative elements and electronic functional components for the interior of the vehicle; at this time, automobile manufacturers are also becoming interested in using the technology to produce exterior components. At its exhibition booth, ENGEL will present a first applications in this regard.

High gloss exterior panels will be produced on an ENGEL duo 2460/500 injection moulding machine. In addition to the extremely high quality appearance of the components and the outstanding efficiency of the highly integrated process, extremely scratch-proof surfaces are another advantage that clearmelt technology provides for the exterior area. Testing in a car wash has shown the initial sample parts to be very robust.

In the clearmelt process, at first a thermoplastic base carrier is produced in the injection moulding machine, then coated with polyurethane in a second cavity. The process can be easily combined with IML, allowing for the use of decorative and capacitive foils as well as wood veneers. In a single step, clearmelt technology thus provides pre-finished vehicle components that do not need to be varnished or post-processed in any way. The polyurethane coating provides the high-gloss, scratch-proof surface.

ENGEL developed the clearmelt technology in collaboration with partner companies. The exclusive partner for polyurethane processing is Hennecke in St. Augustin, Germany.

Teletronics: Economic precision for even larger moulds
ENGEL will be going all-electric at the Fakuma in the teletronics exhibition area. Sophisticated connector housings for vehicle doors will be produced on an ENGEL e-mac 940/280. Until now, the e-mac series has been available with clamping forces of up to 1800 kN. In time for the Fakuma, ENGEL has expanded the line with a 2800 kN version.

e-mac machines are distinguished by their speed and precision, extremely energy efficient operation and a high degree of flexibility. They have proven themselves to be extremely reliable in continuous operation, and guarantee stable production around the clock. They are also less expensive to purchase than all-electric high-performance machines. This spectrum of characteristics predestines the series for the production of technical parts and electronic components. In both application areas, the trend is moving towards larger moulds with higher cavitation. With the expansion of the series, ENGEL has taken this trend into account.

With the production of 40-pole connector housings made of glass-fibre reinforced PBT, during the exhibition ENGEL will demonstrate how highest demands on precision can be combined with economic efficiency. In this market segment, due to the very filigree structure inside the connector housing, the competitiveness of the producer is defined by the precision of the injection moulding process. In several sequential process steps, the connector housings are equipped with stabiliser inserts, gaskets and contacts, then laser inscribed. Imprecisely injected areas or warping will impede the automated assembly and may lead to a halt in production. Since injection errors often are not detected until the end of the process chain, rejects also become more costly. To prevent this, the e-mac machine makes sure that very thin-walled areas are filled, even across long flow paths.

With the intelligent assistance systems from ENGEL's inject 4.0 programme, the already very reliable e-mac machines are also perfectly equipped for process fluctuations through external influences. Three iQ products are installed on the exhibition machine: iQ weight control, which maintains constant melt volume and adjusts fluctuations in the environmental conditions and the raw material, iQ clamp control, which continuously adjusts clamping force based on the mould breathing, and the new iQ flow control for the needs-based regulation of the temperature control units. iQ weight control was the first of the iQ systems, and was introduced to the market five years ago. It has already become very well-established in the production of connectors, because in this segment with its especially filigree component structures, process fluctuations are one of the main causes of rejects. iQ weight control is a reliable aid in preventing production-related rejects.

Medical: Maximum integration with a minimal footprint
Highly integrated, compact production cells minimise the system footprint and increase area productivity. These aspects really pay off in the cleanroom. For this reason, ENGEL redeveloped the stainless steel pipe distributor for the cavity specific handling of small injection moulding parts, which it introduced two years ago, so that the handling system now fits completely into the expanded safety gate of the injection moulding machine. This new, extremely compact solution will be presented for the first time at the Fakuma.

During the five days of the fair, an ENGEL e-victory170/80 injection moulding machine will be producing needle holders for 1-ml safety syringes in a 16-cavity mould by Fostag Formenbau (Stein am Rhein, Switzerland). An ENGEL viper 12 linear robot will remove the filigree polystyrene parts from the mould and transfer them to the distribution system. In order to ensure batch traceability down to the level of individual cavities, the injection moulded parts will be packed in cavity-specific bags. For this purpose, 16 bags are hung in a cart located directly beneath the pipe distributor. Individual shots can be extracted for quality control purposes.

For unmanned cleanroom operation – during the night-shift, for example – two carts can be alternated in sequence, with a buffering system enabling the fully automated switch. The entire periphery for this is integrated into the CC300 control unit of the injection moulding machine. Thanks to shared data storage, the CC300 can precisely coordinate the movements of the machine and the robot with each other, thus optimising overall efficiency. In addition to this, there are also especially short robot paths due to the tie-bar-less clamping unit of the e-victory machine. In this application, both of these factors contribute to the short cycle times of six seconds.

So that the machine can also be flexibly used for other products, ENGEL designed the pipe distributor and the bag-packing cart as a fixed unit. This can be easily moved back and forth, ensuring full accessibility of the mould area.

With a shot weight of only 0.08 g and varying wall thicknesses, the filigree needle holders require extremely precise process control. Since fluctuations in the melt volume would immediately lead to rejects, ENGEL uses the iQ weight control software.

At the Fakuma, the highly integrated production solution is presented in its cleanroom version. In contrast to many other systems in the market, all components in contact with the product in ENGEL's pipe distributor are made of stainless steel, which helps to maintain low particle load. As a system provider, ENGEL is continually expanding its portfolio of GMP-compliant peripherals. In addition to the pipe distributors, conveyor belts and robot gripper housings from ENGEL's own development and production are offered.

Technical Moulding: Hydraulic precision for sophisticated LSR
The processing of liquid silicone (LSR) in injection moulding fully utilises the efficiency potential of the tie-bar-less ENGEL victory machines. The process consistency resulting from the design plays an important part in this. The patented force divider enables the moving mould mounting platen to follow the mould exactly while clamping force is building up, and ensures that the clamping force is evenly distributed across the platen face. Both the outer and inner cavities are therefore kept closed with exactly the same force, ensuring consistent compression of the mould and a consistently high product quality. This almost burr-free, zero-waste, rework-free, and fully automatic processing is the key element in the economic manufacturing of high-tech products from liquid silicone. At the Fakuma, with the production of venting valves for beverage bottles on an ENGEL victory 860/160 injection moulding machine, ENGEL will demonstrate how this can look in practice. With a diameter of approx. 50 mm, the venting valves have a geometrically complex structure with varying wall thicknesses. The iQ weight control software, which ENGEL is now offering also for injection moulding machines with hydraulic injection units, ensures that cavities are filled reliably even when there are fluctuations in the raw material.

It will be the first time that ENGEL presents a victory machine with a next generation injection unit at a trade fair. Last autumn, based on its long years of experience in the various application areas of its injection moulding machines, ENGEL reorganised the sizes of the hydraulic injection units and further optimised the performance specifications such as injection pressure, injection speed, and plasticising capacity.

ENGEL is presenting the processing of LSR together with its partner Elmet Elastomere Produktions- und Dienstleistungs GmbH (Oftering, Austria). In this application, Elmet is providing the model OP 5000P LSR dosage system, a 16-cavity mould with a cold runner and demoulding unit. Parts are handled by a viper 40 robot from ENGEL's linear robot programme. The conveyor belt is integrated into the safety gate of the injection moulding machine, keeping the entire system at a compact size.

Focused 100 percent on the requirements of the industry
From the individual injection moulding machine to the highly integrated production cell, ENGEL delivers tailored solutions for the injection moulding industry. Developing customer-specific solutions takes more than technological know-how. This is why at ENGEL, business units are completely focused on a single industry. ENGEL employees are therefore on the same level with customers when discussing projects, able to understand and implement individual requests in detail. Many industry specific developments, such as the GMP-capable periphery devices being presented at Fakuma, are based on the bundled experience of the ENGEL business units.

ENGEL at Fakuma 2017 Hall: A5, stand 5204
(Engel Austria GmbH)

Newsgrafik #32953
 31.08.2017

Drinktec 2017: Production efficiency at its peak  (drinktec 2017)

At Drinktec 2017, the world's leading trade fair for the beverage and liquid food industry, ENGEL will set a new standard of efficiency in the highly integrated production of beverage caps from September 11 to 15 in Munich, Germany. In collaboration with partner companies, the injection moulding machine manufacturer and systems provider based in Schwertberg, Austria, will present a complete system solution.

Photo: Maximum output with minimal energy consumption: During Drinktec 2017, a fully automated e-cap injection moulding machine, equipped with a 96-cavity mould, will be producing 26-mm caps including tamper-proof bands at a cycle time of under 2.5 seconds.

During the five days of the fair, under actual production conditions and at a cycle time of under 2.5 seconds, the production cell will deliver 26-mm caps made of HDPE and including tamper-proof bands. The system scores with outstanding energy efficiency and highest degree of process consistency. At the core of the highly integrated solution is an ENGEL e-cap 2440/380 injection moulding machine with a clamping force of 3800 kN. A 96-cavity mould by Corvaglia from Eschlikon in Switzerland will be used. ENGEL has integrated additional peripherals into the system including a DMS dry-air system by Blue Air Systems (Kundl, Austria), a TWIN model cap inspection system by IMDvista (Brügg, Switzerland), and material handling units by Piovan (S. Maria di Sala VE, Italy). The hot-runner temperature control is made by S.i.S.e. (Oyonnax, France), and partners for the raw materials are Borealis, (Vienna, Austria) and Gabriel Chemicals (Gumpoldskirchen, Austria).

All-electric e-cap for the highest precision and process consistency
"In terms of geometry, beverage caps have reached their lightweighting minimum. This means that the demands on the precision and repeatability of injection moulding machines are higher than ever before", says Frank Schuster, Sales Director of ENGEL packaging, describing a trend that is often decisive in the design of injection moulding machines and production cells for cap production. In addition, the sensitivity of producers to energy efficiency continues to increase. In order to meet both challenges, ENGEL is focusing on all-electric high performance machines for cap production. With clamping forces of 1,100 to 4,200 kN, the ENGEL e-cap series was developed specifically for this market segment.

Among other things, the high-performance servo direct drives are responsible for the outstanding process stability and precision of the e-cap injection moulding machines. They ensure the required plasticising capacity and a maximum of usable parts even when using the new high-strength HDPE materials with a MFI significantly lower than 2 or even 1 g/10 min. In addition, the increased ejection and clamping forces help to achieve very short cycle times. In spite of its impressive performance, the e-cap requires very little energy and cooling water, even at constant high-speed.

Everything from a single source for faster project planning
As a complete system, the production cell represents the state-of-the-art in highly efficient cap production. Both Blue Air Systems and IMDvista will be presenting their latest innovations at the ENGEL booth. The DMS series devices by Blue Air Systems allow for higher product quality and energy savings of up to 85 percent as compared to conventional mould dehumidifiers. What makes this series special is that it works without water. Without pre-cooling, it guarantees condensation-free production conditions regardless of the weather and the climate zone.

With its TWIN flying closure system, IMDvista has solved one of the biggest challenges in the inline-inspection of beverage caps. Usually, the freshly produced caps undergo camera inspection while lying on a conveyor belt. This means that the top side of the caps cannot be viewed by the cameras. With the new technology, caps are lifted by a stream of air, and can thus be inspected from above and below without extending processing time.

From a single source, ENGEL delivers highly integrated and automated system solutions for the production of bottle caps worldwide. This results in several advantages for the producer. For one thing, efficiency and quality potentials can only be fully utilised when the individual components of the production cell have been precisely synchronised from the start. Apart from that, the systems solution accelerates project planning and commissioning due to the fact that the producer does not need to coordinate various suppliers.

inject 4.0 for even higher efficiency and quality
In addition to the injection moulding machine, automation, peripherals, and mould, software products for digitalisation and networking are more and more often part of the package. "Industry 4.0 is opening up huge opportunities for even higher efficiency and quality", clarifies Schuster. "We support our customers in realising this potential."

Under the inject 4.0 name, ENGEL offers a comprehensive range of products and solutions for the three areas of the smart factory. The first products entered the market many years ago and have become well-established worldwide. ENGEL is consistently developing the inject 4.0 programme and will clearly demonstrate its new opportunities and possibilities at the Drinktec 2017. Among other things, the focus will be on MES authentig.

In order to be able to monitor and analyse the current condition of individual machines from a central computer, including their utilisation and output, all the production units are interconnected through the Manufacturing Execution System. Transferred in real-time, their data can be correlated to both quality and business performance indicators, and analysed in various ways. Tailored to the specific requirements of the injection moulding industry, authentig achieves particularly deep vertical data integration, down to the level of individual cavities.

authentig was developed by T.I.G. Gesellschaft für Informationssysteme GmbH, which has now been part of the ENGEL Group for a year. With the integration of T.I.G. into the ENGEL Group, the companies have combined their MES know-how and their many years of experience with MES projects worldwide, thereby achieving innovation at an even higher pace.

ENGEL at Drinktec 2017: Hall A4, booth 324
(Engel Austria GmbH)

Newsgrafik #32677
 02.06.2017

ENGEL grows worldwide  (Company news)

ENGEL continues to grow. The Austrian injection moulding machine manufacturer, automation expert and systems supplier has increased its annual revenues for the third time in a row. The group of companies closed fiscal 2016/2017 at the end of March with sales of 1.36 billion euros, 8.6 percent up on the previ-ous year. It started the new business year 2017/2018 with a workforce of 5,900 – another new record.

Photo: “Asia developed faster than average in fiscal 2016/2017,” says Dr Christoph Steger, Chief Sales Of-ficer of the ENGEL Group.

“The markets in Asia have played a big role in the success of the ENGEL Group,” say the directors of ENGEL at the start of the Chinaplas 2017 trade fair, where ENGEL traditionally announces its annual results. “Asia grew faster than average in the last fiscal year, primarily due to China. On top of this, we are benefiting from the strong momentum in Southeast Asia,” says Chief Sales Officer Dr. Christoph Steger in Guangzhou. At the same time, growth in Europe continues unchecked and demand in North America increases further. The directors of the ENGEL Group expect further growth in the new business year, albeit at a somewhat lower level than in the recent past.

Main growth driver: customised solutions
ENGEL delivers both individual injection moulding machines as well as integrated turnkey solutions worldwide, the latter accounting more and more for incoming orders around the globe. “Customised solutions are currently our main driving force for growth,” says Steger. “Here, too, Asia, and China in particular, grow at above-average rates.” Apart from injection moulding machines, robots and other automation solutions, the system solutions tailor-made to meet the requirements of the respective applications include process technologies, periph-eral systems, moulds as well as software solutions for digitalisation and networking. ENGEL unlocks the potentials for efficiency and quality particularly well by adapting all components in the manufacturing cell to each other exactly right from the start, thereby strengthening the competitiveness of its customers.

Increased industry expertise in America and Asia
The development of customised injection moulding solutions necessitates not only especially deep technological know-how, but also an understanding of the particular industry, which ENGEL ensures with its business unit structure. At its headquarters in Austria, ENGEL main-tains separate teams dedicated wholly to the requirements of the automotive, technical moulding, teletronics, packaging and medical industries respectively.

More than two years ago, ENGEL also started to entrench industry-specific know-how locally at its customers’. In a first step, unit managers were appointed in North America for the five business units, and at present ENGEL is introducing a business unit structure in Asia. “We will then also have industry know-how available to us for Asia at our site in Shanghai, thereby enabling us to grow our market position in the five business units further,” says Gero Willmeroth, Sales and Service President at ENGEL Machinery Shanghai. “This is an im-portant step in our efforts to strengthen our technological expertise here in Asia.” “The global trends in manufacturing and increasing process integration or Industry 4.0 mean that we work ever-more intensively with our customers over the complete lifecycle of the machines and manufacturing cells,” Christoph Steger underlines. “More and more, we are becoming part-ners in the endeavour of continuous process optimisation. We are implementing our new structures to meet the needs of this development.”

Remote maintenance and condition-based predictive maintenance are just two of the possibil-ities leading to closer cooperation in after-sales. At Chinaplas, ENGEL presents both its estab-lished as well as new innovative smart service solutions. “Industry 4.0 is rapidly gaining im-portance here in China,” says Willmeroth. “The major international players have been tackling this issue for a long time and have first successes to show. Many other companies still find it difficult to deal with digitalisation and networking. This is where we see our role to support our customers with their very special problems to enable them to make full use of the fourth in-dustrial revolution and to accompany them on their road to becoming smart factories.” ENGEL has fully developed products that have proven themselves time and again around the world for all three parts of the smart factory – smart machine, smart production and smart service – thereby enabling it to fall back on vast experience in this field.

Bigger service teams
ENGEL is changing its organisational structure and hiring new staff worldwide not only in its sales department, but also in service. It appointed a service manager for Southeast Asia for the first time as of 1 April. Dave Lock comes from Great Britain, has lived in Thailand for five years and has a wealth of experience in production in both Asia as well as Central America and Europe to contribute to his new role. He will henceforth coordinate the service teams in the various countries of Southeast Asia and remain in constant contact with headquarters in Austria.

ENGEL has realigned itself completely in Southeast Asia and established a regional hub in Bangkok to this end. “The new structure has already produced successes,” says Steger. “We have been able to strengthen our position in Southeast Asia further in the last months.” One important task of the hub is to supply customers with spare parts. The new spare-parts store started work in May. “We now have spare parts worth 8 million euros in stock on site in Southeast Asia,” says Steger. “We can deliver stock parts to the important industrial centres of the ASEAN region within 24 hours.” In the past, spare parts for Southeast Asia came main-ly from China. The new concept of a Free Trade Warehouse Zone (FTWZ) has eliminated trade barriers in operational business. In this way ENGEL will achieve significant time and cost benefits for its customers.

100 million euros annually for extension of plants
ENGEL is currently investing more than 100 million euros per year in the extension and mod-ernisation of its plants. One of its largest projects worldwide is the expansion of its headquar-ters in Schwertberg. Additional space of 10,000 square metres has been erected in the south-ern part of the premises. It includes offices, a childcare centre for the children of staff mem-bers and an even bigger and more modern apprenticeship workshop. In the next step, the production shop at the northern end of the factory site, built in 2013, will be expanded and a new customer technology centre built.

At the same time, the two large-scale machine plants in St. Valentin and Shanghai will be en-larged. “Building work in Shanghai progressed well over the winter,” says Willmeroth. “We plan to inaugurate the new production hall together with our customers and partners in Sep-tember.” This is already the second major expansion since ENGEL Machinery Shanghai was established exactly 10 years ago. A new apprenticeship workshop has also been built in Shanghai as part of the expansion project. At present, 45 apprentices are training there as CNC, mechatronic and plastics technicians.

Workforce to top 6,000 soon
ENGEL is counteracting the increasing lack of skilled labour worldwide effectively by training young people in technical jobs. Around 180 young men and women are currently in appren-ticeships in the company’s Austrian plants. In addition to this, ENGEL trains its own upcoming stock of skilled workers in China, the Czech Republic and Germany and is increasing its in-volvement in the advanced education and training of graduates with a special international sales trainee programme.

Towards the end of fiscal 2016/2017, ENGEL employed more than 5,900 personnel world-wide, more than ever before in the company’s history. The workforce has grown by 10 per-cent on average over the last three years. “We will pass the 6,000 mark in the first quarter of the new business year,” Christoph Steger announces. ENGEL is increasing its workforce to meet the needs from growing sales and changing requirements in the plastics industry. “In-dustry 4.0 means we will need more highly qualified personnel in future,” said Steger.
(Engel Austria GmbH)

Newsgrafik #32541
 08.05.2017

ENGEL AUSTRIA honoured for its loyalty to Upper Austria  (Company news)

ENGEL AUSTRIA has been given the gold Corona 2017 award. Conferred by the Federation of Austrian Industries in Upper Austria, the award is an acknowledgement of ENGEL's strong commitment to people at its headquarters in Upper Austria.

Photo: “We are delighted about the award and particularly pleased that our commitment is not only recognised and appreciated by our staff and customers, but also by the whole region,” says Joachim Metzmacher.

The Corona 2017 award was bestowed in two categories. ENGEL won first prize in the category Location. Explaining its decision, the jury says: “ENGEL has increased its workforce in Upper Austria by 16 per cent in two years and has invested a particularly large amount of money in the expansion and modernisation of its headquarters. It has therefore made a lasting contribution to strengthening Upper Austria as a business location."

"We are delighted about the award and particularly pleased that our commitment is not only recognised and appreciated by our staff and customers, but also by the whole region," says Joachim Metzmacher, Chief Production Officer at ENGEL, in accepting the prize on the company's behalf. "ENGEL's continuous growth is based on our innovative capacity and this is largely dependent on the general conditions in the region. Here in Upper Austria we benefit from a very good climate for innovation."

Headquarters in Schwertberg expanded significantly
ENGEL has invested 55 million euros in Upper Austria in the last three years. A new building offering a total of 10,000 square metres of additional space has been erected in the southern part of the headquarters in Schwertberg. Of these, more than 6,000 square metres are being used for new offices to strengthen the sales and service teams. The apprentice workshop have moved into the new building on about 1,300 square metres and equipped with new machines, while 300 square metres have been allocated to the day nursery. By having its own childcare centre, ENGEL is making it even easier for its staff to balance family and professional obligations.

Further building measures for the Schwertberg site are already being planned. The main priority here is to increase the assembly capacity. Among other things, the North Hall, which was built in 2013, will be expanded. A new customer technology centre is also being built at the headquarters.

“We are delighted about the award and particularly pleased that our commitment is not only recognised and appreciated by our staff and customers, but also by the whole region,” says Joachim Metzmacher.
(Engel Austria GmbH)

Newsgrafik #32578
 27.04.2017

ENGEL Group appoints new chief financial officer  (Company news)

The ENGEL Group, headquartered in Schwertberg, Austria, has appointed Markus Richter (photo) as chief financial officer with effect from May 1st, 2017. He succeeds Klaus Siegmund, who left ENGEL in March.

Markus Richter has more than 25 years of experience in commercial management roles in globally successful companies in the industrial, energy, transportation and personnel services sectors. As chief financial officer (CFO) at ENGEL, Markus Richter, who holds a master degree in commerce, will be responsible for the fields of finance, human resources and IT and will head the operational business of the group together with Dr. Stefan Engleder (CEO), Dr. Christoph Steger (CSO) and Joachim Metzmacher (CPO).

“We are pleased to have found in Mr. Richter an acknowledged expert in international finance who also has experience in human resources and global IT projects,” says Dr. Birgitte Engleder, Chairwoman of the Supervisory Board of the ENGEL Group.

The previous CFO Klaus Siegmund left the company in March in agreement with the supervisory board of the ENGEL Group. He was a member of the Board of Directors for two years, during which extensive investments were made in the expansion of sites and the workforce increased considerably worldwide. “Mr. Siegmund helped drive the expansion in our business with great dedication. We would like to thank him warmly for this,” says Dr. Engleder. “We wish Mr. Siegmund all the best for his professional and personal future.”
(Engel Austria GmbH)

Newsgrafik #32424
 02.03.2017

ENGEL at Koplas 2017  (Company news)

„Experience the smart factory“ – this is the theme of the Koplas 2017, which will take place from March 7 through March 11 in Goyang, South Korea. At the ENGEL AUSTRIA exhibition booth, visitors of the plastics trade fair can experience this theme in real time. The injection moulding machine builder and system expert, headquartered in Austria, will provide demonstrative examples of the opportunities created by digitalisation and networking, and how inject 4.0 can help to take advantage of these in a simple fashion.

Photo: Thanks to its lightweight construction swivel arm, the e-pic pick-and-place robot achieves high dynamics and requires very little space.

inject 4.0 – this is ENGEL's answer to the challenges of the fourth industrial revolution. The goal is a smart factory in which production processes continuously self-optimise through the networking of production systems, the systematic use of machine, process and production data, and the deployment of decentralised, intelligent assistance systems. Producers can thus increase the productivity and quality of their production and respond flexibly to ever faster changing requirements.

In all three areas of the smart factory – smart machine, smart service and smart production – ENGEL today already offers mature products and solutions that provide an immense benefit individually as well as in the context of an overall digital strategy.

Compensate for process fluctuations before they result in defects
In the factory of the future, the human/machine interface plays an even bigger part than today. With processes becoming more and more complex due to increasing integration and automation, steering and controlling them must become that much more simple and intuitive. Self-adapting, decentralised assistance systems increase process capacity and quality, without requiring the machine operator to acquire special expertise. During the five days of the exhibition, in order to clearly demonstrate the functionality of these smart-machine solutions, at its booth ENGEL will be producing inject 4.0 logos on an all-electric, tie-bar-less ENGEL emotion 80 TL injection moulding machine. The CC300 control is capable of simulating process fluctuations; the automatic readjustments by the intelligent assistance systems can then be tracked on the display of the machine. While iQ weight control maintains consistent injected melt volume throughout the entire injection moulding process, iQ clamp control monitors the mould breathing and continuously readjusts the clamping force. This way, fluctuations in the environmental conditions and in the raw material are automatically detected and compensated for within the same shot, before resulting in rejects.

iQ flow control, the third assistance system that is being presented at the Koplas, is based on e-flomo, the temperature control water manifold by ENGEL that monitors and documents all cooling and temperature control cycles of injection machines and independently regulates either the flow volume or the temperature difference. iQ flow control now connects e-flomo with the temperature control unit, thus the pump speed automatically adjusts to the actual need. This results in higher energy efficiency. ENGEL developed the integrated temperature control unit in cooperation with the Swiss temperature control unit manufacturer HB-Therm, and continues to strengthen its systems competency with the new e-temp line of temperature control units.

With its ENGEL e-motion 80 TL injection moulding machine and the integrated ENGEL e-pic robot, the production cell being presented at the Koplas also achieves high standards of efficiency and precision in terms of design. The e-motion TL series combines the benefits of ENGEL’s tie-bar-less technology, such as quick setup processes, efficient automation solutions and compact production cells, with all-electric drive technology. Thanks to these characteristics, the e-motion 80 TL is being preferentially deployed in the production of precision components and high-quality optical components in the electronics industry.

The innovative kinematics of the e-pic pick-and-place robot combines linear movements with a swivel arm, thus requiring very little space. The swivel arm is made of a thermoplastic composite material tailored to the specific requirements of lightweight construction, which additionally increases the energy efficiency and dynamics.

Machine and robot with a uniform control logic
ENGEL's second machine exhibit also emphasises the efficiency potential of tie-bar-less technology. On an ENGEL e-victory injection moulding machine, gear components made of TPE will be produced live at the exhibition. These sophisticated products require a high degree of precision, which the tie-bar-less hybrid machine ensures with its electric injection unit and outstanding platen parallelism. During the Koplas, the e-victory will also be working with integrated parts handling. An ENGEL viper linear robot will extract finished parts from the mould and place them on the conveyor belt. Since the RC300 robot control is designed as a subsystem of the CC300 control, the robot and the machine can be programmed and controlled through a uniform control logic. Furthermore, both systems access a common database, which reduces cycle time in many applications since the robot and the machine can precisely coordinate their motion sequences.

Keeping an eye on production
Besides the machine exhibits, visitors can dive even deeper into the subjects of automation and inject 4.0 at several Expert Corners in the ENGEL exhibition booth area. The areas of smart production and smart service have their own dedicated Expert Corners.

The smart production Expert Corner is focused on e-factory, ENGEL's MES (Manufacturing Execution System). Tailored to the specific requirements of the injection moulding industry, it achieves an especially great depth of vertical data integration, down to the level of individual cavities. e-factory creates transparency, for example to optimise the utilisation of a machine pool's total capacity, or to correlate key productivity indicators with economic objectives. It becomes especially interesting when e-factory not only connects the production cells of a single site, but creates an entire worldwide production network. This allows company headquarters to also optimise processes at other sites, and to provide support even to far-away colleagues. The MES has a modular design. The solution can thus be adapted precisely to the individual requirements of the producer, and can be flexibly expanded as needed.

Avoid unplanned system downtime
In order to increase the availability of machines and production cells, smart service relies on short paths, remote maintenance, and a view towards the future. The new ENGEL solution e‑connect.monitor thus makes it possible to analyse the condition of process critical machine components during operation, and to generate a reliable failure prognosis. This condition-based, predictive maintenance allows for the maximum use of critical machine components while still avoiding unplanned system downtime.

ENGEL at Koplas 2017: hall 5, booth P640
(Engel Austria GmbH)

Newsgrafik #32281
 03.02.2017

inject: the injection moulding forum, from March 7th to 8th in Schwertberg  (Company news)

inject, the injection moulding forum organised by ENGEL AUSTRIA, will take place for the second time on March 7th and 8th in Schwertberg, Austria. Following on from the highly successful premiere of the new forum series in the spring of 2016, the injection moulding machine manufacturer expects visitor numbers to be high. The aim of the event is to enable injection moulders to harness the latest research and development findings faster, and to promote the mutual exchange of experiences.

The two-day forum, which will be held in German, is aimed at injection moulders, plastics technicians, process optimisation specialists, quality managers, production managers and company directors. Many of those participants who attended last year have already registered for the follow-up event in early March. “Those who attended were struck by the many new ideas and tips they were able to take back to their businesses with a view to resolving specific challenges,” says Robert Brandstetter, head of ENGEL’s training department, referring to the highly positive feedback generated by inject 2016. “In 2017, we want to bridge the gap once again between basic development and practical, day-to-day challenges. It is precisely this aspect that sets inject apart from other forums in the sector.”

Food for thought, live demonstrations and space for networking
This year’s presentations and short contributions will focus on the design of injection moulding machines and moulds, process optimisation and production monitoring. The aim is to impart knowledge while providing food for thought and encouraging exchanges of experience. Developers and product managers from ENGEL will speak alongside experts from partner companies. Topics on the agenda will include:
-The selection of injection moulding machines and plasticizing units,
-Energy calculation tools,
-New possibilities for intelligent temperature control,
-Close-contour cooling,
-Hot runners,
-Intelligent assistance systems for more consistent processes and
-Condition monitoring.

Live demonstrations in the ENGEL technology centre will build directly on the presentation topics, illustrating the practical usages of the innovative products and technologies. For example, sample parts will be produced on an all-electric, tie-bar-less ENGEL e-motion 80 TL injection moulding machine to demonstrate how the potential of smart machines can be exploited. The machine’s CC300 control unit enables users to simulate fluctuating process conditions and track automatic readjustment by intelligent iQ systems.

The injection moulding forum will also provide ample opportunity for networking away from the live demonstrations, during breaks and at the evening function.

Access to knowledge ensures competitiveness
As it continues to invest heavily in research and development, ENGEL is setting its sights not only on application-based challenges, but also the fundamentals. “There is still significant room for improvement in the field of standard injection moulding technology. We are continually exploiting that potential through new developments and opening it up to injection moulding businesses,” emphasises Professor Georg Steinbichler, Senior Vice President of Technologies Research and Development at ENGEL AUSTRIA and Director of the Institute of Polymer Injection Moulding and Process Automation at Johannes Kepler University Linz. “For injection moulders, access to that knowledge is a key factor in securing competitiveness.”

"inject – the injection moulding forum" takes place on March 7th and 8th, 2017 at ENGEL's technology centre in Schwertberg, Austria. The event will be held in German and the attendance fee is EUR 490.
(Engel Austria GmbH)

Newsgrafik #32218
 03.01.2017

ENGEL at Interplastica 2017 in Moscow  (Company news)

Many different factors have an influence on unit costs, from the energy requirement and repeatability to space productivity. At Interplastica 2017, which takes place from January 24th to 27th in Moscow, ENGEL will be demonstrating how solutions precisely tailored to individual requirements can combine cost-efficiency with top quality. At its stand, the Austrian injection moulding machine manufacturer will also show how the new opportunities presented by digitalisation and networking can be utilised simply for practical situations through inject 4.0.

Photo: Free access to the mould area enables efficient automation solutions.

For everything from single injection moulding machines to integrated and fully automated manufacturing cells, ENGEL ranks as a preferred partner to the injection moulding industry in Russia. At Interplastica 2017, ENGEL will present a tie-bar-less ENGEL e-motion 170/80 TL, an injection moulding machine which guarantees very high overall efficiency, especially in the manufacture of precision parts. Design features and innovative products in ENGEL’s inject 4.0 range both serve to achieve this.

Efficient integration of handling robots
Large mould mounting surfaces and free access to the mould area enable fast set-up processes, efficient automation solutions and compact manufacturing cells. The e-motion TL draws together these advantages of ENGEL tie-bar-less technology with all-electric drive technology. The machine on the ENGEL stand at Interplastica will produce sample parts. An integrated ENGEL e-pic robot will remove the parts from the mould and place them on a conveyor belt. The innovative kinematic system of the pick-and-place robot combines linear movements with a jib arm, and thus requires minimal space. The jib arm comprises a composite material which additionally raises energy efficiency and dynamism.

Intelligent assistants for enhanced efficiency and quality
inject 4.0 is ENGEL's answer to the challenges of the Fourth Industrial Revolution. The aim is to bring about the smart factory, in which production processes continually self-optimise through the networking of production systems, the systematic usage of machine, process and production data and the deployment of decentralised, intelligent assistance systems. In this way processing firms can increase the productivity and quality of their production operations while responding to demands – which are changing ever more quickly – with maximum flexibility.

To identify and automatically compensate for fluctuations in environmental conditions and raw materials, for example, ENGEL will utilise three assistance systems at the Interplastica event: iQ weight control, iQ clamp control and iQ flow control. Visitors to the trade show will be able to track how rejects are thereby actively avoided on the live display of the CC300 control unit of the injection moulding machine.

While iQ weight control keeps the injected melt volume consistent throughout the injection moulding process, iQ clamp control determines mould breathing in order to readjust clamping force continually.

The new iQ flow control is based on e-flomo, the electronic temperature-control water distribution system from ENGEL which monitors and documents all cooling and temperature control circuits linked to injection moulds and autonomously regulates either flow volumes or the temperature difference as required. iQ flow control connects e-flomo to the temperature control unit so that the rotational speed of the pump in the temperature control unit is automatically adjusted to the actual requirement. This results in greater energy efficiency. ENGEL developed the integrated temperature control solution in partnership with HB-Therm of St. Gallen, Switzerland; ENGEL has boosted its level of systems expertise with the new e-temp temperature control units.

Secure monitoring of complex processes
The use of intelligent assistance systems is a key feature of the smart factory. As processes become more complex in the face of increasing integration and networking, the means of controlling and monitoring those processes must be simplified. This is precisely where assistance systems can be used to raise process capability and quality without the machine operator needing to acquire additional specialist knowledge.

With its inject 4.0 range, ENGEL already offers numerous sophisticated products and solutions for all three areas of the smart factory – smart machine, smart production and smart service. These generate considerable benefits both in isolation and as part of a digitalisation strategy encompassing the entire production operation.

Customer proximity ensures high system availability
ENGEL opened its own sales and service subsidiary in Russia in 2006. “We have managed to expand our market share in the last few years,” says Olaf Kassek, Managing Director at OOO ENGEL in Moscow. “The field of technical injection moulding is attracting the most investment, followed by the packaging industry.” With 29 employees, ENGEL continues to play to its strengths in Russia under the prevailing economic conditions in the country. “It is very important to our customers that we reach their premises quickly when something needs servicing,” says Kassek. “That is only possible if we have the necessary manpower.” ENGEL maintains its own spare parts warehouse and runs a special service hotline in Russia. Alongside the sales and service subsidiary in Moscow, there are two service and training centres in St. Petersburg and Nizhny Novgorod bringing ENGEL close to users.

ENGEL at Interplastica 2017: Hall 2.1, stand A 25
(Engel Austria GmbH)

Newsgrafik #32149
 09.12.2016

ENGEL at Arabplast 2017  (Company news)

Top efficiency and extremely low unit costs for the packaging industry – this is the theme of the ENGEL presentation at Arabplast 2017 from January 8th to 10th in Dubai, United Arab Emirates. The Austrian injection moulding machine manufacturer exhibits product examples, technology presentations and videos at their stand that clearly demonstrate how integrated system solutions from a single source help leverage an even greater extent of the potential for better quality and efficiency.

Photo: The caps and closures market in the Middle East is extremely dynamic.

"Our first goal is to provide our customers with a competitive edge," says Andreas Leitner, Middle East Sales Director at ENGEL. "A particularly important key for this is our extensive system solution and automation expertise. Only when we coordinate all components of a production cell with each other from the very beginning can we guarantee a very high overall efficiency." As the general contractor, ENGEL has the overall responsibility for the system, and this includes components that are implemented in collaboration with partners. This also simplifies communication between project partners, and in many cases this can speed up project planning and commissioning for new production solutions.

ENGEL has built up a strong worldwide network of partners for its system solution business. Two of these partners are presenting themselves together with ENGEL in Dubai: the Swiss mould manufacturer Otto Hofstetter, and the inspection and testing system specialist IMDvista, which is also headquartered in Switzerland. In the Middle East, the three partner companies can already point to many very successful joint projects.

Energy-efficient, precise and powerful, all rolled into one
The caps and closures market in the Middle East is extremely dynamic. The all-electric injection moulding machines of the ENGEL e-cap series have established themselves very well here. "In the United Arab Emirates, for example, all the well-known bottlers and bottle cap producers now use ENGEL technology," says Leitner. Besides the machine and mould, most projects also include further peripheral equipment and integrated quality inspection systems.

"In the field of caps and closures with very short cycle times and very high material throughput, the trend is clearly going towards all-electric," emphasises Leitner. "The issue of energy efficiency is continuing to grow in importance." In addition, there are very high requirements for machine precision and performance. In terms of geometry, caps have reached the limits of lightweighting and therefore require greater repetition accuracy than ever. In addition, the demands on plasticizing performance have also increased enormously due to the new, high-strength HD-PE materials with MFI values significantly lower than 2 or even 1 g/10 min.

Ready for filling in a single step
The production of cartridges for the do-it-yourself sector also requires efficient thin-wall technology to be combined with high output. In order to produce ready-to-fill cartridges in just one step, ENGEL integrates IML automation from Beck Automation in an ENGEL e-speed injection moulding machine that operates with a 16-cavity mould from Otto Hofstetter.

The cartridge production makes optimal use of the advantages of the hybrid machine, which has an electric clamping unit and a servo-hydraulic injection unit. Moulding the long hollow bodies with a wall thickness of only 1.2 mm requires very high dynamics and injection performance. Very short cycle times are achieved despite the relatively high total shot weight of 800 grams. A basic requirement for the high efficiency of the IML process is very precise movements of the mould mounting platen, which the ENGEL e-speed ensures with its all-electric clamping unit.

A plastic solution for greater sustainability
The third application example at the ENGEL stand at Arabplast presents the production of pallets on ENGEL duo dual-platen large-size machines. Plastic pallets are the more environmentally-friendly and robust alternative to wooden pallets in the Gulf region. As there are no forests, all the raw material for the production of wooden pallets has to be imported, whereas plastic granulate is produced in the region. In addition, plastic pallets do not have to be treated with pesticides and fungicides, which means environmentally harmful chemicals do not have to be used. Plastic pallets are also neither hygroscopic nor combustible, have no sharp edges and cannot splinter. This reduces the risk of injury and simplifies customs clearance procedures in many countries.

In order to make the pallets lighter while keeping them very stable and stiff at the same time, ENGEL and its system partners and raw material producers take advantage of a broad spectrum of technologies and materials. "Some companies are already using plastic pallets to reinforce their image," as Andreas Leitner reports. "A high-quality product calls for high-quality packaging."

ENGEL at Arabplast 2017: hall 6, stand D122
(Engel Austria GmbH)

Newsgrafik #32102
 24.11.2016

K 2016: a resounding success for ENGEL  (Company news)

Thanks to a wealth of innovation, a positive climate for investment and enthusiastic attendees, the K 2016 fair was a resounding success for ENGEL AUSTRIA. inject 4.0 – ENGEL’s answer to the challenges of the fourth industrial revolution – played a key role in this achievement. Furthermore, topics such as DecoJect and in-situ polymerisation had a magnetic appeal on visitors.

Photo: The company’s stand attracted a stream of visitors throughout the event.

“K 2016 confirmed the very good mood in the plastics industry,” says Dr. Christoph Steger, Chief Sales Officer at the ENGEL Group. “In Düsseldorf we found that the investment climate was extremely positive. On the basis of discussions with our clients, we are confident that the trend will continue in the months ahead. We are encouraged to see that a positive impetus is coming from every region – things are even looking up in Russia.”

ENGEL noticed the rise in visitors numbers compared to K 2013, which itself was very well attended: the company’s stand attracted a stream of visitors throughout the event. However, Steger emphasised that the quality of dialogue – which was generally excellent – was more important than the actual number of visitors. “During the fair we discussed numerous new projects and got them moving. The number of agreements we concluded was far in excess of our target, which was an ambitious one,” concludes Steger.

Comprehensive inject 4.0 solution
Industry 4.0 – the core theme of K 2016 – was strongly in evidence at the ENGEL stand, which was designed to resemble a smart factory. With concrete products and solutions for all three areas of the smart factory – smart machine, smart service and smart production – ENGEL is already offering customers a coherent concept known as inject 4.0. Many products and solutions are firmly established in practical situations, while other new solutions were premiered at K. With its modular structure, inject 4.0 promises plastics processors a very straightforward, step-by-step introduction to digitalisation. “Processing businesses used the trade event to find out how they can make the most of the opportunities presented to them by Industry 4.0,” says Dr. Stefan Engleder, Chief Technical Officer and designated CEO of ENGEL. “A lot of visitors to the fair were amazed to find that even individual, small-scale solutions can make a big difference in terms of optimising production processes.” Just like process technology and automation, Industry 4.0 calls for tailored solutions – another point underlined at the ENGEL stand.

All machines exhibited were equipped with the inject 4.0 products best suited to their particular application. At the same time, ENGEL demonstrated how to maximise the potential of smart machine in practical situations by manufacturing inject 4.0 logos on an ENGEL e‑motion 80 TL injection moulding machine. Fluctuating process conditions were simulated in the machine’s CC300 control unit, while visitors were able to monitor the automatic readjustment of the iQ weight control and iQ clamp control assistance systems live on the machine display.

Technological innovations for higher cost-effectiveness
be the first: the ENGEL motto is both an aspiration and a promise to customers. ENGEL demonstrated its technological pre-eminence yet again in Düsseldorf – not just with its inject 4.0 range, but also its machine exhibits. Through a wide array of demanding applications, ENGEL presented innovative process technologies for the target sectors of Automotive, Teletronics, Technical Moulding, Packaging and Medical.

The DecoJect process emerged as a magnet to visitors. ENGEL unveiled the film solution for high quality parts visible in car interiors (developed with system partners) using fully automated manufacturing cell. One special feature of the technology is the combination of injection moulding and in-mould graining in the roll-to-roll process on an ENGEL duo injection moulding machine. Surface structures, colour and haptical features are created through the film. By using different base materials, DecoJect simplifies the harmonisation of interior components. The application presented in Düsseldorf also incorporated MuCell technology to save raw materials as well as component weight. Trade fair visitors were impressed by the high degree of process integration and the extremely compact footprint of the manufacturing cell.

In-situ polymerisation also attracted a great deal of attention as ENGEL showcased an integrated manufacturing cell ready for industrial use for the first time. Over the eight days of the fair, thermoplastic-based, functional composite components were produced from dry reinforcing fabrics in a single work step. To achieve this, polymerisation and the injection moulding process take place in parallel in the ENGEL v-duo machine. The fibre fabrics are inserted into the first cavity of the mould and infiltrated with ε-Caprolactam. After polymerisation to polyamide 6, the preform is transferred to the second cavity in order to inject reinforcing ribs directly, for example. This kind of process integration guarantees cost effective composite processing, which is particularly important to the automobile industry. Visitors to the event were also impressed by the new reactive aggregate, which reduces thermal load by melting and processing monomers according to need.

More precise injection
ENGEL staged the world premiere of the new hydraulic injection units for its ENGEL duo and ENGEL victory injection moulding machines at K 2016. The units are based on years of development work that focused on precision, ergonomics and efficiency. “The new injection units enable even more precise injection and generally improve process stability,” says Engleder. “We have also enhanced energy efficiency and ergonomics. The new ENGEL duo and ENGEL victory machines are fitted with the ENGEL servohydraulic ecodrive as standard. Energy efficiency remains an important issue to our customers.”
(Engel Austria GmbH)

Newsgrafik #32038
 10.11.2016

ENGEL to reorganize Plasticizing Systems division  (Company news)

The plasticizing unit is key to the quality and performance of injection moulding machines. The screw, non-return valve and barrel are critical to the melt quality and repeatability of the injection moulding process as well as the service life and cost-effectiveness of a machine. To respond even better to individual requirements of clients, ENGEL has reorganised its Plasticizing Systems division and is investing 17 million euros in expanding capacities and introducing new technologies.

Photo: In the Plasticizing Systems division, all efforts lead to increased benefits for customers: ENGEL’s plasticizing solutions are targeted to fulfill the customer’s individual requirements while guaranteeing unbeatable quality and fast delivery times.

Demands on plasticizing units are rising: innovative additives and higher filler content, economising on weight and material, tighter dimensional tolerances and increasing requirements for higher surface quality. All these factors are constantly driving development. “The challenge for us is to ensure that even new materials can be processed faster and to a higher quality standard despite the increasing stresses on mechanical components,” says Günther Klammer, head of the Plasticizing Systems division. Screw technology has been a constant in Klammer’s career since 1995, and his team can draw on a wealth of experience. They are responsible for the development and production of ENGEL plasticizing units as well as consulting customers on process technology.


Development, production andsupport from a single source

The recently established process of Concurrent Development ensures that the experience and ideas of users are applied to the development of new products, and that ENGEL can continuously improve its production concepts. “Our aim is to increase the benefit to the customer,” says Klammer. “Therefore, we work closely with our colleagues in the application technology and service divisions, and even consult with customers at their production facilities. This is how we can offer ideal solutions to highly individual requirements across many different sectors.”

To analyse the plasticizing unit itself, as well as in interaction with other components of an injection moulding machine, the team around Günther Klammer has pooled a whole range of skills – from metallurgy and welding technology to rheology, plastics engineering, design, NC programming, manufacturing technology and support. Experts are researching the complex physical and chemical influences in the plasticizing process while optimising the company’s own manufacturing processes. ENGEL combines a high vertical integration of manufacture with lean and resource-efficient production processes to guarantee high quality and fast delivery.

At present, ENGEL produces some 6,000 screws and barrels with diameters from 15 to 170 mm annually – a figure set to double by 2020. With this in mind, ENGEL is investing 17 million euros in new machine tools, heat treatment equipment, material flows and new technologies. A fully integrated CAx process chain will raise productivity even further.
(Engel Austria GmbH)

Newsgrafik #31988
 17.10.2016

ENGEL presents new injection units at K 2016   (Company news)

ENGEL AUSTRIA has revised its hydraulic injection units from scratch and will present the next generation of its successful ENGEL victory and ENGEL duo series of injection moulding machines at the K 2016 trade fair in Düsseldorf, Germany, from October 19th to 26th. With their innovative features, the machines achieve even higher levels of precision, ergonomics and efficiency than before.

Together with the clamping unit, the injection units form the heart of every injection moulding machine. These two central elements are responsible for the performance of the machine and decide on its efficiency. ENGEL will present the result of its long development work on the hydraulic injection units at the K 2016.

Even more precise injection
Based on its many years of experience in the different fields of use of its injection moulding machines, ENGEL has restructured the sizes of the units and optimised their performance data, such as injection pressure, injection speed and plasticising capacity, for current and future requirements. As a result it will be possible from now on to accommodate the individual wishes of users more specifically when designing the machine. All in all, the new units enable more precise injection and higher process stability. Control of temperature and pressure in the barrel contribute to this in equal measure. Special attention was paid in development to temperature control of the feed throat. The temperature control range was enlarged to safely rule out clumping in the feed zone and absorption of moisture across a wider range of materials. The new concept minimises energy losses both during heating and cooling of the feed throat. The main contributor to better controllability of the pressures is the revised piston design.

To achieve high process stability even when ambient conditions and raw materials fluctuate, ENGEL has developed its iQ weight control software to detect such variations and to compensate for them automatically within the same shot. This solution has established itself well in injection moulding machines with electric injection units. As from K 2016, the software will also be offered as option for hydraulic injection moulding machines.

Even faster barrel changes
The new design features of the hydraulic ENGEL injection moulding machines moreover improve ergonomics, both for the machine operator as well as the maintenance technician. The new arrangement of the control cabinets and pumps of the ENGEL duo injection moulding machines has improved clarity of the layout and accessibility. In some machine models the footprint has even been reduced. The new covers now consist of two parts and are equipped with integrated handles. They are very quick to open, which saves time, for example, when servicing the pumps.

When replacing barrels, the dismounted barrel can from now on be put down outside the machine without any need for additional equipment. The barrels are equipped across the board with stable pedestals. No special tools are needed to mount or dismount the barrels, which speeds up the process and reduces downtimes. Efficiency has been improved considerably in the large units as only a few screws now need to be loosened and tightened again when replacing them. With the new design, ENGEL has applied the principle of quick mould clamping to the barrel.

Even more energy savings
In addition to the new feed throat temperature control, another strong contributor to the energy efficiency of ENGEL victory and ENGEL duo machines is ecodrive. The ENGEL servohydraulics, proven in many years of use, belong to the standard equipment of the new machine models. The key to high energy efficiency here lies in needs-related pump output. If the machine is at a standstill, for example during cooling, the motors are also idle and do not use energy. The positive side effects of this are that the machines run much more quietly and that the hydraulic oil does not heat up as much, which also reduces the workload on oil cooling.

K 2016 sounds the starting point
ENGEL will present the hydraulic injection moulding machines in new design for the first time at K 2016, where it will dedicate a separate Expert Corner to the injection units. To begin with, the ENGEL victory machines from an injection unit size of 860 (screw diameter from 45 to 55 mm) and the ENGEL duo machines to size 23060 (screw diameter from 135 to 170 mm) will be available for order in the new design. The other sizes will follow successively after the fair. The ENGEL victory and ENGEL duo injection moulding machines both belong to the most-sold ENGEL injection moulding machines worldwide. The ENGEL victory covers a wide spectrum of applications. Due to its tie-bar-less clamping unit, it enables especially efficient manufacturing concepts in highly integrated and automated processes as well as in multi-component applications. The series covers clamping forces from 280 to 5,000 kN. Thanks to their two-platen construction, the ENGEL duo large-size machines with clamping forces from 3,500 to 55,000 kN combine very high efficiency with a comparably small footprint for the manufacture of large components.

ENGEL at K 2016: hall 15, stand C58
(Engel Austria GmbH)

Newsgrafik #31961
 13.10.2016

ENGEL boosts sales in Southeast Asia   (Company news)

Southeast Asia is one of the most dynamic, rapidly growing markets in the world. To further strengthen its position in this region, ENGEL AUSTRIA, the injection moulding machine manufacturer with headquarters in Schwertberg, Austria, establishes a regional hub in Bangkok, Thailand, for its local subsidiaries and representatives.

With sales and service subsidiaries in Singapore, Thailand and Vietnam, as well as several representatives, ENGEL is already very well positioned in Southeast Asia. "We are viewed as a technological leader in the region, are among the leading regional providers for the automotive supply sector, and are experiencing a great deal of growth, especially in the area of packaging", says Dr. Christoph Steger, Chief Sales Officer of the ENGEL group. "This is precisely why we are now combining the responsibilities for these dynamic markets: to benefit even more from the resulting synergies in future, while at the same time, together with the strong local teams, fulfilling the specific requirements of individual countries in an even more customised manner."

Many years of experience – in the industry and in the region
As of October 1, 2016, Romain Reyre (photo) will be taking on the management of the new organisational unit. As President Southeast Asia, he will be responsible for the entire region. Romain Reyre can look back on 25 years of professional experience in the plastics and packaging industry. Within this time, he has lived in Europe, the United States, Latin America and Southeast Asia. "We are pleased to have found a sales expert like Romain Reyre, who, on the one hand, is very proficient in the plastics industry and our target industries, and who, on the other hand, has been living in Southeast Asia for some time and understands the local markets", says Steger. "In combination with the established teams in the individual countries, the new Southeast Asia hub will increase our market clout in the region. We will be able to even more effectively support our customers there in successfully solving the challenges presented by increasing quality and efficiency requirements."

Strong local presence is the basis of success in Asia
A major factor in the long-term success of ENGEL in Asia has been its ongoing investment into local branches. ENGEL is the only European injection moulding machine manufacturer that has three production plants in Asia, thereby guaranteeing its customers short delivery times, fast service, and flexible adjustment of products and system solutions to regional requirements.
(Engel Austria GmbH)

Newsgrafik #31925
 23.09.2016

e-connect: fit for the smart factory  (Company news)

The e-connect customer portal provides fast access to the world of ENGEL. To meet the demands posed by new digital solutions in the inject 4.0 programme, the injection moulding machine manufacturer and system expert ENGEL AUSTRIA has redesigned the platform from the ground up. At K 2016 ENGEL will present a preview of the new look and feel and the new functions.

Want to be the first – all the time? – The preview of the new customer portal shows how to do it. e-connect reduces inconvenient waiting times and eases the administrative process. In the case of spare parts, for example, ENGEL customers are able to check prices and availability online.

All ENGEL machines and manufacturing cells are stored in the system and can be displayed showing their current status. For the best possible overview, users can organize their machines the same way they are managed on site. Production systems can be assigned to different halls or departments online.

Status of critical components available online
Now that the new e-connect.monitor smart service solution has been integrated into the customer portal, the status of critical machine components is available online as well. Condition-based predictive maintenance makes it possible to utilise the full service life of machine components while avoiding unscheduled system downtimes. To ensure this, the condition of components is monitored by sensors, measurement data is analysed using mathematical models developed by ENGEL, and the remaining service life of components is calculated. At the K Show, ENGEL will present two modules of this new solution – one for screws and the other for spindles. The condition of screws is assessed in the course of regular field service, while spindles are monitored continuously and automatically in the machine. In both instances, the resulting data and analysis are stored on the e-connect platform, where they can be processed by the customer.

e-connect.monitor is part of the inject 4.0 programme, which ENGEL uses to assist clients meet the challenges of the fourth industrial revolution head-on. ENGEL is continually developing new products and services for the smart factory. The new version of the e-connect portal is ideally equipped for handling additional requirements of ongoing digitisation, whenever they may arise.

Customers and ENGEL on the same page
Service requests (to replace a machine component, for example) can be sent directly to ENGEL via e-connect. This is not only highly convenient for users, but also speeds up order processing. As soon as the request is placed, it will be sent automatically to the responsible service team, and processing can start without delay. The fact that ENGEL service technicians use the same database means that the customer and the ENGEL team always work with the same information. The service technicians can access the machine/system history, which helps them find a solution faster. Every service order is fully documented in e-connect.

In addition to new functions, the ENGEL customer portal offers more transparency and even simpler navigation. ENGEL customers have 24/7 access to a variety of useful information, from product descriptions and upcoming events, to details of their ENGEL contacts. A calendar shows scheduled on-site service and sales visits, booked seminars and more. Moreover, the ENGEL e-learning platform is just one click away from e-connect.
ENGEL at K 2016: Hall 15, Stand C58
(Engel Austria GmbH)

Newsgrafik #31878
 12.09.2016

Maximum process stability for hydraulic injection moulding machines  (Company news)

Picture: iQ weight control balances out process fluctuations before rejects are produced. ENGEL will offer the assistance system for hydraulic injection moulding machines too as from the K 2016

Thanks to more than 1000 installations on injection moulding machines with electric injection units, the iQ weight control software developed by ENGEL AUSTRIA has become very well established worldwide. To coincide with K 2016, ENGEL is now presenting a new version, which also increases process stability in injection moulding machines with hydraulic injection units.

Producing moulded parts of a consistently high quality shot by shot is the aim of every injection moulder. Simply using a precise injection moulding machine will not achieve this, however. Even minor changes in ambient conditions or in raw materials and wear have an effect and can mean that parameters need to be readjusted. The iQ weight control software now also makes it possible to automatically recognise deviations and compensate for them in the same shot in hydraulic injection moulding machines such as, for example, the ENGEL victory and ENGEL duo. In this way rejects are prevented actively and productivity is increased decisively.

To achieve this, the software analyses the pressure profile in real time during the injection process and compares the measured values with a reference cycle. The injection profile, switchover point and the post injection pressure are adjusted to the current conditions for every shot, which keeps the injected volume constant during the entire production run.

inject 4.0 paves the way to the smart factory
ENGEL uses the prefix iQ to denote intelligent, decentralised assistance systems that enable injection moulding companies to optimise their productivity, efficiency, quality and flexibility. Decentralised intelligence is a key feature of the continually self-optimising smart factory, the goal of Industry 4.0. ENGEL's answer to the new challenges of this development is inject 4.0. inject 4.0 already offers numerous products and solutions for all three parts of the smart factory – smart machine, smart service and smart production – and new ones are being added continuously.
ENGEL at K 2016: hall 15, stand C58
(Engel Austria GmbH)

Newsgrafik #31871
 09.09.2016

ENGEL opens subsidiary in Vietnam  (Company news)

Picture: Duc Hieu Nguyen is the new local contact for ENGEL’s customers in Vietnam

"The Vietnamese market has grown strongly over the last few years and indications point to continuing above-average dynamics for the future," explains Dr. Christoph Steger, Chief Sales Officer at ENGEL AUSTRIA. "We are responding to this growth with the founding of our own sales and service subsidiary. Thus we are closer to our customers and in future can react even faster and more flexibly to their requirements."

Until now, ENGEL Singapore was responsible for business in Vietnam. Thomas Lim, managing director at ENGEL Singapore, will continue to support the colleagues in Ho Chi Minh City. The local contact is Duc Hieu Nguyen, who has just joined ENGEL. "We are happy to have won Mr. Nguyen as a very experienced sales and injection moulding expert," says Steger. "Our goal is to continue to expand our service and sales infrastructure and customer base in Vietnam."

Electric machines for high-precision, high-speed applications
The Vietnamese injection moulding industry is characterized by the investments of the major international electronics companies and OEMs that produce for example smartphones and tablet PCs in the region and have announced that they will be transferring more production to Vietnam. For many years already, ENGEL has been supplying these companies with injection moulding machines and integrated system solutions. Among others, Samsung is one of the long-standing partners. "Today, the high-tech field is one of the major segments in the Vietnamese injection moulding market," says Steger. "For the fabrication of sophisticated small components and thin-walled products, above all electric machines are used that combine top performance and precision with short cycle times and very low unit costs."

Decentralised production in Asia ensures short delivery times
Besides the teletronics industry, chances are opening in the areas of packaging, household goods and construction. Currently, numerous injection moulding companies are being founded. Thanks to its extensive technology, system solution and automation expertise, ENGEL is able to develop and supply cost-effective fabrication solutions for both simple and sophisticated applications as a single source supplier. Customers also benefit from the fact that ENGEL is the only Western injection moulding machine manufacturer that is represented with several production plants in Asia and that produces the entire spectrum of machines for processing thermoplastic, duroplastic and elastomer materials locally. Injection moulding machines in the small and medium clamping force segment of the ENGEL victory, e-victory, e motion, e-cap, e-mac and insert model series come from Pyungtaek-City in South Korea. Shanghai, China, is the home of the plant for large-size machines of the ENGEL duo and e duo model series. In 2013, the capacities at both locations were increased significantly. "Today, we generate 85 percent of our turnover with our local production in Asia," says Steger. "This means we can guarantee short delivery times for our customers and ensures that we can adapt our injection moulding machines and system solutions very flexibly to the country-specific requirements."

Since it was founded in 1945, ENGEL has been 100 percent family-owned and independent of external investors. This has provided stability and a dependable long-term perspective. ENGEL achieved a global turnover of 1.25 billion euros in the 2015/2016 financial year and currently employs more than 5200 staff worldwide.
(Engel Austria GmbH)

Newsgrafik #31842
 01.09.2016

Energy balance made transparent  (Company news )

With its new energy module, ENGEL e-factory makes it possible to track the energy consumption of individual consumers in production with greater transparency. In addition, starting at K 2016, the MES from ENGEL is capable of avoiding power peak requirements automatically and reducing power costs across the entire machine pool.

Photo: The new Energy module in the ENGEL e-factory MES solution makes the actual energy requirement of each consumer transparent.

The networking and integration of production systems is one of the key features of the smart factory, which forms the core of ENGEL's inject 4.0 program. With its own MES (Manufacturing Execution System), the Austrian machine manufacturer assists its customers to increase their productivity and efficiency by networking. ENGEL e-factory is tailored to the requirements of the injection moulding industry and therefore ensures very deep vertical data integration down to individual cavity level. New modules are being constantly added to the modular system. ENGEL is unveiling a new module at K 2016 – the Energy module. It permits a detailed display, evaluation and optimisation of energy consumers. Machines from different manufacturers can be integrated to obtain a complete energy balance. At the same time, consumers not integrated in the MES can be recorded manually. These functions form the basis for certification according to EMAS, the European Union Eco-Management and Audit Scheme.

Avoiding energy peaks reliably
An additional advantage of the new module is the intelligent distribution of available power sources to individual consumers. This hall management system is particularly beneficial when the entire machine pool is started up at once after a weekend or a factory shut-down, for example. The dynamic allocation of machine-specific consumption limits prevents energy peaks even in these cases.

To ensure the needs-related distribution of power requirements, the Energy module accesses data in the ecobalance energy management system which is included in the functionality of the CC300 control system of ENGEL injection moulding machines. The ecobalance system allocates specific consumption limits and a specific priority to each consumer within the machine or production cell for machine start-up and in production mode. For example, it takes into consideration the high power demand required by an injection moulding machine during warm-up and the high demand for plasticising and injecting the material during production. After each cycle, the system redefines the consumption limits and priorities. The priority of each consumer which received a high amount of power in the previous cycle is reduced and the priority of each consumer which received no or little power is increased.

What ecobalance does within a machine or production cell is performed by the Energy module for the entire machine pool. Thereby, the machines and production cells can be grouped arbitrarily to allocate individual consumption limits to different production halls or hall areas. The more consumers and energy sources that are available to the energy management system, the more effective distribution can be.

Basis to achieve low unit costs
The Energy module provides injection moulding companies with greater leverage to reduce their power costs since power is a significant cost factor, especially at energy peaks. Even when maximum power requirements are seldom reached, they must be constantly provided by the electricity supplier. If the maximum connected load is exceeded, penalties must be paid.

As before, energy efficiency is a vital key to achieving low unit costs. In the past, a large number of developments in drive systems have helped reduce the energy consumption of individual consumers. But today, the accent is more on the intelligent distribution of energy. Rapid advances in the networking of machine pools offered by Industry 4.0 open up new opportunities here.

ENGEL at K 2016: Hall 15, Stand C58
(Engel Austria GmbH)

Newsgrafik #31559
 16.06.2016

ENGEL's worldwide course of growth continues  (Company news)

In the 2015–2016 financial year, ENGEL was again able to achieve an increase in turnover. Worldwide, the ENGEL Group with headquarters in Schwertberg, Austria, generated 1.25 billion euros in turnover. For ENGEL's current financial year, the numbers continue to point to growth. "The order books are well-filled," reports the ENGEL management. In the 2016–2017 financial year, almost 100 million euros are being invested in the further expansion of facilities and capacities. Austria is one area of focus for investments.

Photo: Starting in September, the occupants will then move into the new building in Schwertberg.

All of the company's regions and fields of business contribute to ENGEL's continuing success. "In the 2015–2016 financial year, we were able to consolidate our excellent market position in Europe and have expanded our market shares in Asia and America even further," reports Dr. Christoph Steger, CSO of ENGEL Holding. Despite the overall slight slowdown in growth and the decline in a few individual markets, ENGEL is expecting order intake to remain at a high level for the 2016–2017 financial year.

ENGEL’s extensive system solution and technology expertise belong to the significant factors sustaining this growth. "The European markets, in particular Germany, are still the motors for innovation," emphasises Steger. "And even in America and Asia we are delivering more and more tailor-made solutions for sophisticated applications which include not just the injection moulding machine, but also automation, process technology or mould technology."

Another factor for success is the quality. "The same high standards for quality apply in all ENGEL Group factories," says Dr. Peter Neumann, CEO of ENGEL Holding. "Our staff also have a high level of qualification worldwide. We achieve this through our own apprenticeship programmes and extensive continuing education measures." More than 5200 staff members were employed by ENGEL as of the close of the 2015–2016 financial year that ended in March. ENGEL is hiring further employees on all continents.

ENGEL in the international markets
Asia: the most important growth market – high-tech is in demand
Asia is the most important growth market for ENGEL, although the overall growth in China, the largest market there, continues to slow down. The trend towards greater quality, the pressure on prices that is also increasing in Asia, and the new challenges facing society are making it necessary to invest in advanced technology and automation in an increasing number of areas. ENGEL is benefiting from this trend. "Electromobility is increasingly coming into focus in Asia," says Dr. Stefan Engleder, Chief Technical Officer at ENGEL Holding, naming an example. "Similar to Europe, research institutes and material producers in Asia are pushing ahead with innovative composite technologies. In our Center for Lightweight Composite Technologies, ENGEL engages in intensive collaboration with customers and partners to develop economical processing methods for the new materials."

Lightweight design is not only a motor for innovation in automobile manufacturing. The consumer electronics industry is also closely investigating composite materials with the goal of making their products lighter and thinner. "We are presenting the next step in this development at the K trade show," says Engleder. "Thermoplastic fabrics will for example replace magnesium frames in laptops and thus not only improve the product characteristics, but also lead to an even more efficient manufacturing process. We see enormous potential in this area."

Teletronics follows the automotive industry as the second-strongest contributor to turnover for ENGEL in Asia. Growth motors include the fields of infotainment, vehicle assistance systems, automotive electronics and precision optical components. "With our all-electric, tie-bar-less ENGEL e-motion TL injection moulding machines, we have gained a very good foothold in the market for precision optical parts and have been able to assert ourselves several times against Japanese competitors who have dominated the market until now," says Engleder.

Packaging is also on a growth course. Above all, China and India have a great need for efficient and sustainable solutions for the fabrication of caps and closures for water and carbonated beverages. In the all-electric ENGEL e-cap machine series, ENGEL successfully combines high throughput with high energy efficiency. Besides caps and closures, great opportunities are opening up in the large container business due to the increasing substitution of plastics for sheet metal.

Particularly close collaboration between ENGEL and the processors is already necessary in the project planning phase in order to adapt the injection moulding solutions to the individual requirements of the customers and the specific demands of the different national markets and industries. ENGEL is therefore continually investing in the further expansion of its worldwide sales and service network. Beyond that, ENGEL is consistently strengthening the specialist expertise of local staff. In Shanghai, ENGEL has already established an automation centre, opened its own mould technology department, and strengthened the application technology department. Now ENGEL is building up the company infrastructure for the whole of Asia in order to provide consulting services that are even more industry-specific.

ENGEL has been present in Asia for 30 years
ENGEL had recognised the great potential of the Asian continent very early and established its first subsidiary in Hong Kong in 1986. At the Chinaplas trade show in Shanghai in April of this year, ENGEL celebrated 30 years in Asia. In this time, further sales and service subsidiaries were established successively in Singapore, Korea, India and Thailand. In Vietnam, ENGEL will be opening its sixth subsidiary in Asia by the end of the year.

ENGEL is the only western injection moulding machine manufacturer producing machines at multiple sites in Asia for the local markets. In 2001, the production plant for injection moulding machines with low and medium clamping forces was opened in Pyungtaek City, South Korea. Since 2007, ENGEL has been producing large-size machines at its plant in Shanghai, and with the founding of WINTEC as a secondary brand in 2014, a third plant in Asia was established in Changzhou, China. In the meantime, the ENGEL Group achieves 85 percent of its turnover in Asia with its local production.

North America: automobile boom gives the plastics industry a boost
Aside from Asia, North America is currently one of the most dynamic regions in the world. Car sales figures and overall consumption are remaining at a high level. Other factors include a renewed appreciation for goods produced in the country and the fact that the sometimes very old machinery is now being modernised and brought back to a competitive level with innovative technologies. "We are expecting the very positive investment climate to continue," says Steger. Due to the fact that ENGEL had already appointed Business Unit managers for North America two years ago, it is now in a good position to participate very successfully in the upswing.

The booming automotive industry in the USA has two evident centers of activity: the Southeast and the Detroit area. In Detroit, ENGEL is in collaborative partnerships with two Technology Centers, SA Engineering and Hi-Tech Mold & Engineering. At both facilities, there are ENGEL machines available for trials, technology demonstrations and development projects. The range of possibilities is broad; the largest ENGEL machine available is an ENGEL duo 3500 US.

At the technology centre operated by SA Engineering in Detroit, ENGEL will be hosting the first trend.scaut in North America in late June, taking into account the fact that the automotive industry in North America is of great significance. In Europe, the ENGEL automotive conference has long become established as one the most important networking events in the industry.

Mexico is also benefitting from the automobile boom in North America, partly as a kind of prolonged assembly line for the USA, but also because of the strong domestic demand.

Technical Moulding, Medical and Packaging also see strong growth
All ENGEL Business Units in North America are benefitting from the machinery modernising and reshoring trends. In the area of technical moulding, it is above all toy manufacturers that are relocating their production back from Asia. In the building and construction sector, new investments are very often entrusted to ENGEL. For example, the tie-bar-less ENGEL victory and ENGEL e-victory injection moulding machines provide significant added value in the production of large fittings.

In the packaging market, replacement investments play an important role, because processors can only maintain competitiveness in the mid-term by employing highly efficient injection moulding solutions. Another factor is the trend towards high-quality functional packaging that places high demands not only on the efficiency of the injection moulding machines, but also on their precision.

For the medical sector, North America is of great fundamental importance. On the one hand, it is the largest market worldwide for medical technologies. On the other, the USA is next to Europe the most important motor for innovation in this industry.

Europe: large market share consolidated further
In Europe, ENGEL successfully continued to consolidate its large market share in the 2015–2016 financial year, and was even able to significantly expand its share in the packaging sector. Among other things, this was due to large projects in the area of beverage caps.

Germany remains one of the markets with the highest turnover for the ENGEL Group. The sales and service subsidiaries in Nuremberg, Hannover, Hagen and Stuttgart are showing continued positive development. The ENGEL Deutschland Technologieforum Stuttgart – the youngest of the four German subsidiaries – has more than doubled its personnel since opening in April of 2013.

But not all machine projects that are ordered and carried out in Germany remain in the country. ENGEL customers often plan for them to go directly to their international locations. In Spain and France, this kind of cross-border business also makes up a large share of the very good results achieved in the 2015–2016 financial year. Italy continues to profit from a strong domestic market.

Investments in worldwide locations
The company headquarters are at the focus for investments
Altogether, ENGEL is investing almost 100 million euros in different company locations in the 2016–2017 financial year. The largest part will remain in Austria. Construction work on a significant expansion of the company headquarters in Schwertberg has been underway since the summer of last year. While construction was still ongoing, the scope of the expansion was enlarged. Instead of two, the new building will now have three upper floors. The new building is connected with the technology centre that was completed in 2009 and provides more than 10,000 square metres of floor space. Of these, more than 6,000 square metres are reserved for new offices to strengthen the sales and service teams. A new apprentice workshop is being built on approx. 1,300 square metres, and around 300 square metres will be available for day nursery facilities.

In September, the day nursery will be the first to move into the new building, followed by the ENGEL apprentices. The machines for the new apprentice workshop will already be installed in July. The apprentice workshop at the company headquarters is already one of the most modern in the country and has received numerous awards. In time for the start of the next school year, it will gain even more on attractiveness. "We want to provide optimal working conditions for our staff from the first day on," says Peter Neumann. "With lots of daylight and an open room atmosphere, the new apprentice workshop will provide an even brighter working environment. Beyond that, the workplaces are designed according to the most recent ergonomic findings."

More than 150 young men and women are receiving training in eight technical professions at ENGEL in Austria. With a retention rate of 98 percent, the in-house professional training is an important factor in terms of securing skilled workers. The apprentice workshop in Schwertberg serves as a model for the worldwide apprentice trainee programme of the ENGEL Group. ENGEL also provides training in technical professions at its German site in Hagen, at its component plant in Kaplice in the Czech Republic, and at its large-size machine plant in Shanghai, China.

With its own childcare centre, ENGEL is making it even easier for its staff to balance family and professional obligations. There are already 13 children registered for the day nursery although it has not opened yet, and interest continues to be high. In the future, two groups of up to 24 toddlers up to age three will be cared for. The day nursery will have its own garden that will not only serve as a playground, but also provide space to grow its own vegetables for the breakfast breaks.

Further building measures for the Schwertberg site are already in planning. The focus lies on increasing capacities for assembly. Among other things, the North Hall that was built in 2013 will be expanded. "More space will be created above all for the middle clamping force segment," says Stefan Engleder. "Another area of focus for the planned investments is the customer technology centre. In the future, we will have even greater capacities for customer trials and technology demonstrations in Schwertberg."

More capacity for large-size machines in St. Valentin
Parallel to the expansions at the company headquarters, construction work has begun at the location of ENGEL's large-size machine plant in St. Valentin in Lower Austria. By late summer of this year, two warehouses will be completed, and then in the autumn, work will start on an additional production hall. This will be erected in the south of the site and be connected to the existing halls, significantly expanding the capacity for the manufacture of large-size machines.

The ENGEL Center for Lightweight Composite Technologies located in St. Valentin will be provided with more space in the course of expanding the facilities at that site. A second, even larger ENGEL v-duo machine was already taken into operation at the technology centre in the spring of this year. Now the facilities can cover an even broader spectrum of fibre composite material applications for ENGEL's own development tasks as well as for projects with customers and partners.

Equipping Kaplice for further growth
The component plant at Kaplice in southern Bohemia is being equipped to increase the machine assembly capacity. By the autumn of 2017, production floor space will be more than doubled. The company's facility in the Czech Republic is its centre of excellence for sheet-metal processing and electrical fitting. Among other things, control cabinets, machine frames, housing parts and conveyor belts are produced in Kaplice. "It is only due to our very high vertical manufacturing range that we are able to deliver a consistent high quality worldwide, and yet also flexibly fulfill the increasingly individualised requirements of our customers," says Engleder. "The Kaplice location therefore plays a key role in ENGEL's global production network."

In addition to a new production hall, an even larger administrative building is being constructed, because the number of employees is not just growing in production, but also in administrative areas.

Shanghai: more space for assembly, offices and the apprentice workshop
In Asia, the focus for investments this year lies on Shanghai. There also, both the production facility and the office wing will be significantly expanded by April of 2017. Construction of the production hall has already begun. It will provide 1,600 square metres for additional CNC processing machines. 450 square metres of floor space is being added for offices and the apprentice workshop. Since 2014, ENGEL has been providing vocational training in Shanghai. It built its own apprentice workshop for the programme there and entered a cooperation agreement with a local educational institution for the theoretical instruction. In setting up a dual vocational training programme, ENGEL is emerging as a pioneer in China. "The interest in our training programme is very high," emphasises Peter Neumann. "We were able to expand our training programme sooner than expected." At present, more than 30 apprentices are receiving training as CNC and plastics technicians. In the coming school year, ENGEL will also be accepting mechatronics trainees in Shanghai.

ENGEL breaks new ground in professional training
First trainee programme spanning three continents
Professional qualification has always had a high priority at ENGEL. The focus is not limited to apprentices, but also includes young academics for whom ENGEL also offers trainee programmes and final thesis projects.

ENGEL is breaking new ground with its international trainee programme. After a six-month introductory phase in Austria, the participants in the two-year programme will work at the ENGEL plants in the USA, China and Korea, as well as at two ENGEL subsidiaries. During this time, the trainees will become familiar with the ENGEL products and technologies and acquire industry-specific expertise and leadership competence. "Our goal is to get young people excited about gaining international experience and to promote intercultural understanding," says Christoph Steger. "When they have successfully completed the programme, we will offer the graduates a challenging job in our international sales operations." Five young men and women will be admitted to the programme this September. The applicants come from Europe as well as America and Asia. The prerequisites for participation in the international trainee programme are a technical or business degree and a maximum of three years of professional experience.
ENGEL will be conducting the international trainee programme regularly.
(Engel Austria GmbH)

Newsgrafik #31342
 27.04.2016

ENGEL at Plastpol 2016  (Company news)

Picture: Using an all-electric ENGEL e-motion injection moulding machine, the production of the housing components will impressively showcase the strong potential of the iQ software solutions

ENGEL is making its customers more competitive with reliable, flexible and efficient machine concepts along with automation from a single source. The system expert headquartered in Schwertberg, Austria, will demonstrate what this means in practical terms by presenting two technically demanding applications at Plastpol 2016, which takes place in Kielce, Poland, from May 17th to 20th. The demonstration will clearly illustrate how the ever accelerating integration of intelligent assistance systems and the networking of machines and systems can unlock even more efficiency and quality potential.

iQ solutions raising process stability and quality
Producing parts of consistently high quality shot for shot calls for more than just an accurate injection moulding machine: fluctuations in environmental conditions as well as raw materials and wear have an impact, and may necessitate the readjustment of parameters. At Plastpol, ENGEL will be presenting iQ weight control, software that recognises and automatically compensates for deviations from the specified melt flow by adjusting the switchover point, injection speed profile and holding pressure in the same shot. The production of complex, three-dimensional housing components using an all-electric ENGEL e-motion 170/110 T injection moulding machine will impressively showcase the strong potential of the software. The component design includes various breaks, delicate grid structures and alternating wall thicknesses; in this case, even the smallest changes in general conditions can mean the cavity is not completely filled and rejects are produced. “With iQ weight control, we are improving the cost-effectiveness of injection moulding production significantly,” points out Piotr Nachilo, managing director at ENGEL Polska with headquarters in Warsaw. “Demand is increasing for self-adapting assistance systems. Integrating additional intelligence in the CC300 control unit for injection moulding machines enables customers to improve process stability and product quality, regardless of how qualified their employees may be.”

While the iQ weight control software optimises the injection process, the focus in developing iQ clamp control was on the injection moulding machine's clamping unit. This software will also be installed on the ENGEL e-motion injection moulding machine at the Plastpol event. On the machine display, visitors to the trade fair will be able to see how iQ clamp control determines and automatically adjusts the ideal clamping force shot by shot on the basis of the mould breathing.

inject 4.0 points the way to the smart factory
The iQ weight control and iQ clamp control software solutions, developed by ENGEL for electric injection moulding machines, are part of ENGEL’s wide-ranging inject 4.0 programme. With inject 4.0, ENGEL is enabling clients around the world to utilise the possibilities presented by the fourth industrial revolution. “Industrie 4.0 is nothing new for ENGEL – in many areas it has been current practice for a long time,” says Nachilo. “Our modular approach to inject 4.0 makes it easy for our customers to get on board. There is no need for a complete solution from day one: optimisation of production processes starts with individual machines and may be expanded gradually into a global production network.”

The aim of inject 4.0 is to establish the smart factory: a production operation that continually enhances itself through the networking and integration of production systems, systematic utilisation of process and production data and the deployment of adaptive production systems. A smart factory has three areas: smart machines for greater process capability, smart production for higher productivity and smart services for improved availability. The ENGEL range already has solutions in all areas, and will present some of these in Kielce. Visitors to the ENGEL stand will be able to experience the smart factory at first hand with iQ products (smart machines) as well as e-factory (smart production).

ENGEL has its own manufacturing execution system (MES): specifically tailored to the needs of the plastics processing industry, ENGEL e-factory achieves very deep vertical data integration (to the level of individual cavities). ENGEL e-factory ensures transparency by enabling centralised access to all relevant status and process data and comparing this with quality indicators and commercial objectives. The networking of injection moulding machines and manufacturing cells makes it much easier for a processing firm to utilise its machine park as effectively as possible, check the status of injection moulding machines and create documentation. It is not only machines in a machine park that can be integrated into the system, but also (if required) various locations around the globe.

Both of the processing cells at ENGEL’s stand are incorporated in the ENGEL e-factory and may be controlled via a central master computer.

More output per square metre
The second machine on show at the ENGEL stand will focus on the need for maximum output from minimal floor space. “For many of our customers, surface area productivity is a major indicator of efficiency,” emphasises Nachilo. “ENGEL offers compact solutions across its range of machines, including large-size machines.” Thanks to its dual-platen technology, ENGEL duo machines with clamping forces from 3,500 to 55,000 kN are more compact than injection moulding machines from other manufacturers in the same clamping force class. Low-friction platen guidance on carriages facilitates outstanding platen parallelism and sensitive mould protection, thus ensuring a high level of operating safety and lowering the number of rejects.

In Kielce, ENGEL will use an ENGEL duo 3550/500 with clamping force of 5,000 kN to produce stable stacking boxes from polypropylene. An ENGEL viper 20 linear robot will remove the boxes and place them on a conveyor belt. The RC300 control unit for the robot is fully integrated in the CC300 control unit of the injection moulding machine. The additional movement instructions for the robot integrate seamlessly with the graphical user interface of the machine control unit, which considerably simplifies above all the programming and operation of complex process workflows and makes an additional PLC unnecessary. To enable fast parameterisation despite the complexity of the system as a whole, the CC300 control unit offers users various process mapping options, from simple selection of prefabricated standard processes to the object-based graphic generation of complex sequences.

Within the integrated system solution, machine and robot access a shared database and coordinate their movements in the interests of greater overall efficiency. As a result, for example, it is not necessary for the robot to wait until the mould is completely open; part removal can begin during the actual opening, which cuts the cycle time.

In view of accelerating networking and the systematic use of process data, the human/machine interface is becoming ever more important. Given the development of the CC300 control unit and a consistently applied control philosophy, ENGEL was geared to needs of the factory of the future at an early stage.
ENGEL at Plastpol 2016: hall F, stand F-3
(Engel Austria GmbH)

Newsgrafik #31379
 20.04.2016

Engel Group: Sorrow at the deaths of Irene and Georg Schwarz  (Company news)

The owner families and staff of the ENGEL Group mourn the loss of their senior directors. Irene and Georg Schwarz both passed away within only a few days of each other in late March and early April at ages 86 and 88. For decades, they jointly managed the business and laid the foundation for the extraordinary success of what is today a worldwide group of companies with more than 5000 staff members. Both followed the development of the company with great interest until the end.

Irene Schwarz had dedicated her life to the company already as a child and shaped ENGEL for more than 70 years. Born in 1929 in Neu-Werbaß (today called Vrbas) in Serbia, Irene Engel came with her family to Austria in 1944, where one year later her father Ludwig Engel founded a machinery construction company in Schwertberg. She worked in the company from the very beginning. Over many years she was bookkeeper, financial director, controller and director of human resources all at the same time.

In 1951, she married Georg Schwarz, who also joined the staff at his father-in-law's company. Georg Schwarz was born in 1928 in Essegg (today called Osijek) in Croatia. His family history was also marked by displacement and flight as a refugee at the end of the Second World War. In 1945, the Schwarz family found a new home in Upper Austria. Georg Schwarz attended the technical school for mechanical engineering in Linz, and completed an apprenticeship as a machinist parallel to these studies.

Side by side in working and private life
After the sudden death of Ludwig Engel in 1965, Irene and Georg Schwarz took over the management of the company that had 380 employees at the time. With entrepreneurial courage and a special intuition concerning industry trends and growing markets, they guided the company onto a path of growth that continues today. Early on they decided to establish foreign subsidiaries, opened two production plants in North America and already set the course for the system solutions business in the 1980s with the development and production of the company's own robots.

They led the company with farsighted vision and always kept the family succession in focus. In 1997, they turned over the operational management to the third generation. Currently, ENGEL is implementing the next generational transition, and the senior directors were also involved in the process.

Both of them were actively involved in the business well beyond their 80th birthdays. At the start of the new millennium, they oversaw the step into Asia with the founding of the production plants in Korea and China, and when flooding destroyed the production facilities at the headquarters in Schwertberg in 2002, they also joined in actively tackling the task of rebuilding.

Quality, customers and staff always in focus
Irene and Georg Schwarz always set their goals on top quality and on fulfilling the needs of their customers worldwide, and still today, the management and staff in the company orient themselves on this excellent example.

Georg Schwarz was full of passion for sales, but above for production. He always strove to orient the ENGEL production plants on state-of-the-art technology and new possibilities. He placed the same demands on the company's own products: he wanted ENGEL injection moulding machines to open up production possibilities that no one else could offer their customers. Very early, he made a name for himself as a visionary in the world of plastics. He gave his staff much freedom; he demanded and fostered innovation. Thus he was a decisive factor in advancing the development of the first tie-bar-less injection moulding machine worldwide. Thanks to continuous development and consequence in securing patents, the tie-bar-less technology has remained a unique selling proposition for ENGEL until today.

Irene Schwarz understood how to connect entrepreneurial vision with the practical details. Economy and modesty were her guiding philosophy, and the financial security of the company was her top priority. In the process, she never lost sight of what was in the interest of the employees. She gave special attention to the optimisation of internal processes. Wastefulness was a thorn in the flesh for her long before the first ideas from lean management philosophy appeared in Europe.

Country and industry honour accomplishments
In their company, the plastics industry and beyond, Irene and Georg Schwarz were highly appreciated as businesspeople, but also at a personal level.

The government of Upper Austria honoured their contributions in the plastics industry and their exemplary service for the company and the region with the Decoration of Honour in Gold. Georg Schwarz had also been also awarded the Grand Decoration of Honour in Gold of the State of Lower Austria and the Grand Decoration of Honour in Silver of the Republic of Austria.

In 1978, Georg Schwarz was appointed Honorary Senator of the University of Leoben and in 1992 Honorary Senator of the Vienna University of Technology. In 2009, his name was added to the Plastics Hall of Fame. This has its headquarters at the University of Massachusetts in Lowell, USA, and represents the highest honour awarded in the international plastics industry. Georg Schwarz was a member of the board of the Federation of Austrian Industries for many years, and also represented the Austrian Chamber of Commerce.

Irene Schwarz was appointed Honorary Senator of the University of Leoben in 2006, the first woman in the history of the university.

For ENGEL, the deaths of Irene and Georg Schwarz mark the end of an era. They leave behind a void that cannot be filled.

For a number of decades, Irene and Georg Schwarz led the company together. At the end of March and the beginning of April, both senior partners of ENGEL AUSTRIA passed away aged 86 and 88 years.
(Engel Austria GmbH)

Newsgrafik #31309
 14.04.2016

ENGEL presents Liquidmetal at the 2016 Hannover Messe  (Company news)

With its completely new material characteristics and ability to be injection moulded, Liquidmetal revolutionises the fabrication of high-quality metal components. The potential of this new class of materials is being presented by the injection moulding machine manufacturer ENGEL AUSTRIA – headquartered in Schwertberg, Austria – at the 2016 Hannover Messe from April 25th to 29th.

Both hard and elastic
Liquidmetal stands for a class of material with completely new characteristics. The zirconium alloys have an amorphous structure that makes Liquidmetal components extremely hard and at the same time very elastic. A hardness of 53 HRC is achieved even without any thermal treatment. The elasticity lies at 1.8 percent while in comparison steel has an elasticity of approx. 0.2 percent and titanium approx.1 percent. In addition, the Liquidmetal materials are characterised by a low specific weight as well as excellent corrosion resistance and biocompatibility. This range of characteristics predestines them for use in precision and functional components that are subjected to high mechanical stresses. This opens up new opportunities from medical technology to electronics, automotive to aerospace and even sports equipment. Electronic components, surgical instruments and particularly high-quality decor elements will be among the first applications. The Liquidmetal experts at ENGEL will be presenting diverse sample components in Hannover, as well as several videos illustrating the great potential of the new class of materials.

More efficient than CNC and MIM
The fact that these materials can be processed in injection moulding is another advantage. Compared with the metal injection moulding (MIM) and CNC processing methods, this makes it possible to realise manufacturing concepts that are significantly more efficient and to achieve a higher level of automation and process integration. In just one single step and in short cycles, fit-for-purpose components with a very high-quality surface finish can be produced. Even sophisticated three-dimensional forms and very fine structures can be moulded with excellent reproducibility and material efficiency.

As the exclusive machine manufacturing partner of Liquidmetal Technologies, which is located in Rancho Santa Margarita, California, USA, ENGEL is the only supplier worldwide offering injection moulding machines and integrated system solutions for the processing of Liquidmetal materials. A further partner is Materion Corporation, the material producer and distributor based in Mayfield Heights, Ohio, USA.

For individual presentations and initial sampling, a Liquidmetal machine is available at the ENGEL technology centre in Schwertberg, Austria. Liquidmetal Technologies has established capacities for contract manufacturing in California; capacities for the European market are currently in preparation.

A leader in production efficiency
For the first time, ENGEL is exhibiting in Hannover. With the processing of metal alloys, the supplier of injection moulding machines and automated system solutions is tapping into a new target group. In the plastics industry, ENGEL is seen as a technology leader, and in the markets worldwide it stands for highest quality combined with maximum production efficiency. With nine production plants on three continents, 29 sales and service subsidiaries and 60 representatives, ENGEL is close to its customers all around the globe. The German subsidiaries are located in Hannover, Nuremberg, Hagen und Stuttgart.
ENGEL at the 2016 Hannover Messe: hall 5, stand G18
(Engel Austria GmbH)

Newsgrafik #31217
 17.03.2016

Generation change at ENGEL  (Company news)

„There is some melancholy“, admits Dr. Peter Neumann as he announced his withdrawal from operational business, “but also optimism because ENGEL is well established and continuity in management has been secured.” Effective November 30th 2016, Peter Neumann, long-term chairman of the executive board of the ENGEL Group of Companies, withdraws from operational business after 35 years.

Photo: The current executive board of the ENGEL Group of Companies: Dr. Peter Neumann, Dr. Christoph Steger, Dr. Stefan Engleder, Dipl-Oec. Klaus Siegmund (f.l.t.r.)

“This step has been long planned on the occasion of my 60th birthday and is the result of a clear mutual agreement between myself and the owning families of the ENGEL Group of Companies”, explains Neumann the background for this change. Indeed, the generation change within the family-run business had been initiated several years ago by introducing the 4th generation of members of the owning family step by step into the executive board. Dr. Stefan Engleder has been responsible for R&D, engineering and production for more than 3 years and Dr. Christoph Steger for Sales and Marketing for more than 2 years.

Now, the final step will be set by Dr. Stefan Engleder, great-grand-son of ENGEL’s founder Ludwig Engel, taking over the position as chairman of the executive board effective December 1st, 2016. The executive board will continue to consist of 4 persons: besides Dr. Stefan Engleder as new Chairman also responsible for R&D, the board will be constituted of Dr. Christoph Steger (also a family member and responsible for Sales, Marketing and in future Customer Service), Dipl.-Oec. Klaus Siegmund (responsible for Finance, Personnel and IT) as well as DI Joachim Metzmacher (so far division manager production large-tonnage machines) for Global Production.

“It is a great honor and also a challenge taking over the chairmanship from Dr. Neumann”, emphasizes Stefan Engleder. “He has shaped the company for decades and played a significant part toward the success of the business. Thus, it has been all the more important, to prepare the transition well on a long-term basis. This we have managed very well over the last couple of years.” And he adds: “Together with my colleagues in the executive board, we aim on continuing the business in Dr. Neumann’s sense and following up from where we are today.”

Dr. Birgitte Engleder, chairwoman of the supervisory board, takes the same line: “Not only as chairwoman of the supervisory board but especially as member of the owning family, I am very pleased that we have concluded the transition within the operational management from the 3rd to the 4th generation. Due to good planning and preparation this step has been executed very professionally and farsighted. I am proud to witness the next generation taking over and I am sure that Stefan Engleder as new chairman of the executive board together with Christoph Steger and the other executives will continue the success story that my grandfather started. At the same time, I would like to dearly thank Peter Neumann and wish him all the best for the new chapter in his life on behalf of all employees, the other members of the executive board and the owning families. His unconditional dedication towards ENGEL has been admirable and reflects his uncompromising commitment. His actions have always truly been focused on the welfare of the company, from the beginning he has fully supported the transition to the next generation and over many years has brought ENGEL to where we are today – among the global leaders in the field of plastics machinery.”

Together, Neumann and Engleder highlight that Peter Neumann will continue to stay connected with the company after the official handover and also in future support the executive board with his expertise in case of need.
(Engel Austria GmbH)

Newsgrafik #31165
 07.03.2016

ENGEL at Chinaplas 2016  (Company news)

ENGEL belongs to the preferred suppliers for injection moulding machines and system solutions for sophisticated applications in Asia. Customers trust their great expertise in system solutions, automation and technology and their profound understanding of local requirements. The injection moulding machine manufacturer with headquarters in Schwertberg, Austria, will once again be demonstrating all these aspects with numerous highlights at the Chinaplas 2016 from April 25th to 28th in Shanghai, China.

Photo: Thanks to in-mould-labeling technology, food containers come ready-to-fill directly out of the ENGEL e-mac 180 injection moulding machine.

• inject 4.0 provides answers to the question of how the productivity, flexibility and quality of manufacturing processes can be maximised.

• The production of clutch pedals with the ENGEL watermelt method demonstrates how innovative technologies create competitive advantages.

• The fabrication of packaging with IML decoration impressively illustrates how collaboration with local partners reduces costs.

• And the example of housing shells with an integrated LSR seal presents how multi-component processes can be mastered reliably.

Make optimal use of the opportunities of Industry 4.0
Productivity, quality and flexibility are decisive for a competitive edge. But to achieve optimal results, it is no longer enough to deploy the best injection moulding equipment; it is all about leveraging its maximum potential. This is the fundamental goal at the focus of the fourth industrial revolution that has come to be known as Industry 4.0. "Industry 4.0 is no longer just a buzzword, but rather a trend that is getting increasing attention among our customers," says Gero Willmeroth, Sales and Service President at ENGEL Machinery (Shanghai) prior to Chinaplas 2016. "We expect that injection moulding processors will inform themselves at the exhibition about the possibilities and opportunities that Industry 4.0 opens up for them. We view ourselves as a partner helping our customers to make the best possible use of these opportunities. For ENGEL, Industry 4.0 is not a new issue, but is already long-established daily practice in many areas. The trust that processors place in the ENGEL solutions in this area is therefore also very high right from the start."

Under the inject 4.0 brand, ENGEL is bundling the products and services that are already available today together with coming products and services that help turn a manufacturing operation into a smart factory. With the help of the networking and integration of production systems, the systematic exploitation of process and production data and the use of decentralised, intelligent production systems, the manufacturing processes in a smart factory continuously optimise themselves and make it possible to react very flexibly to the ever more quickly changing requirements. At its stand, ENGEL is presenting just what this can look like for all three areas of the smart factory – smart production, smart services and smart machines. Numerous live demonstrations bring some transparency into the often quite intangible world of Industry 4.0 and make the factory of tomorrow a real experience today.

During the four days of the trade fair, the parameters from all the production cells in operation at the ENGEL stand are gathered by a central master computer where the ENGEL e‑factory MES solution is running. It provides features for scheduling jobs, querying the status of the injection moulding machines, and creating quality reports and documentation (smart production). At the same time, the exhibit visitors are given insights into how maintenance and servicing tasks can be completed online via remote connection, thus saving the processor time and costs and increasing the machine availability of the production cell (smart services).

There can be no doubt that the machines at the ENGEL trade fair stand work in a smart way (smart machines). For example, the iQ weight control and iQ clamp control software solutions enhance process stability by continually analysing the plasticising and moulding process, automatically adjusting quality-relevant parameters in case of deviations from target values.

The inject 4.0 products that lead to optimal overall results differ for each injection moulding task, each company and each location – another fact that will become clear at the ENGEL trade fair stand. "The modular concept allows our customers to start with a solution adapted to their individual requirements at any time and then gradually develop it further," as Willmeroth emphasises. "There is no need to start with a full solution right from day one. Optimising manufacturing processes starts with the individual machines and can reach all the way up to a global production network."

Integrated system solutions including process technology
Founded in 1945, ENGEL has steadily developed over the course of its history from a manufacturer of injection moulding machines to a system expert. As a single source supplier, the family-owned company provides turnkey manufacturing cells for sophisticated applications which in addition to injection moulding machines also include automation, process technology, the mould and further peripheral equipment. Besides the injection moulding machines, various types of robots and process technologies also stem from ENGEL's own development. Among other things, ENGEL demonstrates its great system solution and technology expertise at Chinaplas with an application for the automotive industry.

Clutch pedals are being manufactured with the ENGEL watermelt method on an ENGEL duo 350 large-size machine. Thanks to the targeted formation of a hollow structure by means of water injection technology, raw material is saved, the component weight decreases and the cycle time drops. Furthermore, the injection of water into a cavity partially filled with plastic melt ensures a uniform wall thickness throughout the clutch pedal and no sink marks despite the complex part geometry. This also results in a very precise part surface.

Together with its system partner PMEfluidtec (Ettenheim, Germany), ENGEL offers tailor-made turn-key solutions for water injection technology worldwide. "In the meantime, we have installed several ENGEL watermelt production cells for customers in China," as Wilmeroth reports. "The method makes it possible to achieve a fabrication process that is not only very efficient, but also sustainable. The issue of sustainability in particular is growing greatly in importance in China." In order to provide optimal local support for its customers, ENGEL Machinery (Shanghai) has established its own department for application technology.

Maximum performance, minimal unit costs
There is hardly another industry in which the unit costs are subject to greater pressure than in the packaging industry. Competitive production is only possible when maximum throughput, a stable process and a high degree of process integration all come together. An increasing number of processors are turning to in-mould labeling technology so that for example ready-to-fill food containers come directly out of the injection moulding machine. IML makes a high-quality decoration economical, even in the production of smaller batch sizes. In order to take full advantage of the efficiency potential of IML integration, the injection moulding machine, the mould and the handling of the labels and finished products must be perfectly coordinated with each other. For this, ENGEL has built up a worldwide network of partner companies. The ENGEL e-mac 180 injection moulding machine being presented at Chinaplas is operating with a 4-cavity mould from CNN Plastic System of New Taipei City in Taiwan, producing oval bowls that are for example used for convenience meals, and the IML automation has been realised by YET Engine Automation – also located in New Taipei City, Taiwan. "The collaboration with local partners makes it possible for us to guarantee high cost-efficiency for our customers, even for very sophisticated, innovative technologies, and also keep the delivery times for the complete production cell very short," emphasises Willmeroth.

High productivity requires a reliable high-performance machine. The all-electric ENGEL e‑mac is a high-performance, high-precision, compact and at the same time energy-efficient solution. From injecting and metering to mould and ejector movements, all drives in the ENGEL e-mac are servo-electric. This guarantees the best possible precision and process stability while maximising the effectiveness of the machine as a whole. The drives are operated by a modern axis system solution involving a stabilised intermediate circuit, with the braking energy being recovered and fed back into the grid. The synchronous movements of the drive axes ensure short cycle times. With acceleration of up to 20 m/s², the injection axis of the ENGEL e-mac is among the fastest worldwide.

Reliably master LIM multi-component processes
Process integration is a key factor for top competitiveness. Besides the integration of process steps upstream and downstream of the injection moulding process into the manufacturing cell, the parallel processing of different materials also offers particularly great potential for more efficiency. The fabrication of housing shells for flow metering devices reveals how this potential can be optimally exploited. On a tie-bar-less ENGEL e-victory 120 combi injection moulding machine with an integrated ENGEL viper 20 linear robot, four housing shells are first injection-moulded of thermoplastic in a 4+4 cavity mould. These are transferred to the second set of cavities by the robot where a seal of liquid silicone (LSR) is subsequently applied directly in the same mould. While the soft components of one set of housings are being processed, the next housings of thermoplastic are already in progress in the lower half of the mould. "Having the seals moulded directly onto the housings not only increases production efficiency, but also product safety, because the thermoplastic and the elastomer then form one inseparable unit," says Willmeroth.

The processing of two diverse materials in one step is not the only challenge presented by the manufacture of the housing parts here; handling the liquid silicone reliably is also difficult, particularly because its low viscosity makes it hard to work with. Important demands placed on the processing of liquid silicone rubber (LSR) are that it must be low in burrs and require no post-processing. Various factors contribute to ensuring that these demands are fulfilled reliably. The servo-electric injection units and the tie-bar-less clamping unit of the ENGEL e-victory machine for example help achieve very high precision and process consistency levels. The patented force divider ensures that the moving mould mounting platen follows the mould exactly while clamping force is being built up. It guarantees high platen parallelism and distributes the clamping force evenly across the entire platen face. All cavities are therefore held closed with exactly the same force, resulting in extremely consistent wall thicknesses as well as significantly reducing mould wear.

Its tie-bar-less technology gives ENGEL a unique selling proposition unmatched anywhere else in the world. In addition to high process consistency levels, the machine concept makes it possible to achieve very fast set-up processes, compact production cells and efficient automation concepts. This will also be clearly demonstrated at the Chinaplas exhibition. The ENGEL viper robot can reach the cavities directly from the side without having to circumvent any obstacles.

Faster positioning for shorter cycle times
At Chinaplas 2016, the new generation of ENGEL viper linear robots is celebrating its premier in Asia. A special highlight is the new active vibration control that boosts positioning speed and thus contributes to achieving shorter cycle times. While up to now vibrations were reduced through intelligent programmed trajectories, external influences can now also be compensated for online using active vibration control.

An ENGEL viper 40 double robot will demonstrate this during the four trade show days. The respective grippers hold a sleeve and a corresponding core. The two robots with a common Z-axis rotate the two parts together, inserting one inside the other and separating them again multiple times within a very short time without the sleeve and core touching each other. In addition to the active vibration compensation, another advantage ot the ENGEL viper robots comes into play: the perfect synchronisation of independent movements. Each of the twin robots has three NC and three servo rotation axes. A total of twelve axes will be controlled synchronously – which is far from exhausting all the possibilities.

All ENGEL viper robots will be equipped with active vibration control starting from size 20 up to the largest ENGEL viper 120 robots with a load capacity of 120 kilograms. The transition is being implemented successively starting with the ENGEL viper 40 and 60 robots.

Tailor-made solutions – produced locally
The injection moulding machines presented at Chinaplas all stem from local production. Shanghai is the home of the plant for large-size injection moulding machines of the ENGEL duo model series. Injection moulding machines with small to medium clamping forces come from Pyungtaek-City in South Korea. ENGEL is the only non-Asian injection moulding machine manufacturer with multiple production plants in Asia. Decentralised local production guarantees short lead times for customers and also ensures that the products and system solutions can be flexibly adapted to regional and customer-specific requirements.

In order to provide optimal on-site support for its customers, ENGEL now employs nine application technicians in China. Additionally, ENGEL has founded its own Automation Center at its large-size machine manufacturing plant in Shanghai.

Exactly 30 years ago, ENGEL opened its first subsidiary on the Asian continent in Hong Kong. Besides China, ENGEL is today also represented in Asia by its own sales and service subsidiaries in South Korea, Thailand, Singapore and India. In addition, there are further sales offices, service centres and representatives. "Above all when it comes to application-specific consulting and service, close proximity to our customers is extremely important. The short distances save our customers time and costs, and speed up the project planning and commissioning of new manufacturing cells," emphasizes Gero Willmeroth. "We are therefore continuing to expand our sales and service network."

ENGEL at Chinaplas 2016 in Shanghai: hall E3 stand E3E01
(Engel Austria GmbH)

Newsgrafik #31074
 09.02.2016

ENGEL at Plastimagen 2016  (Company news)

Set out to reach new horizons in quality and efficiency – that's ENGEL's focus at Plastimagen 2016 from March 8th to 11th in Mexico City. The injection moulding machine manufacturer and system expert with headquarters in Schwertberg, Austria, and a subsidiary in Querétaro, Mexico, presents this theme from two perspectives: both innovative processing technologies and Industry 4.0 open up new possibilities for injection moulding processors to boost their productivity, quality and flexibility in their fabrication and thus consistently reduce unit costs.

inject 4.0 – take advantage of the full potential
"Industry 4.0, the fourth industrial revolution that we are currently experiencing, is both a challenge and a chance," emphasizes Walter Jungwirth, Managing Director of ENGEL de Mexico in Querétaro. "Our goal is to master the challenges together with our customers in order to gain the maximum benefit from the new chances that are arising. We view ourselves as a partner helping our customers to optimize their production processes." ENGEL can draw on rich experience in this area, because in their own business, Industry 4.0 is already long-established practice. inject 4.0 – under this name, ENGEL bundles all its products, systems and services that make both individual injection moulding machines and the entire production network smarter in the sense of Industry 4.0.

In order to continue to boost productivity, efficiency, quality and flexibility in production, you need to do more than simply use the best injection moulding equipment; its potential must be leveraged to the max. This is where inject 4.0 comes to play with the smart factory concept. With the help of the networking and integration of production systems, the systematic exploitation of process and production data and the use of adaptive production systems, the manufacturing processes in a smart factory continuously optimise themselves. The smart factory is based upon three pillars:
-smart machines that boost process capability and quality with self-adapting, decentralised systems,
-smart production to ensure high levels of productivity thanks to horizontal and vertical data integration, and
-smart services that improve machine availability quickly and efficiently thanks to close proximity and the use of remote maintenance tools.

ENGEL is bringing solutions for all these areas to Plastimagen, for example the iQ weight control und iQ clamp control software products that continuously monitor and automatically readjust quality-relevant parameters (smart machines), the ENGEL e-factory MES that is specifically tailored for the requirements of the plastics processor and therefore achieves an extremely high level of vertical data integration all the way down to the level of individual cavities (smart production), and ENGEL e-connect.24 for fast online support and remote maintenance.

"The modular concept allows our customers to start with a specific solution adapted to their own requirements at any time and then gradually develop it further," as Jungwirth emphasises. "Industry 4.0 will be different for each business and it doesn't always have to be a comprehensive solution. Optimising manufacturing processes starts with the individual machines and can reach all the way up to a global production network."

Technology integration opens new vistas of quality
ENGEL is presenting two process technology highlights in Mexico with sophisticated applications for the automotive and packaging industries.
In the automobile industry, the trend towards a greater degree of process integration is advancing particularly quickly. The object is no longer simply to integrate process steps upstream or downstream of injection moulding, but also to combine different process technologies with one another. In the production of centre console components out of PC-ABS at its trade show stand, ENGEL will be using an ENGEL duo 2550/600 injection moulding machine with integrated ENGEL viper 20 robot to combine two technologies: ENGEL foammelt, the MuCell foam injection moulding process developed by Trexel of Wilmington in the USA, and ENGEL variomelt, a variothermal injection moulding process. "Combining the two processing technologies makes it possible to produce thin-walled parts with very high surface quality and at the same time excellent fine structure reproduction using just a single injection moulding step," says Walter Jungwirth.

To demonstrate the versatility of this combination of technologies, the sample part will have varying wall thicknesses and surface structures. The mould for the variothermal process demonstration will be supplied by ENGEL's partner Roctool (Le Bourget du Lac, France). Thanks to ENGEL foammelt, the cavity including the undercuts is completely filled and the component has no sink marks after cooling; additionally, the variothermal temperature control provides a high gloss finish. Apart from applications aimed at car interiors, integrating ENGEL foammelt and variomelt opens up new vistas of efficiency and quality for white goods and household products.

The controls of the ENGEL viper robot are entirely integrated into the CC300 control unit of the ENGEL duo injection moulding machine so that machine operators no longer need to familiarise themselves with separate control logic concepts. The additional movement instructions for the robot integrate seamlessly with the graphical user interface of the machine control unit, which considerably simplifies above all the programming and operation of complex process workflows and makes an additional PLC unnecessary. To allow for fast parameterisation despite the complexity of the overall system, the CC300 control unit provides the user with different ways of visualising the process sequence, from the simple choice of preprogrammed standard sequences to the object-oriented graphical creation of complex process sequences.

IML with maximum flexibility
Flexibility is the focus of ENGEL's Packaging exhibition area at Plastimagen 2016. An ENGEL e-motion 440/160 will be producing 155 ml round containers with an integrated tamper-proof seal using a 4-cavity mould from Otto Hofstetter (Uznach, Switzerland). Thanks to in-mould labelling, the production cell will be outputting ready-to-fill packaging. In this application, Beck Automation (Oberengstringen, Switzerland) is presenting its new BECK-FLEX system with which IML-packaging can also be produced in small batch sizes with high economic efficiency. BECK-FLEX supports flexible use with various moulds – for both containers and caps –, labels and injection moulding machines with a clamping force of up to 420 tonnes.

As cycle times, in addition to flexibility, are decisive for a packing manufacturer's ability to compete, ENGEL has designed its all-electric ENGEL e-motion injection moulding machine for high-performance operation throughout. Cycle times of well below 3 seconds and injection speeds of more than 500 mm per second are achieved. ENGEL e-motion machines combine best-in-class performance with maximum energy efficiency and hygiene. The closed system for toggle levers and spindles guarantees optimal, clean lubrication of all moving machine components at all times, thus complying with the strict cleanliness requirements of the food industry.

ENGEL at Plastimagen 2016: Austrian Pavilion, stand 405
(Engel Austria GmbH)

Newsgrafik #31029
 28.01.2016

Building bridges between development and practice  (Company news)

"inject – the injection moulding forum" from ENGEL AUSTRIA takes place for the first time on March 8th and 9th, 2016 in Schwertberg, Austria. The purpose of the German speaking two-day event is to make the latest research findings more accessible to injection moulders and to promote the sharing of experiences among them.

Knowledge gives one an edge over competitors and is the basis for success. ENGEL's system philosophy has therefore always included an extensive array of training courses. "inject – the injection moulding forum" signifies a step in a new direction for the injection moulding machine manufacturer and system expert. Unlike the forum events focusing on applications and technologies that ENGEL regularly holds in Austria and at its subsidiaries around the world, the new injection moulding forum will connect the basic development of injection moulding technology with the practical challenges faced on a daily basis.

"Progress is continuously being made even in standard thermoplastic injection moulding, but it is often a very long time before plastics processors learn about the latest findings and are able to use them to optimise their processes," as Robert Brandstetter, the manager of ENGEL AUSTRIA's training department in Schwertberg, Austria, points out. "In 'inject – the injection moulding forum', we are creating a platform that will enable us to present new developments much earlier and in a way that allows them to be used every day."

Food for thought and sharing experiences
The forum, which will take place regularly starting in 2016, is conceived for injection moulders, plastics technicians, process optimisers, quality managers, production managers and managing directors in the automotive, technical moulding, teletronics, packaging and medical industries. Among other things, the following topics will be covered at the premiere event in March:
-Plastification – what really matters
-Material decomposition and its consequences
-Switching over correctly
-Monitoring and adjusting process parameters
-Interpreting injection pressure curves
-Cooling water quality and temperature control technology
-Industry 4.0 – challenges and opportunities

The topics will be discussed in presentations and short talks with the objective being to provide attendees with food for thought and encourage them to exchange experiences and information. "We will be able to say the event has been a success if every attendee can take new ideas and tips for overcoming their specific challenges back to their respective company," says Brandstetter. Both experts from partner companies and ENGEL development and product managers will be giving talks and will be on hand for individual attendees to speak to.

Close connections between industrial and university development
ENGEL invests EUR 80 million in research and development every year, keeping an eye on challenges that are of fundamental nature as well that focus on applications. Many research projects involve partners such as raw material producers and injection moulders, and the Group also works very closely with Johannes Kepler University (JKU) in Linz, Austria, regarding all areas of the injection moulding technology spectrum. Prof. Dr. Georg Steinbichler, the Senior Vice President of Research and Development Technologies at ENGEL AUSTRIA, is also the head of the Institute of Polymer Injection Moulding and Process Automation at JKU. "Even in standard injection moulding processes, there is still plenty of potential for improvement, and with our developments, we are continuously trying to leverage this and make it accessible to injection moulders. Access to this knowledge is crucial to injection moulders if they are to remain competitive in the long term," as Prof. Dr. Georg Steinbichler emphasises. "That will be confirmed again by 'inject – the injection moulding forum'. Our networks also have the important effect of helping to make our industrial locations more competitive."

"inject – the injection moulding forum" takes place on March 8th and 9th, 2016 at ENGEL's technology centre in Schwertberg, Austria. The event will be held in German and the attendance fee is EUR 490.
(Engel Austria GmbH)

Newsgrafik #30878
 14.12.2015

ENGEL at the Saudi PPPP 2016 in Riyadh  (Company news)

Maximum output, consistent quality and constant machine availability: At the Saudi Plastics and Petrochem trade fair taking place from January 18th to 21st 2016 in Riyadh, Saudi Arabia, the injection moulding machine manufacturer and integrated system expert ENGEL will be demonstrating how these requirements can be combined with excellent profitability and energy efficiency through the perfect harmonisation of injection moulding machine, mould, automation, application technology and support. ENGEL's exhibits and demonstrations will revolve around the manufacture of bottle caps, thin-walled packaging, pallets and fittings, as well as consumables for medical and laboratory use.

Photo: Maximum output with minimum energy consumption: the all-electric ENGEL e-cap injection moulding machine produces more than 115,000 bottle caps per hour.

"ENGEL is one of the most preferred plastics processing industry partners in the Gulf States, and our system solutions are responsible for a large percentage of this success," says Andreas Leitner, Sales Director Middle East at ENGEL. "It's only when we coordinate all the components of a production cell from the very beginning while taking individual requirements into consideration that we're able to make full use of the cell's quality and efficiency potential and create competitive advantages for our customers." Besides injection moulding machines, ENGEL system solutions can include automation, the integration of upstream and downstream process steps, process technology, the mould, quality assurance and other peripheral components. ENGEL works with system partners to enable it to develop the optimal solution for each individual situation, and three of those partners will be joining ENGEL in Riyadh. They are mould makers Otto Hofstetter (Uznach, Switzerland) and ifw (Micheldorf, Austria), and BECK automation (Oberengstringen, Switzerland), an automation expert specialising in high-speed and IML applications. The companies will be available during the exhibition to answer specific questions and will be able to offer initial on-the-spot assessments for new project ideas. The partners possess many years of experience and have completed many projects in the Middle East together, particularly in the areas of caps and closures, thin-walled packaging, fittings and pallets.

All-electric ENGEL e-cap has established itself in the caps and closures market
The caps and closures market in the Middle East is extremely dynamic. "ENGEL has established itself here very well with the all-electric ENGEL e-cap injection moulding machine," says Leitner. "In the United Arab Emirates, for example, all the well-known bottlers and bottle cap producers now use ENGEL technology. There is a clear trend towards all-electric machines in this segment.“

In 1998, ENGEL became one of the first European injection moulding machine manufacturers to launch an all-electric machine onto the market and has continued to develop and update the ENGEL e-motion series for high-performance applications ever since. In 2010, ENGEL presented a high-speed all-electric machine specifically tailored to the requirements of the caps and closures industry based on this mature technology in the ENGEL e-cap. With cycle times of under three seconds and injection speeds of up to 460 mm per second, ENGEL e-cap injection moulding machines are designed for highest output performance and have set new standards for the entire industry in process stability and efficiency. Compared to other machines on the market used to produce closures, ENGEL e-cap machines require significantly less energy and cooling water, are very clean and make a sustainable contribution to protecting the environment. "Energy efficiency is becoming extremely important in Saudi Arabia," as Leitner says. "With subsidies being reduced, electricity is going to become considerably more expensive in the next few years."

In addition to their all-electric drive technology, ENGEL e-cap machines also boast other features that contribute to their particularly high efficiency levels. These include a powerful, premium-quality injection unit, increased ejection force and a reinforced, faster clamping drive unit. Thanks to their powerful direct drive units, ENGEL e-cap machines are able to process even non-free-flowing types of HDPE with the greatest precision and therefore guarantee extremely low unit costs even in the manufacture of lightweight closures.

Plastic pallets make logistics sustainable
ENGEL is helping plastics processors in the Middle East to follow the trend of switching to plastic pallets with flexible plant concepts based on its large yet compact ENGEL duo machines. "In the Middle East, pallets made from plastic are especially environmentally friendly compared to wooden pallets," explains Leitner. There are several reasons for this. As there are no forests in the Gulf States, all the raw material for the production of wooden pallets has to be imported, whereas plastic granulate is produced in the region. In addition, plastic pallets don't have to be treated with pesticides and fungicides, which means environmentally harmful chemicals don't have to be used. Plastic pallets are also neither hygroscopic nor combustible, have no sharp edges and cannot splinter. This reduces the risk of injury and simplifies the import and customs clearance procedures in many countries.

A further advantage of plastic pallets is their low weight. Together with its system partners and raw material producers, ENGEL is able to utilise a wide technology and material spectrum to make the pallets lighter while keeping them very stable and stiff at the same time. When subjected to stress tests, these pallets in lightweight design sometimes even prove to be more robust than wooden pallets, which helps to reduce transport damage. Some companies are already using plastic pallets to strengthen their image – high-quality products require high-quality packaging too.

When injection moulding is used to manufacture plastic pallets, the low MFI values of the materials used are a particularly difficult challenge for the machine technology to overcome. With their very high drive capacity and high-quality screws, ENGEL duo dual-platen machines are optimally equipped to deal with it, however.

Industry expertise for flexible solutions
Besides the markets for bottle closures and plastic pallets, the demand for thin-walled containers, fittings and products for medical and laboratory use is also contributing to the growth of the plastics industry in the Middle East. ENGEL and its partners are exhibiting sample parts, presentations and videos that demonstrate how even the highest requirements can also be met safely for these market segments.

At the ENGEL headquarters in Schwertberg, Austria, the expertise obtained from projects all over the world is bundled in the machine manufacturer's five business units. Its experts in the packaging, medical, technical moulding, automotive and teletronics industries work in close cooperation with its production plants, subsidiaries and representatives around the globe, as well as with its product and technology development departments. ENGEL is therefore able to be extremely flexible when meeting individual customer needs.

ENGEL at the Saudi PPPP 2016: hall 2, stand 405-2
(Engel Austria GmbH)

Newsgrafik #30754
 10.11.2015

The Fakuma 2015 was a great success for ENGEL  (Company news)

For ENGEL, the Fakuma 2015 was one of the most successful in recent years. Both the number of visitors at the stand and the project volume discussed at the trade fair are significantly higher than in the previous years. inject 4.0 contributed significantly to this success. The entire stand was designed as a smart factory because Industry 4.0 has long become everyday practice lived out at ENGEL. The visitors at the stand were impressed by the number and consistency of the products and services already available today that provide sustainable increases in productivity, availability, quality and flexibility for manufacturing processes and help make enterprises fit to face the challenges of the future.

"The issue of Industry 4.0 is clearly more than just a buzzword; it is the megatrend among the plastics processors," says Dr Christoph Steger, Chief Sales Officer at ENGEL. "Many trade fair visitors took advantage of the chance to inform themselves at our stand about the possibilities for networking, systematic data utilization and the use of intelligent assistance systems in the context of our inject 4.0 solutions and to discuss their individual challenges and questions. Once again, it became clear at the Fakuma 2015 just how great the potential is that Industry 4.0 offers and how many products, technologies and services ENGEL already has available to leverage it."

Intelligent systems for greater quality and process capability
ENGEL presented both established and new solutions for the three core areas of a smart factory – smart machines, smart production and smart services. All manufacturing cells were linked with each other via ENGEL e-factory, the manufacturing execution system from ENGEL. In addition, the ENGEL e-connect customer portal on a central main computer provided an overview of the machine statuses and demonstrated how spare parts can be identified and ordered online during real-time operation. Intelligent assistance systems that continuously and autonomously improve process capability and quality were integrated into both the injection moulding machines and the robots. In addition to iQ weight control, ENGEL presented two new products in this respect at the Fakuma 2015: iQ clamp control and active vibration control.

The prefix "iQ" stands for "intelligent quality"; this means that expert knowledge is integrated into the injection moulding machine's control unit. By continuously adapting the clamping force, iQ clamp control automatically keeps mould breathing constant even under fluctuating process conditions. In this way, the software significantly reduces the risk of quality deficiencies, ensures optimal mould ventilation, protects the mould against overfilling and boosts energy efficiency. iQ weight control is the logical companion for the injection side of the machine. The system recognises fluctuations in melt volume and viscosity and compensates for them during injection as well as the holding pressure phase of the same shot.

Thanks to the new active vibration control, the ENGEL viper linear robots not only detect their own oscillations, but can also react to vibrations that are caused by external influences. ENGEL demonstrated the great potential of this new development with an ENGEL viper 40 double robot. Despite the high load weight, the robot operating with active vibration control reached a stable working position within a very short time. This reduces the cycle time in many applications.

Process integration ensures cost-effectiveness
In the area of process technology, ENGEL presented something special in Friedrichshafen for all five target industries: automotive, technical moulding, teletronics, medical and packaging.

Thus at the Fakuma 2015, ENGEL sounded the starting gun for the first highly automated production of decor elements with the ENGEL clearmelt method. The manufacturing cell being presented, consisting of an ENGEL duo combi M injection moulding machine and an ENGEL easix multi-axis robot, is intended for HIB Trim Part Solutions in Bruchsal, Germany. With this cell, the automotive supplier will produce decor elements with real wood veneer for automobile interiors. The ENGEL clearmelt technology combines back injection of inserts with polyurethane surface finishing and thus boosts efficiency significantly in comparison to conventional multiple-step production processes.

Process integration was also the guiding theme in the teletronics part of the exhibition. On an ENGEL insert vertical machine, thermal switch housings were fabricated in a fully automated process. The raw material for the brass carrier plates was fed directly from a reel and pre-punched including creating a thread. The thread was tapped servo-electrically before the carrier plates – still on the line – were overmoulded with fibreglass filled polyamide. Quality inspections including a 100% short-circuit test were carried out directly after the injection moulding process during ongoing production. Eight ready-to-install parts left the production cell every 20 seconds. With this high degree of integration, the system solution implemented by ENGEL in collaboration with its partner MMS Modular Molding Systems guarantees the lowest possible unit costs and makes composite manufacturing economical even at locations with high wage levels.

Further highlights at the ENGEL stand include the fully automatic production of thermoplastic-silicone composite components that require no post-processing, the fabrication of needle holders for injection syringes in a consistently GMP-conform manufacturing cell and the high-speed production of round containers with highly flexible IML automation.

An indicator for further positive development
"Process integration and automation continue to be among the most important motors driving innovation and growth," as Steger emphasises. "This is a worldwide trend, whereas Germany is one of the pioneers." The fact that processors around the world pay close attention to the innovative strength and experience of the technology companies in Western Europe is mirrored in the rising internationality among the visitors at the Fakuma. The very positive mood in Friedrichshafen is therefore an important indicator concerning the economic situation that can be expected in the coming year for the plastics industry, not just in Europe, but also beyond.
(Engel Austria GmbH)

Newsgrafik #30722
 03.11.2015

Faster positioning for shorter cycle times  (Company news)

Thanks to the new active vibration control, the ENGEL viper linear robots not only detect their own oscillations, but can also react to vibrations that are caused by external influences. Actively compensating for oscillations during the running process increases positioning speed and reduces cycle time. At Fakuma 2015, ENGEL was setting a new trend with this development.

In mobile phones, 3D motion sensors have long become standard equipment. Now the ENGEL viper robots also use this technology and thus significantly boost their performance and efficiency. While up to now, the robots own expected oscillations were calculated for vibration control, external influences can now also be compensated for online. Thus the robots now also make a contribution to help the injection moulding process continuously optimise itself and make production smarter in the sense of Industry 4.0.

Thanks to the active vibration control, the ENGEL viper robots reach a stable working position more quickly and operate with significantly greater positioning accuracy, which is important for such tasks as placing insert pieces or transferring pre-moulded parts.

Perfect synchronisation of far more than twelve axes
An ENGEL viper 40 double robot gave an impressive demonstration of this at Fakuma 2015. The respective grippers held a sleeve and a corresponding core. The two robots with a common Z-axis rotated the two parts together, inserting one inside the other and separating them again multiple times within a very short time without the sleeve and core touching each other. In addition to the active vibration compensation, another advantage of the ENGEL viper robots came into play: the perfect synchronisation of independent movements. Each of the twin robots had three NC and three servo rotation axes. During the exhibition, a total of twelve axes were controlled synchronously – which is far from exhausting all the possibilities.

All ENGEL viper robots will be equipped with active vibration control starting from size 20 up to the largest ENGEL viper 120 robots with a load capacity of 120 kilograms. The ENGEL viper 40 and 60 robots made the start in time for Fakuma 2015.

New drive package for more efficient dynamics
In revising its linear robot series, ENGEL has not just increased the positioning speed, but has also boosted the overall performance and efficiency. The new multidynamic drive package ensures that the robots automatically adapt their dynamics to the real weight load. Thus the ENGEL vipers operate faster when bearing lighter loads and slower with heavier ones. The efficiency control function also takes the cycle of the injection moulding process into account. Within only three cycles, the ENGEL viper achieves the optimal dynamics for the respective injection moulding process, for example by reducing its own speed corresponding to a long cooling stage without increasing the overall removal time. While the machine operator previously had to calculate the optimal handling speed for each process individually and set it manually, the ENGEL viper robots now automatically manage this themselves.

All these measures make significant contributions that reduce overall cycle times and boost energy efficiency. Beyond that, the mechanical components are given the best possible protection against wear, making longer maintenance intervals possible and yet still ensuring long lifetimes.

Complete integration makes it easy to master complex processes
The dynamics of the market constantly create new challenges for the injection moulding processors. ENGEL automation provides custom-fit solutions for all applications from simple pick-and-place tasks up to highly-integrated, multiple-stage production processes. What makes ENGEL solutions special is the fact that all components – injection moulding machines, linear and multi-axis robots – harmonise perfectly with each other thanks to their common CC300 control platform, and an existing solution can be easily expanded or set up for a different task at any time.

The CC300 relies on a simple operating concept and intuitive user interface. To achieve this, the robot controls are integrated into the controls of the injection moulding machine as a subsystem of the CC300 so that machine operators no longer need to familiarise themselves with separate control logic concepts. The additional movement instructions for the robot integrate seamlessly with the graphical user interface of the machine control unit, which considerably simplifies above all the programming and operation of complex process workflows and makes an additional PLC unnecessary. To allow for fast parameterisation despite the complexity of the overall system, the CC300 control unit provides the user with different ways of visualising the process sequence, from the simple choice of preprogrammed standard sequences to the object-oriented graphical creation of complex process sequences.

Not only machine and robot merge to become one unit without requiring extra hardware, but also further peripheral equipment like conveyor systems, laser units or optical systems. In the fully integrated solutions, all components of the manufacturing cell access the same shared database. This reduces the risk of data-entry mistakes and further optimises the overall efficiency because all components automatically coordinate their movement sequences and feedback loops with each other.
(Engel Austria GmbH)

Newsgrafik #30736
 30.10.2015

ENGEL at Plast Eurasia 2015  (Company news)

Consistent quality, permanent availability, maximum output and high energy efficiency – in order to reliably achieve these criteria for success, more than reliable machines are needed. It is only the perfect synergy of injection moulding machines, process technologies, automation and further peripheral systems that enables plastics processors to utilise the whole potential for efficiency and quality and always be one step ahead of the competition. At the Plast Eurasia 2015 from 3rd to 6th December in Istanbul, the injection moulding machine manufacturer and system expert ENGEL will demonstrate how this can be translated to practice with innovative applications.

Photo: The all-electric ENGEL e-mac injection moulding machine achieves top performance and maximum precision at very low costs.

Each national market and each industry poses its own specific challenges. Thanks to its global presence, its many years of experience in the industry, its application-specific research and its outstanding expertise in system solutions, ENGEL, with headquarters in Schwertberg, Austria, develops tailor-made solutions for its customers and is therefore a preferred partner for the worldwide plastics processing industry. Such solutions include injection moulding machines, process technologies and robots that are all developed and manufactured by ENGEL. Beyond that, components from partner companies are also integrated into the overall concept. During the four days of the trade fair, ENGEL is presenting an extensive selection from this broad portfolio of solutions. The focus will be on maximum quality, efficiency and productivity.


Large moulds on small machines
Very short cycle times with maximum safety and at the same time with very low investment costs – these are the demands placed on the production of consumable articles for medical and laboratory use that are fabricated in large batch sizes. The exhibit at the ENGEL stand demonstrates how these at first glance contradictory attributes are united in the production of Petri dishes on an ENGEL victory 300 tech injection moulding machine with a clamping force of 3,000 kN.

The special feature of the machines in this series is their tie-bar-less clamping unit which allows for particularly efficient fabrication concepts. Since the mould mounting platens can be used fully, right up to the edge of the platen, large and bulky moulds can be fitted on relatively small injection moulding machines. For many applications, it is possible to use a much smaller injection moulding machine than the mould size would dictate when using a traditional machine with tie bars. This keeps both investment outlay and operating costs low. Applications with multiple-cavity moulds but comparatively small projected component surfaces are a good example for this. For the production of the Petri dishes, a 4+4-mould is used that was manufactured by Plastisud in Castelnaudary, France. The total shot weight for all eight parts – four bottom and four top parts – is only 51 g.

The manufacturing cell only needs 4.8 seconds to produce four Petri dishes. The high-speed automation that ENGEL has realised together with its partner Hekuma (Eching, Germany) makes a significant contribution towards achieving such short cycle times – as does the tie-bar-less technology, because the handling equipment can access the mould area directly from the side without having to circumvent any obstacles.

The hydraulic ENGEL victory injection moulding machine presented in Istanbul is equipped with the ENGEL ecodrive servo-hydraulics – another factor for efficiency. Thanks to ecodrive, the drives are idle and consume no energy during cooling phases, for example. Depending on machine type and application, this reduces energy consumption by 30 to 70 percent.

The entire manufacturing cell is designed for highly regulated clean room operation. As a system provider, ENGEL is continually expanding its portfolio of GMP-compliant products. Besides the injection moulding machines, conveyor belts, pipe distributer systems and gripper housings developed by ENGEL are also available in clean-room designs.

Top performance at minimal costs
At ENGEL's automotive exhibit area at the Plast Eurasia, things go all-electric. An ENGEL e‑mac injection moulding machine convincingly demonstrates that top performance and maximum precision can be achieved at very low costs.

From injecting and metering to mould and ejector movements, all drives on the ENGEL e‑mac are servo-electric and achieve an optimal level of efficiency. The drives are operated by a modern axis system solution with a stabilised intermediate circuit; braking energy is recovered and fed back into the grid in order to achieve high energy efficiency. Short cycle times are ensured by simultaneous movements of the drive axes. With an acceleration rate of more than 20 m/s2, the ENGEL e-mac belongs to the top class in worldwide comparison.

In addition, the particularly compact design of the ENGEL e-mac also increases cost-efficiency, because in many companies, productivity per floor space has already become an important operating figure.


Close to its customers – anywhere in the world
Injection moulding machines and manufacturing cells continually need to boost their output, efficiency and flexibility. This also results in changing requirements for the machine manufacturer's service organisation. ENGEL has taken up this challenge and is continuously expanding its worldwide service network.

Training and service are fixed components of the ENGEL system philosophy all over the world. ENGEL also has its own training centre in Istanbul where seminars and workshops take place regularly. ENGEL has been active in Turkey since 1989. Building on the original distributor, ENGEL founded its own sales and service subsidiary in 2008.

Since the company was founded in 1945, ENGEL has been 100 percent family-owned and independent of external investors, thus guaranteeing both customers and staff stability and a long-term perspective. ENGEL achieved a global turnover of one billion euros in the 2014/2015 financial year. The group has over 4,800 employees.
ENGEL at Plast Eurasia 2015: hall 12, stand 1216
(Engel Austria GmbH)

Newsgrafik #30676
 15.10.2015

inject 4.0 – the answer for a smart factory  (Company news)

Productivity, quality and flexibility are decisive for a competitive edge. But to achieve optimal results, it is no longer enough to deploy the best injection moulding equipment; it is all about leveraging its maximum potential. inject 4.0 – this is ENGEL's approach for meeting these challenges. At Fakuma 2015, the machine manufacturer is presenting products and solutions that are already available today to support production optimisation towards the goals of the "Industry 4.0" concept.

"Industry 4.0 is above all one thing: a tremendous opportunity that we want to take advantage of together with our customers," says Dr Stefan Engleder (photo), CTO of ENGEL AUSTRIA, while at Fakuma 2015 in Friedrichshafen, Germany. "Industrial revolutions occur on average every 50 years. We view it as a great opportunity to experience one and be involved in shaping it for our industry." However, Dr Engleder emphasises that he does not consider the word "revolution" to be very appropriate. "The changes that we are currently experiencing are more like an evolution." Thus for ENGEL, Industry 4.0 is not a new idea, but is already long-established daily practice in many areas. What is new is the fact that, under the inject 4.0 brand, ENGEL is bundling the products and services that are already available now together with coming developments that help turn a manufacturing operation into a smart factory.

To achieve a "smart factory" is the goal of inject 4.0. With the help of the networking and integration of production systems, the systematic exploitation of process and production data and the use of adaptive production systems, the manufacturing processes in a smart factory continuously optimise themselves. "We're not talking about smart products," says Engleder. "That is the domain of the processor. We see it as our job to aid our customers in optimising their manufacturing processes."

The smart factory is based on three core elements:
-smart machines that boost process capability and quality with self-adapting, decentralised systems,
-smart production to ensure high levels of productivity thanks to horizontal and vertical data integration, and
-smart services that improve availability quickly and efficiently thanks to close proximity and the use of remote maintenance tools.

smart machines: distributed intelligence boosts process capability
The human-machine interface is becoming increasingly important. It should also be possible to set up, operate and above all monitor complex injection moulding processes easily and intuitively. In the smart factory, the system operator is supported by a variety of assistance systems to achieve this. They all have the goal of boosting process capability without requiring the operators to acquire special skills. Examples of such systems are the iQ weight control and the iQ clamp control software solutions and the ENGEL e-flomo temperature-control water distribution system. The iQ products continuously analyse process parameters relevant for productivity and quality, recognise deviations from the target specifications and automatically execute countermeasures during the on-going process, while ENGEL e-flomo compensates for temperature fluctuations in the mould and thus also contributes to high process consistency.

smart production for greater productivity
The smart production concept includes the entire machine park in its focus with the goal of increasing productivity. In the ENGEL e-factory, ENGEL has its own MES (Manufacturing Execution System) in its portfolio that is specifically tailored for the requirements of the plastics processing industry and thus achieves an extremely high level of vertical data integration all the way down to individual cavities. By supporting centralised access to all pertinent status and process data and comparing these with quality parameters, ENGEL e-factory improves transparency – both in local operations and at a global production network level. Thanks to the networking of all machines and locations, the processor can make optimal use of available capacities, query the status of all injection moulding machines at any time and create documentation very easily.

smart service: putting the focus on availability
The third core element of the smart factory is smart service. Remote maintenance and preventive maintenance are already a matter of course for many ENGEL customers and important components for high machine park availability. The new ENGEL e-connect customer portal has made the collaboration between plastics processors and ENGEL even easier and faster. For example, spare parts can be identified online and ordered immediately, and service requests can be sent via smartphone.

While the smart machine and smart production factors lie within the responsibility of the processor, some smart service solutions make it necessary for ENGEL as a supplier to have access to specific customer data as released by the customer for that purpose. "This requires more than mutual trust," emphasises Stefan Engleder. Defining security standards is one of the challenges that the fourth industrial revolution entails. "This is not just an internal issue for us, ENGEL is also actively involved at the Euromap level," says Engleder. "We are working towards a common information model on the basis of the OPC UA architecture. This technology-neutral concept offers a unique chance to achieve standardisation that we should definitely take advantage of."

From individual machines to a global production network
With inject 4.0, ENGEL helps its customers to achieve significant increases in productivity, quality and flexibility. The first three industrial revolutions also focused on boosting productivity, but each led to increased complexity as well. The fourth is also no exception here, but it is the first to directly include a solution for increasing complexity. Industry 4.0 provides manufacturers with the tools they need to master this complexity.

However, it is a different matter when it comes to flexibility. In the three previous industrial revolutions, production experienced substantial losses in terms of flexibility. Thanks to Industry 4.0, it is now again becoming possible – for the first time in 200 years – to boost flexibility up to or even beyond the level of purely manual craftsmanship. Industry 4.0 thus opens up the opportunity for the plastics processing industry to solve some of the major challenges of the future.

Industry 4.0 will be different for each injection moulding task, each company and each location – another fact that becomes clear in the inject 4.0 presentation at the ENGEL trade fair stand at Fakuma 2015. "There will be many future challenges and solutions that we cannot even imagine today," says Stefan Engleder. "The advantage of the evolutionary development of Industry 4.0 is the fact that each company can start implementing a specific solution adapted to its own requirements at any time and then gradually develop it further. Optimising manufacturing processes starts with the individual machines and can reach all the way up to a global production network."
(Engel Austria GmbH)

Newsgrafik #30591
 30.09.2015

ENGEL at Andina-Pack 2015 in Bogotá  (Company news)

Picture: Thanks to the barrier-free access to the mould area, the tie-bar-less ENGEL victory injection moulding machines make it possible to realise particularly efficient production concepts.

The injection moulding machine manufacturer with headquarters in Schwertberg, Austria, will be demonstrating an automated and fully integrated production solution for the fabrication of polypropylene stacking boxes on an ENGEL victory 500/120 spex injection moulding machine with an ENGEL e-pic robot. "In order to boost productivity, the packaging manufacturers in Colombia are increasingly relying on high-performance, energy-efficient injection moulding machines and on automation," emphasises Dr. Christoph Steger, Chief Sales Officer at ENGEL.

High performance with a small footprint
The tie-bar-less clamping unit of ENGEL victory injection moulding machine pulls almost all the stops for increased efficiency. For example, the barrier-free access to the mould area accelerates mould set-up, increasing availability and simplifying automation because the robot can access the mould directly from the side without having to circumvent any obstacles. In addition, the tie-bar-less injection moulding machine makes it possible to realise particularly compact production cells, thus increasing productivity per floor space. Because the platen surface can be fully used right up to the edge, much larger moulds can be mounted than on machines of the same clamping force with tie bars. This advantage is particularly great when producing three-dimensionally complex components, when multi-cavity moulds are used, and in multi-component injection moulding. What these applications have in common is that they require bulky moulds, but the required clamping force is comparatively low.

Consistent high quality without post-processing
The patented design concept of the tie-bar-less clamping unit provides high precision. Thanks to the Force Divider flexlink, the moving platen follows the mould precisely while clamping force is being built up and distributes the force evenly across the entire cross section of the mould mounting platen, which leads to very high wall thickness consistency and burr-free components. In addition, the stable machine frame and the precise linear guidance of the moving mould mounting platen make fast, low-friction movements possible and also ensure high platen parallelism while the mould is opening and closing as well as excellent mould protection.

Cost-effective automation
The ENGEL e-pic is the most recent addition to the ENGEL robot family. During the four days of the trade fair, it will be removing the 160 x 90 x 70 mm boxes from the mould and discharging them. The goal in developing the pick-and-place robot was to combine maximum performance with maximum economy. The totally new kinematics makes a decisive contribution towards achieving this, combining linear movements with a swivel arm and thus taking up very little space. Another efficiency factor is the use of weight-optimised parts which keep the accelerated masses low. In this way, the servomotor-driven robot can achieve the shortest possible take-out cycles, and it only has low energy requirements. In comparison with linear robots of the same size, the ENGEL e-pic only needs half the amount of energy or even less.

When ENGEL supplies both the injection moulding machine and the robot as an integrated solution, the robot is integrated into the injection machine's control unit. The robot and machine then access a shared database, thus enhancing process reliability and operator convenience, while achieving efficiency optimisations in production sequences.

Market insight meets industry expertise
As the degree of automation and process complexity are increasing, the need for competent and fast service on site are also increasing. Training and service are therefore fixed components of the ENGEL system philosophy. Thanks to Sinemco, ENGEL is positioned optimally for this in Colombia. The long-year distribution partner with headquarters in Bogotá provides not only engineering, application technology consulting, process optimisation and servicing, it also has its own training centre where schooling for machines, robots and technologies take place regularly.

The experts at Sinemco work closely with the packaging business unit at ENGEL headquarters in Austria, which bundles the experience gained from projects in the packaging industry across the globe. Thanks to its outstanding expertise in system solutions, many years of experience in the industry and its strong global presence, ENGEL is a reliable partner worldwide for all development and production processes.
ENGEL at Andina-Pack 2015: hall 18-23, stand 2728
(Engel Austria GmbH)

Newsgrafik #30383
 05.08.2015

ENGEL to present inject 4.0 at Fakuma 2015  (Company news)

"More than a machine" – this is the motto chosen by ENGEL AUSTRIA for this year's presentation of system solution competency at Fakuma from October 13th to 17th in Friedrichshafen, Germany. Automation, process engineering, process optimisation and services are all an integral part of the system philosophy at ENGEL. Based on five innovative applications for the automotive, technical moulding, teletronics, packaging and medical industries, the machine maker, headquartered in Schwertberg, Austria, will be demonstrating at its trade fair stand how machines and production cells can be leveraged to maximum extent thanks to intelligent components and networking.

Photo: ENGEL introduced the all-electric and tie-bar-less small-scale machine at K 2013, and is now extending the model range upwards with the 80-tonnes variant.

Efficiency, productivity, availability, quality and flexibility are decisive for a competitive edge. But to achieve optimal results, you need to do more than just deploy the best injection moulding equipment; it is all about leveraging its potential to the max. inject 4.0 – this is ENGEL's approach for facing these challenges. To this end, ENGEL already has numerous products in its portfolio today that support customers in these optimisations. ENGEL is showcasing these products at Fakuma 2015. For the first time, the entire trade fair stand has been designed as a smart factory, self-optimising production based on three core elements:
-smart machines that boost process capability and quality with self-adapting, decentralised systems,
-smart production to ensure high levels of productivity thanks to horizontal and vertical data integration, and
-smart services that improve availability thanks to proximity and the use of remote maintenance tools.

During the trade fair, all the machine data will be collected on a central computer. The ENGEL e-factory MES solution running on the computer provides features for scheduling jobs, querying the injection moulding machines' states, and creating quality reports and documentation (smart production). At the same time, trade fair visitors can look forward to insights into using the ENGEL e‑connect online customer portal to identify and order spare parts, or issuing service requests without wasting time (smart services).
There can be no doubt that also the machines at the ENGEL trade fair stand work in a smart way. For example, software solutions from the iQ product family enhance process stability by continually analysing the plasticising and moulding process and automatically adjusting in case of deviations from targets, while ENGEL e-flomo autonomously ensures a constant supply of cooling water, thus contributing towards maximising process capability.
The inject 4.0 products that lead to optimal overall results differ for each injection moulding task, each company and each location – another fact that will become clear at the ENGEL trade fair stand. The smart factory in Friedrichshafen will be presenting five innovative applications from five different industries, each of which poses its individual challenges.

Automotive: economic processing of premium woods
Premium woods in the automobile interior purvey well-being and a touch of luxury. In collaboration with HIB Trim Part Solutions in Bruchsal, Germany – an NBHX Trim GmbH subsidiary – and other partners, ENGEL has developed a process for economical manufacturing of decor elements with genuine wood veneers. Using the ENGEL clearmelt method, the veneers are back-injected with a thermoplastic in a single step and coated with transparent polyurethane to protect the surface. The method was introduced in 2009, and now the first serial application is imminent. Before the first manufacturing cell designed for production use is commissioned at HIB Trim Part Solutions, it will be producing premium wood decor elements in a 2-cavity mould at Fakuma.
The core of the manufacturing cell is an ENGEL duo 3550/650 combi M injection moulding machine with an reversing platen that supports high-volume production with short cycle times and maximum productivity. On one side of the mould, the wood veneers are back-injected with PC/ABS, while at the same time on the other side, the base elements produced immediately prior to this are flooded with PUR. ENGEL's system partner for the PUR technology is Hennecke in St. Augustin, Germany. To be able to manage the entire polyurethane process via the display on the injection moulding machine, ENGEL has fully integrated the Hennecke solution into the CC300 machine control unit.
Advances in terms of materials also help to improve the productivity of the ENGEL clearmelt method. The polyurethane used at Fakuma already includes a separating agent, thus saving an entire step. Thus far, cavity surfaces needed to be sprayed with separating agent before processing PUR.
The production cell is highly automated. An ENGEL easix console robot is located above the clamping unit on the injection moulding machine; it both insert places the wood veneer and removes and discharges the finished parts. This is the first time that ENGEL is presenting its new large-scale ENGEL easix robot at a trade fair.
Just like with the smaller ENGEL easix designs, and the linear robots of the ENGEL viper model range, the large multi-axis robots are also integrated into the CC300 control unit of the ENGEL injection moulding machines. Plastics processors benefit from consistent control logic for the injection moulding machine and the automation solution as well as improved machine availability as the setup technician can now complete many tasks for which a programmer was needed in legacy systems. Because the injection moulding machine and robot access the same database, they automatically coordinate their motion sequences and control circuits to achieve maximum overall efficiency. In many applications, this contributes towards shorter overall cycle times.

Technical Moulding: tie-bar-less technology for best-in-class consistency
The significance of multiple component technology in LSR processing is growing. In many applications it is the prerequisite for the integrated injection moulding process that connects thermoplastics and silicone in stable layers. One example of this is diaphragms, as used to ensure functionality and safety in pumps or ventilation systems. In collaboration with its partner Schneegans Freudenberg Silicon (Losenstein, Austria), ENGEL will be producing diaphragms made of glass fibre reinforced polyamide and liquid silicon at Fakuma 2015. The machine used here is an ENGEL victory 200H/60L/140 combi injection moulding machine with an integrated ENGEL viper 40 linear robot. In each cycle, the robot takes off eight finished parts and transfers the PA base bodies to the second set of cavities in the 8+8-cavity serial mould, where they are overmoulded with silicone. While LSR processing is going on, a new set of base bodies is created.
Manufacturing two-component parts optimally leverages the efficiency potential of the tie-bar-less ENGEL victory machine. The high-volume, two-component mould reaches right up to the edge of the mould mounting platen and thus fits on a comparatively compact 140-tonne injection moulding machine. Automation is a second efficiency factor. The linear robot can access the cavities directly from the side, without needing to negotiate obstacles, and thus operate safely despite the large gripper. Finally, efficiency factor number three results from the very high level of process consistency which the tie-bar-less design of the clamping unit ensures. The patented force divider enables the moving mould mounting platen to follow the mould exactly while clamping force is building up and ensures that the clamping force is evenly distributed across the platen face. Both the outer and inner cavities are therefore kept closed with exactly the same force, significantly reducing mould wear and raising product quality. Virtually burr-, waste- and rework-free and fully automated processing of LSR is the prerequisite to producing high-tech products made of liquid silicone in an economic way.

Teletronics: consistent process integration boosts competitive ability
For the first time at Fakuma 2015, ENGEL is presenting a highly integrated, fully automated process for manufacturing thermal switch housings – from the raw material to the 100% tested and labelled metal/plastic composite parts. The core of the production cell is an ENGEL insert 60V/35 single vertical machine. Upstream of the injection process there are a strip uncoiler, a press module and processing module for tapping a thread; downstream there are quality controls, laser marking and another press module.
Thermal switches, such as those used for monitoring electric motors in automobiles or in the domestic appliance industry, are traditionally produced in a complex, multiple stage process. The metal components are typically punched and overmoulded at different locations. This not only requires a considerable logistics overhead, but also ties up a large amount of material because two independent processes need to be ramped up. This is a considerable cost factor, especially where non-ferrous metals are used.
The savings potential through process integration is correspondingly high. The system solution implemented by ENGEL in collaboration with its partner MMS Modular Molding Systems (Berndorf, Austria) guarantees the lowest possible unit costs and makes composite manufacturing economical even at locations with high wage levels.
The raw material for the brass carrier plates is fed directly from a reel and pre-punched including creating a thread. The thread is servo-electrically tapped before the carrier plates – still on the line – are overmoulded with fibreglass filled polyamide. Quality inspection occurs directly after the injection moulding process. In addition to camera-based checks, high voltage testing has been integrated into the progressive mould for the first time, thus ensuring a 100% short-circuit test during production. The OK parts are laser marked to ensure complete traceability before the sprue and sub-gates are removed in the second press module and the finished parts are taken off the line. Eight ready to install parts leave the production cell every 20 seconds. Thanks to the modular design of the MMS systems, additional processing modules can be easily integrated, for example, for resistance or laser welding, riveting, assembly or cleaning of the parts.
Where ENGEL delivers the production line as system solution from a single source, the entire process is visualised and controlled via the CC300 control unit on the ENGEL injection moulding machine. This substantially reduces complexity and simplifies operation. At the same time, consistent integration of the controls ensures complete process documentation and traceability.

Packaging: IML with maximum flexibility
Flexibility is the focus of ENGEL's Packaging exhibition area at Fakuma 2015. An ENGEL e‑motion 440/160 will be producing 155-ml round containers with an integrated tamper-proof seal using a 4-cavity mould by Otto Hofstetter (Uznach, Switzerland). Thanks to in-mould labelling the production cell will be outputting ready-to-fill packaging. IML automation was implemented by Beck Automation (Oberengstringen, Switzerland). The new BECK-FLEX system will be celebrating its global premiere at the ENGEL trade fair stand.
The partner companies are collaborating to demonstrate how IML packaging can be produced with maximum economic efficiency despite small batch sizes. BECK-FLEX supports flexible use with various moulds – for both containers and caps –, labels and injection moulding machines with a clamping force of up to 420 tonnes.
As cycle times, in addition to flexibility, are decisive for a packing manufacturer's ability to compete, ENGEL has designed its all-electric ENGEL e-motion injection moulding machine for high-performance operation throughout. Cycle times of well below 3 seconds and injection speeds of more than 500 mm per second are achieved. ENGEL e-motion machine's combine best-in-class performance with maximum energy efficiency and hygiene. The closed system for toggle levers and spindles guarantees optimal, clean lubrication of all moving machine components at all times, thus complying with the strict cleanliness requirements of the food industry.

Medical: even more safety in the clean room
The centerpiece in ENGEL's medical exhibition space at Fakuma combines no less than three premieres at the same time: the all-electric and tie-bar-less ENGEL e-motion TL machine in the new 80-tonnes variant; and ENGEL is setting new standards in consistent GMP-compliant clean room production with the new stainless steel pipe distributor and gripper housing.
During the five days of the fair, an ENGEL e-motion 170/80 TL will be producing needle holders for 1-ml safety syringes in a 16-cavity mould by Fostag Formenbau (Stein am Rhein, Switzerland). The filigree polystyrene parts – the shot weight is just 0.08 g per part – are designed with a predetermined breaking point that makes it impossible to re-use disposable syringes. This is an important safety feature, especially in emerging countries.
The very thin and different wall thicknesses require extremely precise process control. Too high a clamping force, or fluctuations in the melt volume immediately lead to rejects. To prevent this, two software solutions from the iQ product family by ENGEL are used. One of them is iQ weight control, which automatically detects fluctuations in the melt volume and material viscosity and compensates for them in the same shot. The other is iQ clamp control, the new ENGEL software, which continuously adjusts the clamping force to match the current process parameters based on the mould breathing.
In terms of design, too, the ENGEL e-motion 80 TL ticks all the boxes for constant process control. The innovative frame concept of the all-electric tie-bar-less machine guarantees particularly high platen parallelism and ensures that the clamping force is evenly distributed across the mould mounting surface.

ENGEL introduced the all-electric and tie-bar-less small-scale machine at K 2013, and is now extending the model range upwards with the 80-ton variant. Because there are no tie bars in the way, the mould mounting platens can be fully used up to their very edges. This means that large moulds can be mounted on relatively small injection moulding machines, which in turn keeps the investment and operating costs low and enables particularly compact production cells. In the clean room in particular, productivity per floor space has already become an important efficiency metric.

Further benefits of tie-bar-less technology include fast tooling processes and efficient automation solutions because the robot can reach the cavities directly from the side without having to work around any obstacles. The trade fair exhibit will also demonstrate this. The ENGEL e‑motion 80 TL is equipped with an ENGEL viper 12 linear robot that hangs over the needle holders to the pipe distribution system. The moulded parts are packed in bags separated by cavity in order to support batch tracking right through to the level of individual cavities. To avoid interrupting production when changing the bags, the distribution system is equipped with a buffer. The pipe distributor developed by ENGEL, in contrast to systems previously available on the market, is made completely of stainless steel and thus contributes towards reducing particulate emissions in the clean room.

The robot gripper housing, also developed by ENGEL, achieves something similar. Thanks to its move, easy to clean surfaces, the housing enables the use of standard grippers in the GMP environment.

As a system provider, ENGEL is continually expanding its portfolio of GMP-compliant peripherals. For example, conveyor belts are also offered in a special clean room design. From a single source, ENGEL supplies highly integrated and automated production cells for medical technology and also handles the entire GMP documentation for its customers, on request.
ENGEL at Fakuma 2015: Hall A5, Stand A5-5204
(Engel Austria GmbH)

Newsgrafik #30269
 01.07.2015

Maximum process stability – minimum rejects  (Company news)

Thanks to more than 600 installations on injection moulding machines with electrical injection units, the iQ weight control software developed by ENGEL AUSTRIA has become well established worldwide. Now the injection moulding machine manufacturer is presenting the product with an enhanced range of functions. In addition to the switchover point and the injection speed profile, now the holding pressure can also be automatically readjusted during the running process.

Picture: iQ weight control ensures constant conditions even during the holding pressure phase. Thus even greater weight consistency can be achieved when viscosity fluctuations arise in the melt.

Producing moulded parts of a consistently high quality shot by shot is the aim of every injection moulder. Simply using a precise injection moulding machine will not achieve this, however. Even minor changes in ambient conditions or in raw materials and wear have an affect and can mean that parameters need to be readjusted. The iQ weight control software makes it possible to automatically recognise deviations and compensate for them in the same shot. Thus rejects can be drastically reduced and productivity can be increased decisively.

Stable conditions from the injection to holding pressure
To achieve this, the software analyses the pressure profile at the screw position in real time during the injection process and compares the measured values with a reference cycle online. Based on these results, the switchover point and the injection profile are adapted to the current conditions which keeps the injected volume constant during the entire production run. Thus the effects of fluctuations in viscosity on the filling of the mould, especially in applications with switchover points that depend on the injection pressure, can also be compensated.
ENGEL even goes one step further in the new version of the software. The automatic holding pressure correction now makes it possible to compensate for fluctuations in viscosity even after the injection phase has been completed by adjusting the holding pressure profile.

Benefits also for thick-walled components
The new feature opens up a wider range of applications for iQ weight control. While the automatic readjustment of the injection parameters increases weight consistency, especially in the fabrication of thin-walled components, it is the holding pressure phase that has a crucial impact on quality in the production of thick-walled parts.
During its symposium, ENGEL will demonstrate the potential of the upgraded software in the production of housing parts for medical use made of polypropylene on an all-electric ENGEL e-motion 170/110 T injection moulding machine. Adding small amounts of a material that flows more easily (wax) simulates realistic fluctuations in viscosity. Without corrections to the holding pressure, the weight of the components increases with sinking viscosity by up to 0.29g. This corresponds to almost one percent of the component weight and leads to unacceptable deviations. However, when the automatic holding pressure correction is activated, the component weight remains consistently within the tolerances with fluctuations of 0.07g, and no rejects are produced.

Consistent control logic makes the application easier to use
iQ weight control is available for all ENGEL machines with electric injection units. This includes the ENGEL e-motion, ENGEL e-mac, ENGEL e‑duo and ENGEL e-victory model series. The software does not require any additional hardware: instead, it is integrated into the CC300 control unit of the injection moulding machines. The consistent control logic ensures that the application is intuitive and comfortable to use.
(Engel Austria GmbH)

Newsgrafik #30028
 22.04.2015

ENGEL Symposium 2015: more than 3000 guests expected  (Company news)

Experience. Innovation. Passion – that is the motto at the ENGEL Symposium 2015 in St. Valentin and Linz, Austria, 16th – 18th June. Every three years, the injection moulding machine manufacturer and system expert invites its customers and partners to Austria for its in-house exhibition. The innovative strength of the ENGEL Symposium 2015 will once again surpass its previous editions with several world premiers, numerous challenging applications and pioneering solutions. More than 3000 visitors from all regions of the world are expected.
For three days, everything at ENGEL in St. Valentin and in the Design Center in Linz will revolve around the current and future challenges of the injection moulding industry. The ENGEL large-size machine production plant will practically be transformed into an injection moulding production facility for this event. Sophisticated components for the automotive, technical moulding, teletronics, packaging and medical industries will be produced at new levels of product quality and with previously unseen efficiency in a total of 15 highly integrated and automated production cells. In numerous Expert Corners, the focus will be on topics like new developments for intelligent process optimisation, controlled plastification and the broad spectrum of ENGEL service products, among other things. Beyond that, a top-class lecture programme, a partner exhibition, and the 2015 ENGEL HL-Awards ceremony make the ENGEL Symposium an important international event for the industry.

Machine innovations: presenting a triple pack
Liquidmetal: efficient injection moulding of metal alloys
With Liquidmetal (photo), ENGEL opens the door to completely new classes of material and product characteristics; metal alloys can now be efficiently injection moulded. As the exclusive machine manufacturing partner of Liquidmetal Technologies from Rancho Santa Margarita, California, USA, ENGEL is the only provider worldwide to offer system solutions for the injection moulding of Liquidmetal materials. For the first time, showcased in the production of medical instruments at its 2015 symposium, ENGEL will be presenting the technological and market possibilities that its collaboration with Liquidmetal Technologies opens up for plastics processors and metal goods manufacturers.
Liquidmetal alloys – also called metallic glass – represent a completely new class of material with outstanding mechanical characteristics. The alloys are significantly stronger and at the same time significantly more elastic than the alloys and steels conventionally used, which makes it possible to produce components with a completely new profile of characteristics. Together with Liquidmetal Technologies Inc., ENGEL has developed an innovative solution for the processing of the Liquidmetal alloys on the basis of its all-electric ENGEL e-motion series of injection moulding machines. This solution prepares the way for economical large-scale production of high-precision metal components that previously could only be fabricated with MIM processing or machined individually with CNC systems.
ENGEL sees great potential for the new technique in the area of medical technology. Beyond that, possibilities present themselves in a number of other areas, such as in the sporting goods or the aviation and aerospace industries. The first Liquidmetal applications have already been realised in the electronics industry.

New O-ring machine: producing mass products competitively
O-rings and flat gaskets are central to the reliability and safety of many different applications. Moreover, standard mass-market products in particular are subject to exceptionally high pressure on pricing. These products can only be built competitively with highly precise, reliable and efficient manufacturing technology. In order to provide even better support for its customers in this area, ENGEL has developed a new hydraulic machine for all common rubber compounds. The horizontal machine with screw injection unit ensures very high precision for production with small and mid-sized shot volumes. It makes fully automatic processing possible with conventional brush modules. Additional features include the compact footprint and high energy efficiency thanks to the standard ecodrive drive unit. Because of the long heating phases, the ENGEL servo-hydraulics achieve particularly large savings in the production of O-rings and flat gaskets.

ENGEL e-speed: new machine size reduces cycle times with large shot volumes
ENGEL e-speed – that is the latest machine innovation from the ENGEL packaging business unit. ENGEL presented the 650-tonne hybrid machine with electrical clamping unit and hydraulic injection unit for the first time at the K 2013. At its 2015 symposium, ENGEL will be presenting a second variation of the large high-speed machine with a larger injection unit. The machine size 6 with a screw diameter of 120 mm has added a larger dimension to what the system can offer. Until now, the ENGEL e-speed 650 was available with a 90 mm screw.
The new machine size guarantees short cycle times even with large shot volumes. The ENGEL e-speed will provide an impressive demonstration of this during the symposium with the production of cartridges for the do-it-yourself market. The cartridges have a wall thickness of 1.4 mm and a weight of 50 g each. In a 16-fold mould from Otto Hofstetter (Uznach, Switzerland), this results in a total shot capacity of 800 g. A cycle time of under 10 seconds is achieved for this process.
The cartridge production makes optimal use of the benefits of the hybrid machine. The long hollow forms require a high injection force while the mould must also be able to be opened and closed very quickly. For such requirements, ENGEL has a particularly energy-efficient – with ecodrive as a standard – and also IML-capable solution in its programme: the ENGEL e‑speed. The ENGEL e-speed 650 in machine size 6 achieves the highest hydraulic force that ENGEL has realised in the area of packaging thus far, and with that it sets new standards in the industry.

Large-size machines: sensitivity for flexible integration
Dimensionally stable components with little material
Together with Georg Kaufmann Formenbau (Busslingen, Switzerland), Daimler has developed a production process for the production of boot coverings based on the ENGEL coinmelt injection compression moulding technology. Before this process will go into series production after the ENGEL Symposium, the visitors at the Symposium can convince themselves of its high efficiency. An ENGEL duo 11050/1700 injection moulding machine with an integrated ENGEL viper 60 linear robot will be demonstrating the production of ready-to-install components.
What is special about this application is the three-dimensional very complex part geometry which is strongly ribbed and has several undercuts. Here, the injection compression process allows an excellent fine structure reproduction without warpage. Compared with compact injection moulding smaller wall thicknesses can be realized. This reduces the weight and saves raw material costs. In the injection compression moulding process, the polymer melt is injected into the gap for the compression stroke which requires less injection pressure compared to conventional injection moulding processes. Just before the polymer melt flow stops, the clamping unit starts to close – with controlled parallelism and defined clamping force. The sealing pressure, which replaces the post-injection pressure of the conventional injection moulding process, is distributed homogeneously along the entire length of the part, therefore reducing material shrinkage, also when small wall thicknesses are produced. An important prerequisite for this is a very precise opening stroke of the moving mould mounting platen, which is assured by the individually controlled short stroke pressure pads of the ENGEL duo machine.
ENGEL coinmelt is a low-pressure injection moulding method. This means that machines with lower clamping forces can be used compared to standard injection moulding processes. Under the name of ENGEL coinmelt ENGEL offers system solutions for the different variations of the injection compression moulding.

Set targeted component properties
To control specific component properties with the injection moulding process and boost cost efficiency at the same time – this challenge is at the focus of the production of seat shells for office chairs. The Allgaier Kunststoffverarbeitung company in Nesselwang, Germany, specialises among others in 2K sandwich processes for this purpose. A current project employs a co-injection head, a new development from their machine construction partner ENGEL, that will be presented at the ENGEL Symposium. There an ENGEL duo 4400/700 injection moulding machine with an integrated ENGEL viper 40 robot will be producing seat shells for the new IN office chair from Wilkhahn (Bad Münder, Germany). Because the backrest and the seat constitute one unit, diverse properties must be combined in the component. The backrest must achieve high rigidity, while the seat must be flexible in some areas. In addition, there are high demands placed on the quality of the surface finishing, because the visible areas are not processed any further after the injection moulding. Allgaier masters these challenges with the help of co-injection technology. Glass-fibre reinforced polyamide is processed for the core, and unreinforced polyamide for the outer layer.

Compact integration: an ENGEL easix multi-axis robot does a headstand
The Teletronics business unit also presents itself with a large-scale machine application, the most impressive aspect of which is its extremely space-saving robot integration. The ENGEL easix multi-axis robot hangs head-down into the production cell and therefore needs no separate floor space. An ENGEL duo 1800/400 is employed for the production of operating consoles. The ENGEL easix places two capacitive films in the mould per cycle, and removes a finished part at the same time.
One film provides a single-touch and the other a multi-touch functionality. They are situated at the back of the component, while the front side is decorated via IMD. The decoration film has blank areas that will later be backlit in the completely assembled console. Transparent ABS is injected between the decoration film and the functional films. In so doing, the ENGEL duo machine demonstrates its sensitivity. In order to avoid displacing the films or damaging the capacitive electronics, the flow of the melt must be controlled very precisely.
Together with Leonhard Kurz and the functional film manufacturer PolyIC (both located in Fürth, Germany), ENGEL presents the immediate future of functional surfaces with ready-for-connection capacitive film technology with this application. The exhibit shows a complete process chain for the production of sensitive functional components in a clean-room environment. After take-out, the multi-axis robot transfers the component to a cleaning station provided by the Kist Maschinenbau company (Dresden, Germany) for the ENGEL Symposium. The laminar flow unit is provided by Max Petek Reinraumtechnik of Radolfzell, Germany.

Technology Centre for Lightweight Composites
Composite technologies from a single source
Lightweight design in automobile construction is currently one of the strongest motors for innovation. Aircraft construction leads the way, although the processes for producing lightweight components that have become established there cannot be transferred to the automobile industry that is characterised by large batch numbers. It is therefore necessary to develop new processes as well as new materials that achieve the productivity and cost-efficiency required for automobile manufacturing. Important keys for this include injection moulding, which offers much potential for process integration and automation, and also thermoplastic matrix systems that allow for short cycle times. As an injection moulding machine manufacturer with a great amount of expertise and experience in automation, ENGEL makes significant contributions in this area. At its Center for Lightweight Composite Technologies in St. Valentin, ENGEL promotes the intensive interdisciplinary development of fibre composite technology together with partner companies and universities. During its symposium, ENGEL provides visitors insights into the work being done at the technology centre and calls attention to the opportunities that collaborative research make possible.
Together with its partners Fill (Gurten, Austria) and Hennecke (St. Augustin, Germany), ENGEL will be giving a step by step demonstration of an HP-RTM process with a generic test component on an ENGEL v-duo 3550/1100 machine during the symposium. Hennecke is its partner for polyurethane processing; Fill specialises in the production and processing of fibre-reinforced composite preform elements. Thanks to the close cooperation with its partners, ENGEL can also provide highly integrated system solutions – including the production of preforms – for the production of FRP components from a single source.

ENGEL v-duo keeps production cells compact
The ENGEL v-duo was developed specifically for fibre-reinforced composite applications, but is also flexible enough to be used for processes involving high cavity pressures such as those employed in conventional injection moulding. The large-size vertical machine is characterised by a very high degree of rigidity and excellent platen parallelism, and platen-parallelism control for injection compression moulding is included in the standard version of the machine.
The ENGEL v-duo enables very compact production cells to be used at low costs. In comparison with conventional presses, the ENGEL v-duo machine has only about half the height and is about 60 percent lighter. This reduces the work and costs involved in laying a base for the machine. In many cases, existing hall structures can be used. The clamping unit can be accessed from all four sides instead of just two, which speeds up maintenance work and also simplifies automation. In addition, handling devices can be integrated to save space, and move straight into the mould area. Using sliding tables, insertion tasks, for example, can be carried out outside the clamping unit, which slashes the cycle time even further for many applications. The standard version of the ENGEL v-duo also comes with the ecodrive servo-hydraulic system. The usual hydraulic accumulator has been done away with completely here, allowing the ENGEL v-duo to set new standards in energy efficiency as well.
Visitors at the ENGEL Symposium will also be given exciting insights into the assembly of the ENGEL v-duo machines during the tour of the exhibits. Among the things that can be seen will be an ENGEL v-duo 3600 – the largest model in the series.

All-electric: efficient implementation of high performance
LSR: take advantage of the full potential
High-precision, burr-free, no reworking required, automated – these are the demands placed on elastomer processing. ENGEL demonstrates just how the full potential can be optimally exploited in this area with the production of earplugs made of liquid silicone rubber on an all-electric ENGEL e-mac 170/50 injection moulding machine. For this, a four-cavity mould is used provided by ENGEL partner awetis engineering+manufacturing from Laudenbach, Germany.
The earplugs are removed by an ENGEL e-pic robot. The new pick-and-place robot from ENGEL convinces with a completely new kind of kinematics that combines linear movements with a swiveling arm making it particularly compact and energy-efficient. The ENGEL e-pic fits in the space within the extended safety perimeter of the ENGEL e-mac injection moulding machine.

Maximum performance up into the largest clamping force classes
High performance is the theme of the packaging exhibit. Disposable cutlery will be produced on an all-electric ENGEL e-motion injection moulding machine. Knives and forks, sorted and packaged respectively, leave the manufacturing cell to 24 pieces each per shot. The manufacturing of mass-market products in the packaging industry is subject to particularly strong pressure on pricing. One trend is therefore moving towards multiple-cavity moulds that require correspondingly larger injection moulding machines. ENGEL responded very early to this trend, and today it is the only injection moulding machine manufacturer to offer all-electric machines with a clamping force of up to 6,500 kN.
Because the mould for producing the cutlery does not include any hydraulic components, the efficiency potential of the all-electric machine can be exploited optimally. The machine's rapid acceleration, short opening stroke and simultaneous movements reduce cycle time. About 4.5 seconds are required for the injection moulding of the forks and knives. The production process is fully automated. The cutlery is removed from the side, separated, stacked and packaged. The automation technology partner is Campetella from Montecassiano, Italy. Since absolutely no oil is required, the production cell fulfills the high hygienic demands placed on applications for the food sector.

Expert Corners: intelligent add-ons for machines
Increase the homogeneity of the melt without intervening in the process
One prerequisite for the production of high-quality injection-moulded parts is the thermal homogeneity of the plastificated plastic mass. However, the mass transported by the screw into the screw antechamber exhibits radial and axial gradients in temperature. For a long time, the precise measurement of these differences in temperature during the injection moulding process was impossible due to the difficult conditions. Together with the Johannes Kepler University of Linz, ENGEL has developed an innovative method for measuring the radial and axial temperature gradients in the melt in the screw antechamber based on fact that the speed of ultrasonic waves varies depending on temperature. During its symposium, ENGEL will be presenting the potential this method has for applications.
Measuring systems based on ultrasound are of interest for the monitoring of injection moulding processes because it is a non-invasive method that can be carried out without interfering with the process. The applications for the ultrasonic methods range from the efficient verification of numeric simulations to the optimisation of components in the mix.

New iQ software automatically determines the required clamping force
The iQ product family for intelligent process control and optimisation is growing. A new software will celebrate its world premier at the 2015 symposium. The software automatically determines the clamping force required for the respective mould – without any specifications being set by the technicians. The clamping force is ascertained quickly and objectively on the basis of mould breathing.
Since mould breathing is caused by the expanding pressure in the cavity, it can therefore be used – like the cavity pressure – to optimise the process. In contrast to the cavity pressure, this significant signal can be utilised without additional sensors. By monitoring mould breathing, the risk of flaws such as burr formation can be reduced significantly, and the mould can be reliably protected against overfilling. Even when the process conditions change, the software ensures that mould breathing remains constant by automatically adjusting the clamping force accordingly.
The software and the functions it includes is the first of its kind worldwide and represents yet another unique product that distinguishes ENGEL on the market. The innovation is already the second product in the iQ family. The iQ weight control software, which automatically detects fluctuations in the ambient conditions and raw materials and compensates for them within the same shot, has already been very successful in establishing itself on the market.

ENGEL plus – More than a machine
Smart solutions are also the topic in the ENGEL plus exhibit area of the ENGEL customer service division. There it becomes clear that industry 4.0 is not just a buzzword for ENGEL, but has already long become daily practice in many areas. The latest product is the new ENGEL e-connect customer portal that makes processing service requests and ordering spare parts even easier and quicker while also adding even more transparency. The customer app which carries the same name makes it possible to send service requests directly from a smart phone from any location.
Further smart solutions in the Expert Corner are ENGEL e-factory, the MES solution from ENGEL for the far-sighted control of production processes on a real-time basis, and ENGEL e-flomo, the intelligent cooling water monitoring and control system which is integrated into the machine control unit.
In addition to ENGEL e-connect, two more apps are being presented: ENGEL e-calc for the configuration of injection moulding machines according to material and component being produced, and ENGEL plastyfine, the comprehensive image database that not only helps operators identify faults, but at the same time also describes the physical causes and possible technical processing solutions.
Industrie 4.0 – for ENGEL, that means supporting the people in the production department. The goal is not just to boost the productivity, efficiency and availability of the machines and system solutions, but also to increase the stability and safety of the processes.

Anniversary: 25 years of tie-bar-less technology
Special exhibit showcasing the success story
Compact manufacturing cells, efficient automation and fast set-up processes: With their large platens and free access to the mould area, tie-bar-less injection moulding machines fulfil the need for high efficiency and cost-effectiveness in production in the best possible way. 25 years ago, ENGEL became the first injection moulding machine manufacturer worldwide to present a tie-bar-less machine that still today remains a unique product distinguishing ENGEL on the market. The tie-bar-less injection moulding machines have long become one of ENGEL's biggest revenue sources. More than 60,000 tie-bar-less machines have been delivered worldwide and are successfully adapting to constantly changing requirements. The ecodrive servo-hydraulics and the new ENGEL e-motion TL all-electric tie-bar-less compact series show that ENGEL also has tie-bar-less answers to the trends of the 21st century. "25 years of tie-bar-less technology" – ENGEL is dedicating a special exhibit to this success story at its 2015 symposium.
The 2015 ENGEL HL-Awards ceremony on the evening of June 16th represent another highlight of the anniversary celebrations. ENGEL will be honouring outstanding tie-bar-less applications for the eighth time. New this year is that the prizes will be awarded in three categories: efficient use of the mould area, innovative process integration and economical automation concept.

Learning from a master of the trade: Karim Rashid is coming to Linz
It is already a long-standing tradition for ENGEL to not only present numerous innovations in the areas of products and technology at its symposium, but also to organize top-quality presentations and speakers for the accompanying conference at the Design Centre Linz. Industry 4.0 is only one of the many interesting topics that will be discussed this year in the context of the current challenges and trends in injection moulding.
A special highlight will be the topic presented by Karim Rashid, who will be coming to Linz from New York for the ENGEL Symposium. Karim Rashid is considered to be the pop star in the world of design. Over the past 30 years, his product designs, which are unusual, but always suitable for everyday life, have significantly influenced the way we see products. Rashid will take the guests at the ENGEL Symposium into his world of "blobism" and will reveal new aspects of functionality and design.
(Engel Austria GmbH)

Newsgrafik #29920
 25.03.2015

The direct route  (Company news)

With ENGEL e-connect, the injection moulding machine manufacturer and automation expert, ENGEL makes processing service requests and ordering spare parts even easier and faster, while also adding even more transparency. ENGEL will be presenting its new customer portal for the first time at the NPE2015 from March 23rd to 27th in Orlando, Florida, USA. Another new service product will also be part of the line-up; A customer app, which opens the doors to the world of ENGEL and at the same time to one's own machine park, anytime and anywhere.

Picture: Via the ENGEL e-connect app, machine status and other operating figures can be kept track of in real time.

Be the first in line at any time of day: With its new customer portal, ENGEL shortens the distance to its customers, cuts annoying waiting time and reduces the administrative burden for customer support processes, such as ordering spare parts. With ENGEL e-connect plastic processors, can now request quotations and place orders online at any time. The advantage: It is not necessary to know the exact designation of the spare parts that are needed. In the system, all machines and manufacturing cells that ENGEL has delivered to a respective company are documented along with the corresponding parts lists. There are animated 3D-models of many machine components, so the part that must be replaced, can quickly and easily be found and selected, with just a click. In addition, the online-catalog also contains the current prices for the parts as well as availability information. Should personal advice be needed, or if there are any questions, a number of diverse communication tools are provided such as text and video-conferencing modules, as well as an electronic whiteboard.


Keep track of processing progress at all times

Placing service requests via the ENGEL e-connect portal, is just as easy as ordering spare parts. Immediately after the order has been placed by the user, the request is automatically sent to the respective service team and processing can begin without delay. The system also provides the service technicians with access to the complete history of the plant, which speeds up their search for the solution. Once submitted, the processors can track the status of their service requests, making it possible to plan more reliably.


Service requests via mobile phone

The new customer app – which also carries the name ENGEL e-connect – makes it possible to send service requests to ENGEL from any location, directly from a smart phone. If the injection moulding machines, robots and system solutions are linked via network, the app provides a complete overview of the machine park at all times. Machine status, alarm lists, production volume, cycle times and other operating figures are transmitted in real time to the mobile phone. In the case of unplanned downtime or in the event of a fault, the person responsible for the process can immediately initiate corrective measures via the app, without having to be physically present on site. Commencing with NPE2015, the app will be available in German and English for iOS and Android.

"Throughout its entire life cycle, processing equipment must meet constantly increasing demands on output, efficiency and flexibility. In light of this trend, service products and support are gaining in importance worldwide," says Wolfgang Degwerth, Vice President of the Customer Service Division at ENGEL AUSTRIA. "It is therefore only natural for ENGEL to also be innovative concerning service, to develop new products and thereby also create more added value for its customers."
(Engel Austria GmbH)

Newsgrafik #29900
 19.03.2015

ENGEL at Plast 2015 in Milan  (Company news)

With highly integrated and automated system solutions from a single source ENGEL increases product quality, manufacturing efficiency and thus its customers' competitiveness. The injection moulding machine manufacturer and system supplier will demonstrate how this can be translated to practice with five innovative applications at PLAST 2015 in Milan, Italy from 5th to 9th May.

Photo: With its compact size, the ENGEL e-mac machines provide space-saving solutions.

Double technology integration opens new vistas of quality
The trend of process integration as a path to greater efficiency, safety and quality is well established. Now it is necessary to adopt a more diversified stance. The object is no longer simply to integrate process steps upstream or downstream of injection moulding, but also to combine different process technologies with one another. To produce centre console components in PC-ABS at its trade show stand, ENGEL will be using an ENGEL duo 2550/550 injection moulding machine with integrated ENGEL viper 20 robot to combine two technologies: ENGEL foammelt, the MuCell foam injection moulding process developed by Trexel of Wilmington in the USA, and ENGEL variomelt, a variothermal injection moulding process on the basis of Roctool technologies (Le Bourget du Lac, France). The double technology integration enables the production of thin-walled parts with very high quality surfaces and excellent fine structure reproduction at the same time in a single injection moulding step.
To demonstrate the versatility of this amalgamation of processes, the sample part will have varying wall thicknesses and surface structures. Thanks to ENGEL foammelt the cavity, including the undercuts, is completely filled, and the component has no sink marks after cooling; meanwhile variothermal temperature control provides a high gloss finish without weld lines.

Efficient solution for the highest design requirements
In cooperation with its customer Wegaplast (Toscanella di Dozza, Italien), ENGEL has been developed a production process for designobjects, also using variothermal injection moulding technology. In this application HB-Therm (St. Gallen, Switzerland) is the partner for heating and cooling.
The little trees out of PC-ABS with a high-gloss piano black finish make a good figure whether as a doorstop, bookend, or smartphone holder for battery recharging. The objects have been designed by Francesca Acciardi, who has been awarded with a prize from the ISIA Design Institute in Faenza, Italy.
During the trade show a tie-bar-less ENGEL victory 330/80 tech injection moulding machine and an ENGEL viper 6 robot to will be used. For controlling the whole injection moulding process centrally via the CC300 control panel of the injection moulding machine, HB-Therm’s switching unit Vario-5 will be integrated using an interface.
The tie-bar-less clamping unit of the ENGEL victory injection moulding machine further contribute to a high overall efficiency. Since the mould mounting platens can be used to the hilt, the relatively large mould can be mounted on a small injection moulding machine, resulting in a compact manufacturing cell and low operating costs.
The ENGEL victory tech on show at Plast 2015 will feature the ENGEL ecodrive servo-hydraulic system. With ecodrive, the energy consumption of hydraulic drives is reduced by up to 70 %, depending on machine type and application.

Highest performance with maximum energy efficiency
500 ml food containers will be produced on an all-electric ENGEL e-motion 440/160 featuring a 2-cavity mould by Glaroform (Näfels, Switzerland). In-mould labelling (IML) will be used to decorate the packaging; to do this, ENGEL will collaborate with partner company BECK automation (Oberengstringen, Switzerland).
The steady enhancement of the ENGEL e-motion series is serving to establish the machines in the field of high performance applications for the packaging industry. The newest machine generation is able to achieve cycle times of well under three seconds and injection speeds of more than 500 mm per second, thereby combining maximum performance with maximum energy efficiency. The closed system for toggle lever and spindle always guarantees optimal, clean lubrication of all moving machine components. This makes the ENGEL e-motion the preferred machine type even in regulated areas such as food packaging production.

Higher productivity per square metre of production space
Using the example of a medical technology application ENGEL demonstrates how maximum efficiency can be reconciled with maximum process reliability. An all-electric ENGEL e mac 440/100 injection moulding machine will be manufacturing polystyrene needle holders for safety hypodermics using a 16-cavity precision mould by Fostag, Stein am Rhein, Switzerland.
The ENGEL e-mac injection moulding machines provide extremely high repeatability, and reduced cycle times with parallel movement of the different drive axes. From injecting and metering to mould and ejector movements, all drives in the ENGEL e-mac are servo-electric. This guarantees the best possible precision and process stability while maximizing the effectiveness of the machine as a whole. The drives are operated by a modern axis system solution involving a stabilised intermediate circuit in which the braking energy is recovered and fed back into the grid, thereby achieving very high energy efficiency. The ENGEL e-mac achieves a very high acceleration of up to 20 m/s² on the injection axis. Another benefit is the compact size of the ENGEL e-mac machines which provides space-saving solutions. As a result, the productivity per square foot of production space increases, which has become a key figure for efficiency in an increasing number of businesses.

Efficient use of LIM multi-component processes
The main demands as regards the processing of liquid silicone (LSR) are that it must be fully automatic, waste-free, low in burrs and require no reworking. An ENGEL e-victory 200H/80W/120 combi injection moulding machine – automated with an ENGEL viper 20 linear robot – will impressively show that ENGEL system solutions not only meet these requirements fully, but also handle LIM multi-component processes securely and efficiently. A mould provided by ACH solution (Fischlham, Austria) will be used to produce sensor housings for flow measurement with integrated seals. ENGEL can guarantee maximum precision by using servo-powered injection units. The shot weight is 0,04 g per part, i.e. a total of 0,16 g. Normally the LSR field requires special solutions where very small injection unit volumes are involved. In this case ENGEL meet that need with a standard unit. For dosing the LSR, mini-pumps with 1 litre cartridges are used. They work inside the machine's safety gate without needing extra space. Developed and patented by ENGEL, iQ weight control software applied in the system recognises and automatically compensates for fluctuations in melt quantity during the actual injection process.
The tie-bar-less technology of the ENGEL e-victory machine also makes a decisive contribution to high process stability in this application, while the patented force divider evenly introduces force to the mould across the platen face. Both outer and inner cavities are thereby kept closed with precisely identical force, significantly reducing mould wear and raising product quality. On top of this, free access to the tie-bar-less machine's mould area facilitates the most effective automation concepts.
ENGEL at PLAST 2015: Hall 24, Stand A/B 33/32
(Engel Austria GmbH)

Newsgrafik #29865
 05.03.2015

ENGEL at Chinaplas 2015  (Company news)

With four innovative applications for the automotive, teletronics, medical and packaging industries, ENGEL will again be giving an impressive demonstration of its great industry and system solution expertise at Chinaplas 2015 from 20th to 23rd May in Guangzhou, China. On board: The entire ENGEL robot product range; underlining the fact that automation is becoming increasingly important in Asia. The new ENGEL e-pic pick-and-place robot (photo) is celebrating its first outing in Asia at Chinaplas 2015.

"Quality requirements in China are continuing to rise," as Gero Willmeroth, Sales and Service President at ENGEL Machinery (Shanghai) says in the run-up to Chinaplas. "The biggest challenge is reconciling increasing quality requirements with maximum efficiency and minimum unit cost." The key to this is tailored machine concepts, process integration and automation. In project business, in particular, it is important to not just be familiar with the requirements of the country markets, but also to understand the individual target industries. With its five business units, Automotive, Teletronics, Technical Moulding, Medical and Packaging, ENGEL is perfectly geared for this. Industry experts at ENGEL's headquarters in Schwertberg, Austria, cooperate closely with the subsidiaries, bundling know-how from global projects and defining important research and development focuses with their experience.

ENGEL e-motion TL – making precision economical
The latest machine innovation, the all-electric and tie-bar-less ENGEL e-motion TL, was designed specifically for manufacturing small precision parts, and premium optical components in the electronics industry. The objective here is to combine the highest levels of precision and productivity with maximum energy efficiency and an extremely compact machine design. In this market segment, all-electric machines are the standard. To offer highly compact manufacturing cells here, ENGEL combines all-electric drive technology with a tie-bar-less clamping unit in its ENGEL e-motion TL small-size machine.
ENGEL will be using an ENGEL e‑motion 50/30 TL injection moulding machine with 300 kN clamping force at its trade fair stand to produce 60x board-to-board plug-in connectors in a 16-cavity mould. The very tight pin spacing of just 0.5 mm defines the required level of precision in this application. The machine's most important performance characteristics are an injection pressure of 3200 bar, an injection speed of 800 mm/s and acceleration of more than 40 m/s². At the same time, the high cavity count boosts productivity. Moulds with 4 to 8 cavities have generally been used in the production of FFC/FP connectors up to now.

Tie-bar-less ENGEL victory boosts productivity-to-floor-space ratio
Tie-bar-less injection moulding machines allow for extremely compact production cells, facilitate mould changing and support efficient automation. In its medical exhibition area, ENGEL will be demonstrating how these benefits can also be achieved in production in other industries featuring a hydraulic ENGEL victory tech tie-bar-less machine.
As mould mounting platens on a tie-bar-less clamping unit can be used fully, right up to the edge of the platen, large and bulky moulds fit on relatively small machines. This means that in many cases a smaller machine can be used for the same mould size than compared to a machine with tie bars. The efficiency potential is particularly large in manufacturing complex components, the use of multi-cavity moulds as well as multi-component processes. What these applications have in common is that, although the moulds are large, the required clamping force is low, due to fairly small, projected part surfaces. All over the world, tie-bar-less injection moulding machines represent one of ENGEL's biggest revenue sources. The tie-bar-less ENGEL victory is the top-selling ENGEL machine in China.
Other machines on exhibit at Chinaplas 2015 include an ENGEL duo 2550/600 large-size machine with an integrated ENGEL viper 20 linear robot in the Automotive exhibition area, and an all-electric ENGEL e-cap 440/100 injection moulding machine, which will be producing caps for drinks bottles with a 24-cavity mould at the stand of ENGEL partner HTW Formen- und Fertigungstechnik (Ludesch, Austria) in Hall 9.2 (B61).

New ENGEL e-pic combines linear motion with a swivel arm
Robots are increasingly becoming fixed components of any injection moulding machine in China. "The production of premium parts depends on reproducible cycle times, which can only be achieved through automation," says Gero Willmeroth, citing one of several factors that have caused the percentage of system solutions to continually grow in the order books of ENGEL Machinery (Shanghai). Another factor is that automation, as an integrated part of the process, supports new processes, component functions and product qualities, thus substantially improving the plastics processor's competitiveness.

Chinaplas 2015 takes this trend into account with a special event. ENGEL is involved in the event with a second stand of its own in the "Robot Parade" in Hall 4.2, directly one floor above the ENGEL main stand. One highlight there is the new ENGEL e-pic small-size robot which will be presented for the first time in Asia. The objective in its product development was to be able to offer a powerful but economical solution for easy part removal, sprue separation and controlled depositing, grid depositing and stacking of small components. The totally new kinematics makes a decisive contribution towards achieving this by combining linear and swivelling movements. The swivel arm moves in the direction of the x-axis, which thus completely disappears or merges with the y-axis to form a single unit. This means that the ENGEL e-pic needs far less space than a linear robot in the direction of both the injection and clamping sides. It can be integrated within the injection moulding machine's safety perimeter, thus keeping the entire production cell compact. Another efficiency factor is the use of weight-optimised parts which keep the accelerated masses low. In this way, the servomotor-driven robot can thus achieve the shortest possible part removal cycles, and it only has low energy requirements. In comparison with linear robots of the same size, the ENGEL e-pic only needs half the amount of energy or even less.

Equipped with its own control unit, the ENGEL e-pic robot is not exclusively designed for deployment on ENGEL injection moulding machines, but also for third-party machines without needing any machine-specific customisation. In combination with an ENGEL injection moulding machine, the robot can be integrated with the CC300 machine control unit. The robot and machine then access a shared database, thus enhancing process reliability and operator convenience, while achieving efficiency optimisations in production sequences. The control unit converts the rotary motion of the swivel arm into a linear movement. Users who are used to working with a linear robot do not need to learn new skills.
In addition to the ENGEL e-pic, an ENGEL viper linear robot and an ENGEL easix multi-axis robot will also be taking part in the Robot Parade. With its three robot designs, ENGEL offers an efficient solution for a wide variety of handling tasks. On top of this, ENGEL's automation range includes peripheral components such as conveyor belts and tailored automation solutions.

To be able to develop tailored automation solutions in China, too, ENGEL has established a team of automation specialists locally in the past few years. "We will again be increasing staff levels at our Automation Center in Shanghai this year," says Willmeroth.
ENGEL has developed and built its own robots since 1980, and is the world's leading supplier of injection moulding process automation today.

Best-in-class on-site service throughout the product lifecycle
As technology advances, this has also led to increased demand for maintenance services in China. This explains why ENGEL is currently expanding both its local service network and training offerings. "We see a growing need for information and training in China, particularly in the area of processing technologies." says Gero Willmeroth. "It is important to us to support our customers in the best possible way throughout the entire service life of the injection moulding machine, robot and system solution. This is the added value that ENGEL offers its customers worldwide."
ENGEL at Chinaplas 2015: Hall 4.1, Stand J41 and Halle 4.2, Stand K21 (Robot Parade)
(Engel Austria GmbH)

Newsgrafik #29707
 22.01.2015

ENGEL at PLASTINDIA 2015  (Company news)

Compact production cells, fast mould changes and flexible technology integration: at PLASTINDIA from 5 to 10 February 2015 in Gandhinagar, India, ENGEL will be demonstrating how to achieve premium product quality and the lowest possible unit costs with tie-bar-less injection moulding machines. ENGEL will be producing fittings on an ENGEL victory tech injection moulding machine during the six days of the fair.

Photo: Thanks to their free access to the mould area, tie-bar-less machines are a decisive factor for achieving high cost-effectiveness.

Manufacturing plastic pipe fittings places special demands on production engineering. It calls for large moulds with projecting cores, while at the same time the clamping force required for the application is fairly low. Hardly any other machine on the market meets this requirement profile as perfectly as the ENGEL victory, with its tie-bar-less clamping unit. The tie-bar-less machine concept enables full utilisation of the mould mounting platens and maximum space for moulds. This means that large moulds fit on comparatively small machines, thus reducing the footprint of the production cell; this in turn reduces the cost of investment, while at the same time helping to achieve savings in on-going operations as a smaller machine needs less in terms of operating fluids and power than a large one. ENGEL will be convincingly demonstrating what this looks like in practical terms in collaboration with its mould making partner ifw mould tec (Micheldorf, Austria) in the production of pipe distributors for domestic drain systems.

Tie-bar-less technology for improved cost-effectiveness
The machine used for this purpose will be a tie-bar-less ENGEL victory 740/160 tech injection moulding machine with a clamping force of 160 tonnes. "If we used an injection moulding machine with tie-bars, the machine would have to be almost twice the size to be able to mount the voluminous mould," as Jitendra Devlia, the CEO of ENGEL MACHINERY INDIA emphasises. In addition to this, there is no need to remove a tie-bar or dismantle core pulls to set up the mould on the machine. This means substantial time savings for mould changes, which can translate to productivity gains for the injection moulding machine of more than ten percent in case of frequent mould set-ups.
The 2-cavity mould uses hydraulic collapsible cores. To be able to injection-mould different fitting geometries, it is equipped with replaceable cores which are frequently installed and removed in series production. Where this kind of manual work is necessary, barrier-free access to the mould area also improves the ergonomics, because staff do not need to bend through the tie-bars.

Servohydraulics avoid loss energies
The ENGEL victory machine on display in Gandhinagar is equipped with ENGEL's energy-saving servo-hydraulic ecodrive, which can reduce the energy needs of hydraulic injection moulding machines by up to 70%, compared to standard machines without servohydraulics. The key to this is avoiding energy loss. While the machine is idle, during cooling phases for example, the motor is also stationary and does not use any energy. This means that the degree of energy efficiency depends on the application. "Total efficiency is always decisive," says Jitendra Devlia. “Before any investment, we analyse the entire process with our customer. Energy-optimised hydraulic machines are often more favourable than all-electric machines where moulds with hydraulic core-pulls are used."

Robot integration boosts efficiency and safety
From our automation programme, ENGEL will be exhibiting an ENGEL viper linear robot at PLASTINDIA that impresses in operations with its extremely good positioning accuracy and excellent dynamic. The integration of the robot control unit in the CC300 control unit on the ENGEL victory injection moulding machine helps ENGEL to leverage additional efficiency potentials. Since the robot and the machine access the same database, they precisely coordinate their movements with one another, thus promoting shorter cycle times and boosting energy efficiency. Thanks to the tie-bar-less design the robot arm can reach from the side directly into the mould area. This removes the need for painstakingly avoiding interfering edges and means that injection moulding processes can also be automated in factories with lower roofs.
The linear robot's move instructions are integrated in the machine control unit's graphical user interface so that staff no longer needs to familiarise itself with two different operating philosophies. "Thanks to intuitive user guidance and user-specific views, we support very simple operation and thus substantially improve process assurance," as Jitendra Devlia emphasises.

A short distance from the customer
For 16 years, ENGEL has had its own offices in Mumbai, India; in this time, ENGEL has become the number one importer of premium quality and efficient injection moulding technology. ENGEL has responded to the importance of this market by continually expanding its local sales and service capacities. Four years ago, ENGEL MACHINERY INDIA relocated to larger business premises, extending its portfolio with its own technology centre and training centre. Seminars, workshops and conferences regularly take place there. At the same time, the technology centre is available to customers for mould tests and proving. On top of this, the company's own spare parts warehouse and service hotline guarantee a fast response.
ENGEL at PLASTINDIA 2015: Hall 8, Stand 8 B17
(Engel Austria GmbH)

Newsgrafik #29604
 11.12.2014

Five Star Industry Competence  (Company news)

“It’s your choice to be a winner!” is the motto for ENGEL at NPE2015 from March 23 to 27 in Orlando, Florida. Presenting eight innovative applications, the injection moulding machine manufacturer and system supplier will demon-strate how the specific requirements of five industrial branches—automotive, packaging, medical, teletronics and technical moulding—can be realised with efficient and economical injection molding solutions. They will show that the key to increased competitiveness can be found in both customised, highly-integrated system solutions and flexible standard machines.

Picture: The new ENGEL e-flomo supports fully-automated adjustment of flow rates.

The highlights at the ENGEL booth in the West building, hall A will include the first composite brake pedal manufactured in a one-shot process, the new high-performance ENGEL e-speed machine, the particularly dynamic ENGEL e pic pick-and-place robot, as well as innovative service tools for an even higher level of process security and machine availability.
The plastics industry in North America continues on a course of growth. In particular, there is an increasing demand for innovative techniques and economic solutions for high-performance applications. Both trends are reflected in the exhibits at the ENGEL booth at NPE2015.
One main emphasis will be on lightweight construction, which is currently one of the areas with the strongest growth. "In the next few years we can look forward to strong growth in the injection molding industry, particularly in the field of fiber composite engineering," points out Mark Sankovitch, President and CEO of ENGEL North America with headquarters in York, Pennsylvania. Directed fiber systems have long since established themselves in high-performance products—for example in the aircraft industry. For composite materials to find even wider use in high volume applications, such as in the automotive sector, the biggest challenge at present is to develop manufacturing processes that provide low unit costs despite high volumes. "ENGEL is providing ground-breaking offerings in thermoplastics solutions to provide production breakthroughs across all industries," emphasises Sankovitch. Injection moulding technologies offer great potential for this. ENGEL already fulfils another crucial success factor with its high levels of system solution and automation expertise. To promote even faster development of new processes, ENGEL established its own technology center for lightweight composites in 2012 at the site of its large-scale machine production facility in St. Valentin, Austria. The technology center was created primarily as a platform for interdisciplinary collaboration with international partner enterprises and universities. In collaboration with its system partners, ENGEL has been able to set several milestones in recent years.

ENGEL automotive: Cost efficiency for high-volume lightweight construction
ENGEL and its partner ZF-Friedrichshafen will present one of these milestones in Orlando—a geometrically optimised and stress-resistant plastic brake pedal. The concept for manufacturing a hybrid, brake pedal from thermoplastic fabric received the Composite Innovations Award in 2011, and has been consistently enhanced by ZF since then. ENGEL will be offering a glimpse into the efficiency of the new manufacturing process at its stand at the exhibition. Using a vertical ENGEL insert 1050H/230 single US injection moulding machine with an ENGEL easix multi-axis industrial robot and infrared oven, a continuous-fiber-reinforced thermoplastic semi-finished product (known as thermoplastic fabric) will be heated, preformed in a mould and immediately over moulded with polyamide. The system produces ready-to-fit components; no cutting is necessary.
Thermoplastic fabric offers offer high strength and rigidity. In addition, the product developers at ZF have adapted the layer structure to the component load when designing the brake pedal. This enabled the component weight to be reduced by around 30 percent compared to conventional steel brake pedals—without impairing load-bearing capacity. In addition, the lightweight construction method makes many conventional manufacturing process steps unnecessary, thereby increasing productivity and cutting unit costs.
The control unit of the ENGEL easix multi-axis robot is fully integrated into the control unit of the injection molding machine. As a result, besides making it easy to operate and program the robot, the movements of the machine and robot are precisely coordinated with each other. Since the robot has access to the machine parameters, the gripper can enter the mold area during the opening movement, which in turn significantly reduces cycle times. Synchronous movements are particularly important when it comes to handling pre-heated semi-finished products, because semi-finished products must not be allowed to cool too rapidly in advance of the forming process. Another factor that determines quality in this application is the high positional accuracy of the multi-axis robot.

Dual technology integration opens new horizons for quality
Process integration leads to greater efficiency, safety and quality. Using an ENGEL duo 2550/610 US injection moulding machine with an integrated ENGEL viper 20 robot, ENGEL will demonstrate the fact that not only can process steps upstream or downstream of the injection moulding machine be combined, but also different process technologies. To produce center console components of PC-ABS, ENGEL will combine two technologies: ENGEL foammelt, the MuCell® foam injection molding process developed by Trexel of Wilmington, Massachusets, USA, and the variothermal injection molding process from Roctool (Le Bourget du Lac, France). The goal is to produce thin-walled parts with very high surface quality along with the excellent reproduction of fine structure using just a single injection moulding step.
To demonstrate the versatility of this combination of processes, the part being moulded will have varying wall thicknesses and surface structures. Thanks to ENGEL foammelt, the cavity is completely filled, including the undercuts, and the component has no sink marks after cooling. At the same time, the Roctool technology provides a high-gloss finish in piano black. Apart from applications aimed at car interiors, this dual technology integration opens up new horizons for efficiency and quality in white goods and household products.
On exhibit for the first time in North America, this system solution introduces the new design of the ENGEL duo injection moulding machine. Users will benefit in particular from improved ergonomics thanks to a lower operating height providing easier access to the mould and nozzle area. Other features of the new machine generation include roller rail systems for the moving platen, energy-efficient mould movement and a much cleaner mould area thanks to the removal of central lubrication.

ENGEL medical: Higher productivity with a smaller plant footprint
In the Medical section of its display at NPE2015, ENGEL will be producing drip chambers with an integrated filter for blood transfusions. An ENGEL e-victory 310H/80W/50V/180 combi US three-component injection molding machine with ecodrive and a cleanroom design will be used in this highly integrated production process. The drip chambers will include one ABS and one PP component; in a single work step they will be injection moulded, fitted with the filter, and joined by means of over moulding with additional polypropylene. This unprecedented level of integration significantly boosts efficiency in the manufacturing of multi-component hollow bodies with inlays. Conventionally, the two hollow body components are individually injection moulded, with the inlay fitted and bonded in subsequent process steps. However, this leads to longer cycles, a greater logistical effort including a greater risk of contamination, and markedly lower productivity per square foot as production usually requires several independent manufacturing cells. “Drip chambers are mass-market products that need to be manufactured economically while maintaining the stringent demands on product safety and cleanliness,” says Mark Sankovitch, underlining the great significance of the one-shot process. Other industries could also profit from this leap in efficiency. For example, fuel filters are also hollow bodies with an integrated inlay.
For this exhibit, the mold manufacturing partner Hack Formenbau (Kirchheim, Germany), provides a key prerequisite for the high level of integration with the use of servo-electric drive technology for all movements of the index plate mould. This allows the synchronous control of commonly independent movements.
An ENGEL easix multi-axis robot is also integrated into the manufacturing cell for handling both the filter and finished parts. The robot presents the drop chambers to a 100 percent quality control check before they are discharged.

High performance with maximum safety
In order to increase productivity, the field of medical technology is moving more and more to the use of multi-cavity molds along with the larger injection moulding machines they require. As a result, ENGEL has designed the ENGEL e-motion all-electric machine series to meet the requirements of high-performance applications, with no compromise to process stability and part quality, even when used with high clamping forces. Together with automation specialist HEKUMA (Eching, Germany) and mold manufacturer Braunform (Bahlingen, Germany); ENGEL will be presenting the highly automated cleanroom production of needle holders for insulin pens at the NPE.
The cores of the 96-cavity mold have a diameter of just 0.3 mm. To counter deformation of cores effectively, the electric injection unit of the ENGEL e-motion 440/240 T US is equipped with a direct drive, which provides highly dynamic injection movements and injection speeds of up to 500 mm/s. If, however, there is a problem with a manufactured part, the camera-based monitoring system registers it immediately. Thanks to cavity specific handling, reject parts are automatically separated and the injection moulding can carry on producing without deactivating the cavity. Despite the delicate mold cores, the all-electric machine achieves exceptionally short cycle times of around 3.5 seconds.

ENGEL packaging: the best of two worlds
High-performance applications have traditionally been the domain of the packaging industry, and the trend in that sector is energy efficiency. The new ENGEL e-speed 720 US injection moulding machine, presented in North America for the first time at NPE2015, brings together the best of two worlds. The new ENGEL high-speed machine relies on the all-electric technology of the high-performance ENGEL e-motion and ENGEL e-cap series while possessing the benefits of the ENGEL speed series; uniting highest injection speeds with maximum energy efficiency.
The electric clamping unit of the 720-ton hybrid machine utilizes a completely new drive solution. In order to avoid the power peaks when short cycle times are combined with high clamping forces, a flywheel acts as an electrical power reserve. It stores the braking energy from the platen movements and transfers this energy back to the motor when it is required for processes such as the reacceleration of the clamping movements. When the storage capacity is reached, excess energy from the generator is fed back into the grid—not just converted into heat by the braking resistance, which has been the case until now. This allows the ENGEL e-speed 720 US to run with a relatively low and above all constant connected load.
On the injection unit side, the time-tested ENGEL inline injection unit is used. Its particularly high injection dynamics and an electric plasticizing drive enable injection speeds of up to 800 mm per second to be reached.
In addition, its particularly long opening stroke allows the new high-speed machine to work with large stack molds. An ENGEL e-speed 720/90 US with a 4+4-cavity mould from StackTeck (Brampton, Ontario, Canada) will be producing 1.5-liter containers. Thanks to the high-speed automation from CBW automation (Fort Collins, Colorado, USA), the machine only needs a very short 0.5 seconds to remove the containers from the mold.

ENGEL technical moulding: efficient multiple component injection moulding using standard technology
While process integration offers advantages for many multiple component applications, it is not necessarily the most efficient solution. In addition to the requirements of the part being produced, the planned lot size, conditions on site and the existing machinery are also important when choosing the best fabrication process. One alternative to production with a multi-component mold and an integrated manufacturing cell would be to utilizing a transfer process to link two, or more, injection moulding machines with a linear robot. The transfer process is advantageous when standard technology satisfies the production requirements, as opposed to making customised specialty machines necessary. ENGEL demonstrates what this can look like in practice with the production of double-ended wrenches on a system using two ENGEL e-mac 170/55 US machines with four-cavity moulds from Roembke (Ossian, Indiana, USA). The wrenches are made of carbon-fiber-reinforced polyamide which is over-moulded with silicone between the two ends for better grip. The part is injection moulded on the first machine in the cell, removed by an ENGEL viper 12 linear robot and immediately placed in the mould of the second injection moulding machine which is situated opposite. During the processing of the liquid silicone, the first machine has begun production of the next wrench.
The compact size of the all-electric ENGEL e-mac machines provides a space-saving solution for the production of technical parts with high demands on precision. As a result, the productivity per square foot of production space increases, which has become a key figure for efficiency in an increasing number of businesses.
The ENGEL e-mac injection moulding machines provide extremely high repeatability, and reduced cycle times with parallel movement of the different drive axes. From injecting and metering to mould and ejector movements, all drives in the ENGEL e-mac are servo-electric. This guarantees the best possible precision and process stability while maximizing the effectiveness of the machine as a whole. The drives are operated by a modern axis system solution involving a stabilised intermediate circuit in which the braking energy is recovered and fed back into the grid, thereby achieving very high energy efficiency. The ENGEL e-mac achieves a very high acceleration of up to 20 m/s² on the injection axis, setting new standards around the world.

ENGEL teletronics: maximum precision for plastic/metal composites
It is often useful to make use of gravity for insertion applications. During the trade show, ENGEL will be producing connector housings on a vertical ENGEL insert 500H/110 rotary US injection moulding machine. In order to overmould the metal pins directly, an ENGEL easix robot will take four sets of metal pins from the feeding unit and place them in the bottom half of the four-cavity mould, which has been provided for demonstration at the exhibition by Capsonic (Elgin, Illinois, USA). Once again, with this application the multi-axis robot demonstrates its high positioning accuracy. The precision of the robots movements is crucial for final product quality in many insertion applications.
The injection moulding machine operates with a rotary table equipped with two work stations. The metal pins are put in place parallel to the injection process, which not only makes for short cycle times, but also ensures high energy efficiency. Since all part handling takes place outside of the clamping unit, the mold only remains open for a very short time during rotation of the table, eliminating unnecessary heat loss.
The complete automation of the manufacturing cell was designed and built by the ENGEL automation team in York. In order to pose a challenge to the flexibility of the ENGEL easix robot, two different and independent feeding systems have been integrated, and will be in operation on an alternating basis at the exhibition. The robot must repeatedly adapt itself to the changing demands of the process and yet still fulfill all its tasks with consistently high precision.

25 tie-bar-less years—a success story with future potential
"25 tie-bar-less years"—ENGEL will be celebrating this anniversary at the NPE with an ENGEL victory 330/85 tech US machine, which will be producing fittings for drain systems.
Since the first single-screw injection moulding machine was developed in 1956, it was regarded as an unshakable design principle that an injection moulding machine had to have four tie bars. When ENGEL unveiled a tie-bar-less machine at the K 1989 international plastics trade show in Düsseldorf, Germany, the innovation made by the Upper Austrian Company was greeted with astonishment by some, but with ridicule by others, and many arguments were raised against it. Today—25 years later—tie-bar-less injection molding machines are one of ENGEL's biggest sources of revenue. So far, more than 60,000 tie-bar-less machines have been delivered worldwide, underlining the outstanding success of this design principle. With their large platen faces and free access to the mold area, the machines meet the need for high efficiency and cost-effectiveness in injection moulding production better than any other design today, and will continue to do so in the future.
The production of fittings makes optimal use of the tie-bar-less technology. Although the mold provided by ifw-Kunststofftechnik (Micheldorf, Austria) for the production of the fittings at the NPE is of substantial size, it can still be mounted on the 85-ton machine quickly and easily. “If we were using a traditional machine with tie-bars, we would need a much larger machine with a clamping force of at least 150 tons in order to fit the bulky mould. We would also have to remove a tie bar or disassemble core-pulls to set up the mould," says Mark Sankovitch. With no tie bars to interfere with the mould in the ENGEL victory, the mould mounting platens can be used right to their edges. Therefore, very large molds can be mounted on relatively small injection moulding machines. At the same time, overall efficiency is enhanced. The costs for a smaller machine are lower both for purchase and operation, and it also requires less floor space.

Automation: From a simple pick-and-place to a turn-key solution
From the dependable standard machine to the highly integrated and automated manufacturing cell developed under one roof, ENGEL provides solutions with maximum economical efficiency for its customers around the world. In the turn-key business, the processor has only one contact partner for the entire system right from the start, which can markedly reduce the time needed for project planning and commissioning. Even when individual components are provided in collaboration with partners, ENGEL bears the overall responsibility.
"The segment of system solutions is steadily increasing in our business," says Mark Sankovitch. "ENGEL is delivering more and more injection moulding machines with handling included." Automation is increasingly becoming an integrative process component which not only makes production processes more efficient and economical, but also makes it possible to realise totally new manufacturing methods, component characteristics, design solutions and product qualities.
In order to also be able to offer a very economical, dynamic and compact solution for simple pick-and-place applications, ENGEL has developed a new compact robot for horizontal and vertical part removal with a load-bearing capacity of up to 2 kg.
At NPE2015, the ENGEL e-pic will be presented to the American audience for the first time. Thanks to its completely new kinematics, combining linear movements with a swivel arm, the ENGEL e-pic unites maximum performance with maximum economic efficiency. In order to keep the moving mass as low as possible, the robot arm was designed using weight-optimised parts. This ensures the shortest possible take-out cycles and low energy consumption. In comparison with linear robots of the same size, the ENGEL e-pic requires less than half the amount of energy.
The compact design also contributes to its excellent economical efficiency. When utilised on injection moulding machines with an integrated conveyor belt, the robot works inside the machine's safety gate without requiring additional space.
Equipped with its own control unit, the ENGEL e-pic robot can be used not only on ENGEL injection moulding machines, but also on third-party machines. In combination with an ENGEL injection moulding machine, the robot can be easily integrated into the CC300 machine control unit. The robot and machine then access a shared database, thereby enhancing process security and operator convenience while achieving optimal efficiency in production sequences. The control unit converts the rotary motion of the robot swivel arm into a linear movement. Therefore, those who have experience working with linear robots have no need to learn new skills.
With this new development in handling, ENGEL can now cover the complete spectrum of requirements in this area even better, from simple part removal, depositing, and sprue separation, to sophisticated insert-placement and take-out, and to the combination of various process steps in a highly-integrated production cell.
A new generation of the ENGEL viper linear robot will also be presented in Orlando. Thanks to the update, the speed, flexibility, compactness, energy efficiency and ease of use of the robots have all been improved. Also new is the C70 seven-inch hand-held touch terminal, one of the lightest on the market weighing in at only 950 grams. Additionally, to ensure a consistent operating system, the layout of the robot control pages has been adapted to the new design of the CC300 control unit for ENGEL injection moulding machines.

ENGEL plus: a new service portal for even greater customer benefit
Training and service are integral features of the ENGEL system philosophy. Under the ENGEL plus brand name, ENGEL offers not only fast hotline and on-site support worldwide, but also a wide range of optimisation tools that ensure greater efficiency and process stability, increase machine and production cell availability, and help optimise processes. ENGEL plus is being presented at the NPE in several expert corners, featuring ENGEL e-flomo, the ENGEL oil maintenance system, and the new customer portal, among other things.
Mould temperature control has a significant influence on the productivity of the manufacturing process and on the quality of the moulded parts, but despite this, it is usually not given enough attention. ENGEL prompted a change in thinking when it developed ENGEL flomo in 2010. The compact temperature control water manifold with electronic flow monitoring, which can be adjusted manually and integrated into a machine, increased process reliability and simplified process optimisation—in more than a thousand new machines to date. ENGEL is now completing the step from process monitoring to process control. The newly developed ENGEL e-flomo features electrical control valves, which allow the flow rates to be adjusted and controlled in a fully-automated process. “ENGEL e-flomo keeps the temperature in the mould constant throughout the production period, even when water pressure varies,” says Mark Sankovitch. “This results in greater efficiency, process reliability and consistently high product quality.”
The ENGEL oil maintenance system ensures lower costs for upkeep and increased machine availability. Impurities cause 80% of all hydraulic system failures. The ENGEL oil maintenance system tackles this problem at its roots. A cellulose cartridge with a 3 μm fine filter removes solid particles, condensed water, and oil degradation products in one single step. The result is up to 55 % less downtime and a reduction in maintenance costs of 60 %.
A special highlight is the new customer portal that ENGEL will be presenting for the first time worldwide, at NPE2015. Now customers can make service requests and order spare parts even more easily and quickly than before. Another positive aspect is the high level of transparency. The customer can for example track the status of a service request, which makes it possible to plan more reliably. The new customer app opens the doors to the world of ENGEL, as well as one's own manufacturing facility, anywhere and anytime. A concise overview of the current status as well as the availability of all machines can be displayed in the app. "Our innovative strength at ENGEL is demonstrated not only in products and technologies," says Mark Sankovitch. "It is also our goal to continuously increase the benefit customers have from our service."

ENGEL at NPE2015: West Building, hall A, booth W1303
(Engel Austria GmbH)

Newsgrafik #29558
 28.11.2014

ENGEL at Interplastica 2015  (Company news)

At Interplastica 2015 from January 27 to 30 in Moscow, everything will revolve around tie-bar-less technology at the ENGEL stand. More than 25 years ago, ENGEL became the first injection moulding machine manufacturer worldwide to develop a series of machines with a barrier-free clamping unit. Still today, this construction principle remains the key to maximum efficiency and minimum unit cost in many applications.

Photo: ENGEL has delivered more than 60,000 tie-bar-less machines around the world.

"The potential for increased efficiency is particularly great for applications that require a bulky mould, but only need a comparatively low clamping force," emphasises Olaf Kassek, Director of OOO ENGEL in Moscow. This category includes for example the production of three-dimensional, complex parts or multiple-component processes that require core-pulls and sliders. As the tie-bar-less ENGEL victory and ENGEL e-victory machines allow for the platen surface to be used up to the edge or even beyond, much larger moulds can be mounted than on machines of the same clamping force with tie bars. "If the decision is made for a tie-bar-less machine, we can realise many projects with a considerably smaller injection moulding machine than what the customer had originally calculated with on the basis of a machine with tie bars," says Kassek. "Sometimes the machine size can be reduced by 50 percent." The benefits for the customer include lower investment and maintenance costs. Beyond that, the smaller machine requires less floor space, which is an important factor for efficiency for an increasing number of companies.

Control LIM-processes securely
During the trade show, ENGEL will be presenting the full potential of the tie-bar-less injection moulding machines live at their stand. An ENGEL e-victory 120 combi will be producing housings for flow-measurement sensors with an integrated silicon seal. Because of its extremely low viscosity, the processing of liquid silicone poses high demands on the parallelism of the mould mounting platens, and in this respect, the tie-bar-less machines also play out their advantages. "The construction of the tie-bar-less machines achieves a greater platen parallelism than injection moulding machines with tie bars," says Olaf Kassek. "We can securely control LIM applications with the ENGEL victory and ENGEL e‑victory machines, producing with few burrs and no reworking required." Above all two factors are responsible for this. First, thanks to three-point guidance, the moving mould mounting platen retains its orientation even while the mould is being opened and closed. And second, the stationary mould mounting platen is not connected to the machine at its bottom, but at the back side, in order to absorb the vibrations symmetrically and remain parallel to the moving platen during acceleration and deceleration. In addition, the patented Force Divider flexlink applies the force to the mould evenly across the entire platen face. Cavities lying at the outside edge of the platen are kept closed with precisely the same force as the cavities in the middle. This significantly reduces mould wear and increases product quality.

Standard instead of special solutions
On the injection unit side, the servo drive units provide for maximum precision. When very small injection volumes are involved in the area of LSR, special solutions are normally required. The ENGEL machine, however, can accomplish this with a standard drive unit.
The ENGEL e-victory hybrid machine with electrical injection units is equipped with a servo-hydraulic clamping unit in the standard version. The servo-hydraulic ENGEL ecodrive ensures very efficient production even with a hydraulic drive unit. Depending on machine type and application, ecodrive reduces energy consumption by 30 to 70 percent. This is possible because energy loss is consistently avoided. When the machine is idle – during a cooling phase for example – the drive unit stops running and therefore does not consume any energy. As a positive side effect, significantly less heat is absorbed by the hydraulic oil, and the oil no longer needs to be cooled in many applications. At the trade show, an ENGEL viper 20 linear robot will be removing the sensor housings from the mould and placing them on a conveyor belt. Because there are no tie bars to get in the way, the robot can access the mould area directly from the side, which allows automation of the injection moulding process even in production halls with low ceilings.

Controlled Conditions
At the Interplastica, ENGEL will be dedicating an Expert Corner exclusively to its service products and optimisation tools. The main theme of the display will be intelligent mould temperature control. Mould temperature control has a significant influence on the productivity of the manufacturing process and on the quality of the moulded parts, but despite this, it is usually not given enough attention. ENGEL prompted a rethink when it developed ENGEL flomo in 2010. The compact temperature-control water distribution system has manual settings and can be integrated into a machine; electronic monitoring has increased process reliability and simplified process optimisation in more than a thousand new machines to date. ENGEL is now completing the step from process monitoring to process control. In the future, the newly developed ENGEL e-flomo will allow the flow rates to be adjusted and controlled in a fully-automated process. This will result in greater efficiency, process reliability and consistently high product quality.
ENGEL at Interplastica 2015: hall 3, stand B09
(Engel Austria GmbH)

Newsgrafik #29538
 24.11.2014

ENGEL at PLAST EURASIA 2014  (Company news)

With highly integrated and automated system solutions from a single source ENGEL increases product quality, manufacturing efficiency and thus its cus-tomers' competitiveness. The injection moulding machine manufacturer and system supplier will demonstrate how this can be translated to practice with three innovative applications at PLAST EURASIA 2014 in Istanbul from 4th to 7th December.

Photo: An ENGEL e-motion 160 with integrated IML will produce food containers.

Efficient use of LIM multi-component processes
The main demands as regards the processing of liquid silicone (LSR) are that it must be fully automatic, waste-free, low in burrs and require no reworking. An ENGEL e-victory 200H/80W/120 combi injection moulding machine – automated with an ENGEL viper 20 linear robot – will impressively show that ENGEL system solutions not only meet these requirements fully, but also handle LIM multi-component processes securely and efficiently. A mould provided by ACH solution (Fischlham, Austria) will be used to produce sensor housings for flow measurement with integrated seals. ENGEL can guarantee maximum precision by using servo-powered injection units. Normally the LSR field requires special solutions where very small injection unit volumes are involved. In this case ENGEL meet that need with a standard unit. Developed and patented by ENGEL, iQ weight control software applied in the system recognises and automatically compensates for fluctuations in melt quantity during the actual injection process.
The tie-bar-less technology of the ENGEL e-victory machine also makes a decisive contribution to high process stability in this application, while the patented force divider evenly introduces force to the mould across the platen face. Both outer and inner cavities are thereby kept closed with precisely identical force, significantly reducing mould wear and raising product quality. On top of this, free access to the tie-bar-less machine's mould area facilitates the most effective automation concepts.

All-electric for maximum performance
500 ml food containers will be produced on an all-electric ENGEL e-motion 440/160 featuring a 2-cavity mould by Glaroform (Näfels, Switzerland). In-mould labelling (IML) will be used to decorate the packaging; to do this, ENGEL will collaborate with partner company BECK automation (Oberengstringen, Switzerland).
The steady enhancement of the ENGEL e-motion series is serving to establish the machines in the field of high performance applications for the packaging industry. The newest machine generation is able to achieve cycle times of well under three seconds and injection speeds of more than 500 mm per second, thereby combining maximum performance with maximum energy efficiency. The closed system for toggle lever and spindle always guarantees optimal, clean lubrication of all moving machine components. This makes the ENGEL e-motion the preferred machine type even in regulated areas such as food packaging production.

Maximum reliability with excellent efficiency
Using the example of a medical technology application ENGEL demonstrates how maximum efficiency can be reconciled with maximum process reliability. An all-electric ENGEL e‑mac 440/100 injection moulding machine will be manufacturing polystyrene needle holders for safety hypodermics using a 16-cavity precision mould by Fostag, Stein am Rhein, Switzerland.
In order to transfer the specific requirements of the medical technology industry, such as maximum product safety, absolute cleanliness and precision as well as full documentation, to efficient injection moulding processes, ENGEL dedicates an entire business line to this industry. On the basis of its in-house clean room and a series of resulting machine concepts for clean room use, the injection moulding machine manufacturer has acquired extensive experience in the medical field and competence with clean rooms.

ENGEL at PLAST EURASIA 2014: Hall 12, Stand 1217
(Engel Austria GmbH)

Newsgrafik #29513
 18.11.2014

High performance with a small footprint  (Company news)

Sustainable, clean and powerful: at the Arabplast 2015 trade show from January 10 to 13 in Dubai, ENGEL, together with Uni-Cap and other partners, will be presenting its high competence in system solutions. One area of focus will be the packaging industry. An all-electric ENGEL e-cap injection moulding machine will be producing 1881-type caps live at their exhibit.

“Sustainability is very important when it comes to investment decisions in the Arab countries, and the significance of environmentally friendly technology will continue to increase," says Andreas Leitner, Sales Director Middle East at ENGEL AUSTRIA. "All-electric injection moulding machines are becoming increasingly popular for the production of beverage caps." Uni-Cap in Dubai is also a pioneer in this area. The largest cap manufacturer in the Gulf States has been producing on ENGEL e-cap machines since 2009. In addition to the high energy efficiency of the machines, Bassam Hajjar, the CEO of Uni-Cap, is particularly interested in cleanliness. "The bottlers expect to receive absolutely hygienic products from us. With all-electric machines, we can definitely rule out any contamination with hydraulic oil. Thus, the usage of hydraulic oil is superfluous and cooling capacity is saved at the same time, the carbon footprint can be decreased significantly.”
While the one-piece 1881 cap for carbonated soft drinks has already become established in most parts of the world, the GCC countries has long remained the exception. Only the newest, state-of-the-art processing technology has allowed one-piece caps to also be used in regions with extreme temperatures of more than 50 °C. Uni-Cap will be the first manufacturer in the region to produce this type of cap. They plan to achieve an annual capacity of 300 million caps with the ENGEL e-cap machine presented at the Arabplast. Currently, Uni-Cap produces altogether 4.5 billion caps per year.

50 percent less overhead for cooling
It is above all the melt flow rate of as low as 1.5 g/10 min of the poor-flow types of HDPE required to achieve the specified cap characteristics that define the high demands put on the injection moulding machine. Thanks to its direct drive unit, the ENGEL e-cap achieves the precision and performance needed for this application. Beyond that, its increased ejection and clamping force help it attain very short cycle times.
Outstanding process stability and precision maximise the number of good parts. This is due to the servo drive units, among other things. "With the ENGEL e-cap, we were able to markedly reduce the overhead for mould maintenance," says Bassam Hajjar. During the trade show, a system from IMDvista (Brügg, Switzerland) for the fully automatic 100 percent quality control will be employed for cap inspection.
Even with such impressively high performance values, the ENGEL e-cap achieves considerable savings on energy and cooling water, thereby cutting unit costs significantly. "In comparison to hydraulic machines, we need 50 percent less resources for cooling," says Hajjar.
Finally, a third decisive criteria – after sustainability and performance – for the Uni-Cap CEO is the after-sales service. "We achieve a high degree of machine availability. Spare parts are also made available on site very quickly."

System partnerships are cornerstones of success
Service and training are integral elements of the ENGEL system philosophy. ENGEL delivers turnkey system solutions worldwide that are individually tailored to the specific needs of their customers and combine highest performance with maximum efficiency and sustainability. System partnerships with leading international companies and local suppliers are cornerstones for joint success. A point that will be underlined at Arabplast. In the area of packaging, one of the companies who will be presenting themselves at the ENGEL stand in Dubai is Corvaglia. The supplier for the international beverage industry with headquarters in Eschlikon, Switzerland, fabricated the 48-cavity mould for Uni-Cap, which together with the ENGEL e-cap will inaugurate new era in caps and closures technology in the Gulf States at Arabplast 2015.

ENGEL at Arabplast 2015, hall 4, stand G110
(Engel Austria GmbH)

Newsgrafik #29447
 03.11.2014

Gerd Liebig is leaving ENGEL; Management Board and owners express thanks and wish him well ...  (Company news)

...for the future

“We are very sorry that Gerd Liebig (photo) has decided to take this step,” says Dr. Peter Neumann, CEO of ENGEL Holding GmbH. “Over the past nine years, Mr. Liebig has enhanced our global sales and marketing structure considerably. Through his great commitment, talent for dealing with people and sure sense of our markets, he has delivered a contribution to the success of the ENGEL group – and for that we are very grateful.”

Gerd Liebig leaves the company at his own request: he will remain in the plastics industry, accepting a wider scope of duties and greater responsibility in his new position.

“We can look back on a very productive and enjoyable working relationship,” says Neumann. “We would like to wish Mr. Liebig all the best for his future.”
(Engel Austria GmbH)

Newsgrafik #29423
 28.10.2014

ENGEL e-flomo improves process stability and economy  (Company news)

The trend towards complete process monitoring has now reached mould temperature control. The typical, legacy water manifolds are thus increasingly being replaced by state-of-art flow monitoring systems, such as ENGEL flomo. ENGEL e-flomo sees ENGEL take this one step further. The flow control system does not just monitor the relevant parameters, but keeps them constant throughout the production run.

Mould temperature control has a significant influence on productivity of the manufacturing process and on the quality of the moulded parts, but despite this, it did not attract a great deal of attention for a long time. ENGEL prompted a rethink when it developed ENGEL flomo in 2010. The injection moulding machine-integrated, compact and manually adjustable water manifold system improves process reliability and facilitates process optimisation. For Fakuma 2014, ENGEL has taken the step from process monitoring to process control. The newly developed ENGEL e-flomo also features electrical control valves, which allow the flow rates to be adjusted and controlled in a fully-automated process.

Automatically compensating for fluctuations in the water quantity
The available volume of water can fluctuate during production, for example, if filters clog, or system pressure changes are caused by different levels of load on the production equipment. In a production environment, these influences often go unnoticed for a longer period of time, resulting – in the worst case – in the production of scrap. Even the manually adjustable ENGEL flomo water manifold can prevent this thanks to its monitoring feature. The new ENGEL e‑flomo does not just monitor, it automatically adjusts the settings. If the system notices a flow rate dropping in one of the flow circuits, the corresponding control valve is automatically opened to a position where the desired target value is reached again.

Keeping the temperatur under control
The temperature control device is responsible for keeping a constant media temperature. Since a certain amount of heat loss is typical between the temperature control unit and the mould, the ENGEL e-flomo also monitors the supply water temperature throughout the entire production run. At the same time, other parameters can be included for monitoring; for example, the return temperature or the temperature difference between the supply and return sides.
ENGEL e-flomo is designed for water temperatures up to 120 °C. Shut-off valves in the central supply and return lines allow for fast and easy activation and deactivation of the individual manifold units. Just like the ENGEL flomo, the new ENGEL e-flomo is characterized by its resistance to soiled water.
Thanks to its functionality, ENGEL e-flomo improves the economy of the production process by fast mould set-up, higher machine availability, and reducing scrap.
(Engel Austria GmbH)

Newsgrafik #29400
 23.10.2014

Fast, flexible and compact  (Company news)

The ENGEL e-pic was celebrating its world premiere at Fakuma 2014 in Friedrichshafen, Germany. "The level of automation is continuing to increase rapidly worldwide. In Europe, we will not be producing off-mould parts in the long term," said Dr Stefan Engleder, CTO with ENGEL AUSTRIA, when introducing the new development at the fair. This statement unequivocally confirms the fact that, in addition to tailored automation solutions, the need for flexible and, at the same time, standardised robots for simple handling tasks is growing. This new development now sees ENGEL cover the complete spectrum of handling requirements in injection moulding in an even better way, from simple part removal, depositing, and sprue separation, through sophisticated insert-placing and take-out, to combining various process steps in a highly-integrated production cell.

Linear motion with integrated swivel arm
The objective in this product development was to combine maximum performance with maximum economy. The totally new kinematics makes a decisive contribution towards achieving this by combining linear movements with a swivel arm. Another important efficiency factor is the use of weight-optimised parts which keeps the accelerated masses low. In this way, the servomotor-driven robot can achieve the shortest possible take-out cycles, and it only has low energy requirements. In comparison with linear robots of the same size, the ENGEL e-pic only needs half the amount of energy.
The compact design also contributes to its excellent efficiency. When deployed on injection moulding machines with an integrated conveyor belt, the ENGEL e-pic works inside the machine's safety gate without needing extra space. And it needs far less vertical space than comparable third-party robots.

Immediately ready for action
Equipped with its own control unit, the ENGEL e-pic robot can be deployed not only on ENGEL injection moulding machines, but also third-party machines without needing any machine-specific customisation. A separate base is not required, nor is an external switch cabinet. The electronics are completely integrated with the mechanical superstructure.
In combination with an ENGEL injection moulding machine, the robot can be easily integrated with the CC300 machine control unit. The robot and machine then access a shared database, thus enhancing process assurance and operator convenience, while achieving efficiency optimisations in production sequences.
The robot control unit supports intuitive control via the touch panel. When installed on a new or existing machine, the robot can immediately be commissioned, without programming skills. The control unit converts the rotary motion of the robot swivel arm into a linear movement. Those who are used to working with linear robots have no need to learn new skills.
The ENGEL e-pic is designed for horizontal and vertical part removal and handling of small parts and sprues with a load-bearing capacity of up to 2 kg. It is deployed on injection moulding machines with clamping forces up to 2,200 kN.
(Engel Austria GmbH)

Newsgrafik #29216
 05.09.2014

Cost efficiency in CFRP lightweight engineering  (Company news)

Picture: At the ENGEL Center for Lightweight Composite Technologies in St. Valentin, Austria, various production cells are available for joint research projects, mould trials and contract work

This year, ENGEL is – for the first time – presenting its expertise in lightweight composite technologies at the Composites Europe trade fair, which takes place from 7th to 9th October in Düsseldorf, Germany. The manufacturer of injection moulding machines and automated system solutions, headquartered in Schwertberg, Austria, is one of the preferred suppliers to the international automotive industry. At its own centre for lightweight composite technologies, ENGEL co-operates with partner enterprises on developing economical processes for serial production of innovative CFRP-components.

Lightweight construction and injection moulding have long become inseparable key concepts for meeting the increasing mobility demands. Integrated plastics solutions contribute towards reducing vehicle weight, while at the same time empowering economical processes for high-volume serial production. The objective of the ENGEL AUSTRIA Center for Lightweight Composite Technologies, founded in 2012 in St. Valentin, Austria, is to accelerate the development and market launch of new manufacturing processes. With its high levels of system solution and automation expertise, ENGEL already offers one success factor that is crucial for this. ENGEL's understanding of the Technology Centre is above all that of a platform for interdisciplinary collaboration with partner enterprises and universities. "One important precondition for successful CFRP projects is that the materials, design and production process mesh in the best possible way. This can only work if enterprises bundle their expertise along the value chain. Composite engineering needs 'composite' development", says Peter Egger, Director of the ENGEL Center for Lightweight Composite Technologies.

The Technology Centre's current focus is on processing semi-finished thermoplastic products (thermoplastic fabrics and tapes), and on reactive technologies that use thermosets and thermoplastic systems, such as HP-RTM and in-situ caprolactam polymerisation. With sample parts, presentations and videos, ENGEL will be giving trade fair visitors a peek behind the scenes into ongoing research work, and successful customer projects.

Tailor made for BMW in Leipzig
The BMW i3 is probably the best-known electric vehicle on the market right now. Its shell components are made on ENGEL duo injection moulding machines. Two large-scale ENGEL duo machines with a clamping force of 40,000 kN are integrated as a twinned system. In master/slave mode, both machines can be synchronised to injection mould and complete two components at the same time. This manufacturing principle makes sure both components undergo exactly the same material aging process and the high quality requirements are met. Parts are handled by multiple axis robots, which ENGEL integrates into the production solution as the general contractor. ENGEL's most recent delivery to the BMW plant in Leipzig was in March this year.

New ENGEL v-duo reduces machine footprint
In the summer of 2014, the BMW plant in Landshut also commissioned a new ENGEL production cell. On an ENGEL v-duo vertical machine, the plant manufactures large-scale, structural, fibre-plastic composite components using the HP-RTM process. BMW is one of the earliest adopters of the new ENGEL v-duo series, which was specifically designed for fibre composite applications. The ENGEL v-duo enables very compact production cells with comparatively low investment costs. The machines are far more compact than the presses traditionally used for fibre composite applications. Additionally, the machine weight is significantly lower, which reduces the foundation building overhead. Because the ENGEL v-duo completely does without hydraulic accumulators and instead already comes with the ENGEL ecodrive servo-hydraulic system as a factory standard, it also sets new standards in terms of energy efficiency for large-scale machines.

Composite brake pedal now in production
At the K trade fair 2013, ENGEL collaborated with ZF Friedrichshafen to set an important milestone in lightweight design by manufacturing composite brake pedals, which are now entering series production for the first time. Using the ENGEL organomelt process, thermoplastic fabrics are heated, preformed in the mould, and immediately overmoulded with polyamide. The production cell that ENGEL exhibited at K included a vertical ENGEL insert injection moulding machine, an ENGEL easix multiple axis robot and infrared oven for heating the infinite fibre reinforced, semi-finished products. In designing the brake pedal, the layer structure in the thermoplastic fabric was modified to handle the load. This enabled the component weight to be reduced by around 30 percent compared to conventional steel brake pedals without impairing component properties. Moreover, the lightweight construction method renders many manufacturing process steps obsolete, which increases productivity and cuts unit costs.

Seamless system solutions
ENGEL is a one-stop source for tailored system solutions: from automation, process engineering and mould project engineering, through to training and services. In turn-key business, all the plant components are precisely matched right from the outset. This means that efficiency potentials can be made full use of, resulting in the lowest possible unit costs and improved competitiveness. Integrating robots, process engineering, testing equipment and other peripherals with the control technology also facilitates the use and control of more complex processes, thus making a decisive contribution towards greater reproducibility and process reliability. As the general contractor, ENGEL has overall responsibility for the production cell, and this includes system components that are implemented in collaboration with partners. ENGEL works with the global leaders in their respective fields.

Global proximity to the processor
The dynamic markets in the plastics industry require a high level of innovation in the enterprise, and ENGEL delivers this on a daily basis. Besides the automotive industry, the electronics, telecommunications, domestic appliance and household goods, medical technology and packaging industries are all important target markets.

Customer proximity is very important to ENGEL. Eight production plants in Europe, America and Asia, 29 sales and service subsidiaries and 60 representatives guarantee expert advice, fast service response and shorter lead times worldwide.

ENGEL achieved a global turnover of 935 million euros in the 2013/2014 financial year. Of ENGEL’s 4400 staff, 2700 are employed at the Austrian plants in Schwertberg, St. Valentin and Dietach.

Since it was founded in 1945, ENGEL has been 100 percent family-owned; this has meant stability, security and a dependable long-term perspective for customers and partners alike. ENGEL at Composites Europe 2014: Hall 8b, Booth H30
(Engel Austria GmbH)

Newsgrafik #29200
 03.09.2014

ENGEL at Interplas 2014   (Company news)

Picture: The ENGEL easix can be fully integrated into the CC300 control unit of the injection moulding machine

With highly integrated and automated system solutions from a single source ENGEL increases product quality, manufacturing efficiency and thus its customers' competitiveness. The injection moulding machine manufacturer and system supplier will demonstrate how this can be translated to practice with two innovative applications at Interplas 2014 in Birmingham from 30th September to 2nd October. Further highlights at the trade fair stand will be the multi-axis industrial robot ENGEL easix, the new machine control unit CC300 and the range of service products and services, ENGEL plus.

More productivity per square metre of production space
In the automotive sector, the material substitution is progressing increasingly quickly. A growing number of functional components too is being manufactured from plastics. The advantages are in the lower component weight, a more efficient manufacturing process and often in increased sustainability. During the three days of the fair, ENGEL will show an example by manufacturing clutch pedals on a tie-bar-less ENGEL victory 1800/220 injection moulding machine with an integrated ENGEL viper 12 linear robot. Thanks to the targeted formation of a hollow structure by means of the water injection technology ENGEL watermelt, raw material is saved, the component weight decreases and the cycle time drops. Furthermore, the injection of water into a cavity partially filled with plastic melt ensures a uniform wall thickness throughout the clutch pedal and no sink marks despite the complex part geometry. This also results in a very precise part surface.

Together with its system partner PMEfluidtec (Ettenheim, Germany) ENGEL offers tailor-made turn-key solutions for water injection technology worldwide. Other partners for the manufacturing cell demonstrated at Interplas are Moldetipo (Leiria, Portugal) and Akro Plastic (Niederzissen, Germany).

The tie-bar-less technology, which celebrates its 25th anniversary this year, contributes greatly to the high efficiency of the manufacturing cell. Due to the size and the complex geometry of the clutch pedal, the mould is relatively large, whereas the necessary clamping force is comparatively low. The barrier-free clamping unit of the ENGEL victory machines allows selecting the machine size based on the clamping force required in the injection moulding process rather than the mould size. "Particularly in manufacturing technical parts, we can often fall back on a smaller machine, which significantly increases the overall efficiency," says Graeme Herlihy, Managing Director of ENGEL UK in Warwick. "The purchasing cost of a smaller machine is lower. It requires less energy and most importantly takes up less space. Thus the productivity per square metre of production space increases, which in the meantime has become a key figure in our customers' businesses."

Maximum reliability with excellent efficiency
Using the example of a medical technology application ENGEL demonstrates how maximum efficiency can be reconciled with maximum process reliability. An all-electric ENGEL e motion 110 T injection moulding machine will be manufacturing polystyrene needle holders for safety hypodermics using a 16-cavity precision mould by Fostag, Stein am Rhein, Switzerland. The moulded parts are taken off the mould and deposited sorted by cavity in less than 0.5 seconds, thanks to a high-speed handling system which ENGEL developed together with its partner Hekuma (Eching, Germany). In this way defect mould cavities can be switched off individually without disturbing the balance of the complete system.
In order to transfer the specific requirements of the medical technology industry, such as maximum product safety, absolute cleanliness and precision as well as full documentation, to efficient injection moulding processes, ENGEL dedicates an entire business line to this industry. On the basis of its in-house clean room and a series of resulting machine concepts for clean room use, the injection moulding machine manufacturer has acquired extensive experience in the medical field and competence with clean rooms.

Complex processes under control
Process integration and automation are crucial to increasing efficiency in injection moulding production. At the same time, however, they make the manufacturing processes more and more complex. Making the operation of highly integrated and automated production processes easier, more comfortable and safer was therefore ENGEL's goal when developing the new control unit generation CC300, which ENGEL will present at Interplas for the first time in Great Britain.

The new features include the extra-large 21" multitouch display with a new and even clearer structure, separate views for each task, which eliminate operator errors in full-feature scope, and the central control button e-move that gives the operator a feeling for the machine in spite of the multitouch functionality. By turning, e-move can precisely control the speed and path of all machine and robot movements.

"The CC300 is setting a new trend," says Herlihy. "We transferred user technologies that have since become standard to the demands of the injection moulding processes – for example, the intuitive gesture controls found in smartphones. This makes it very easy for machine operators to find their way in the new control unit. Furthermore, we retained basic principles that operators appreciated in the previous model."

ENGEL viper linear robots and ENGEL easix multi-axis robots are fully integrated into the new control unit. This means that the entire production cell can now be controlled and monitored centrally from the injection moulding machine's control panel. The layout of the robot pages has been adapted to the new design of the CC300, ensuring a consistent operating system and uniform presentation. The full robot integration facilitates especially the use of multi-axis robots. Many tasks that previously required calling in a programmer can now be handled by the machine operators themselves, thus improving the availability of the production cell. Another advantage of the control unit integration is that both the injection moulding machine and the robot access the same database and can thus precisely coordinate their move sequences to achieve a higher overall efficiency.

More than a machine
The ENGEL customer service division will be present at the fair under the name of ENGEL plus. Training and service are firm features of ENGEL's system philosophy. Even for pre-existing machines, robots, and system solutions they continue to offer new optimising potential in the course of the entire machine life cycle. ENGEL plus comprises on-site support with spare parts logistics, remote services and a 24/7 hotline, maintenance and repair contracts at fixed prices, retrofitting options and optimisation tools, application engineering consultancy, and professional training and eLearning offers.

ENGEL offers seminars and forums to its customers also at the Warwick site. Furthermore, the technical centre is available to customers for mould proving and customer trials. ENGEL is the largest supplier of injection moulding machines in the United Kingdom and leading in the field of challenging injection moulding application, thanks to its know-how of system solutions.
(Engel Austria GmbH)

Newsgrafik #29156
 21.08.2014

ENGEL at Plastex 2014 in Brno  (Company news)

At Plastex 2014, which takes place from 29th September to 3rd October in the Czech city of Brno, ENGEL will showcase its system solutions know-how for the injection moulding sector by means of an LSR application on a tie-bar-less injection moulding machine. In many applications it is ENGEL's tie-bar-less technology – marking its 25th anniversary this year – that makes the decisive contribution to lowering unit costs; and this quality makes it more relevant than ever today.

Picture: ENGEL develops and produces conveyor systems for bulk goods, boxes, pallets and trays in-house.

The main demands as regards the processing of liquid silicone (LSR) are that it must be fully automatic, waste-free, low in burrs and require no reworking. At the trade fair, a tie-bar-less ENGEL e‑victory 200H/80W/120 combi injection moulding machine – automated with an ENGEL viper 20 linear robot – will impressively show that ENGEL system solutions not only meet these requirements fully, but also handle multi-component processes with LSR securely and efficiently. A mould provided by ACH solution (Fischlham, Austria) will be used to produce sensor housings for flow measurement with integrated seals. Using servo-powered injection units guarantees maximum precision, which would normally call for special solutions in the LSR field where very small injection unit volumes are involved but which in this case is provided by a standard unit. The system utilises iQ weight control software developed and patented by ENGEL, which recognises and automatically compensates for fluctuations in melt quantity during the injection process.

Minimal footprint, maximum efficiency
Tie-bar-less technology offers many advantages in the case of multi-component processes involving silicone. Given that mould mounting platens can be used to the hilt, relatively small injection moulding machines can be fitted with large and complex multi-component moulds. This raises overall efficiency as smaller machines require less energy and, most importantly, less floor space. The outstanding platen rigidity of tie-bar-less machines provides better support to moulds, which reduces burr formation and thus raises product quality. Free access to the mould area also facilitates the most effective possible automation concepts. The integrated ENGEL viper robot quickly accesses the mould area from the side to remove the housing halves.

Maximum productivity throughout the lifecycle
The machine manufacturer will devote a special area of its stand to ENGEL plus, the name of the new umbrella brand for all ENGEL service products. The display will include the ENGEL flomo temperature-control water distribution system, which continuously and electronically monitors all cooling and temperature control circuits, thus rendering high-maintenance cooling water distributors with sight glasses superfluous. Thanks to vortex sensors, ENGEL flomo works with no moving parts or water filters. In addition, all the components are made of premium stainless steel. The temperature-control water distribution system is one of the smallest water distribution systems with manual settings and electronic monitoring on the market. It can be mounted in very close proximity to the mould, which minimises heat loss.

Key role in global production network
With its range of intelligent conveyor systems, ENGEL makes sure systems as a whole – from injection moulding machine to peripherals – are precisely tailored to the specific needs of businesses, the wider sector and national markets. To give an example, ENGEL also develops and constructs GMP-compatible conveyor belts for regulated production areas of the medical technology, pharmaceutical and packaging industries.

ENGEL at Plastex 2014: hall G1, stand 37
(Engel Austria GmbH)

Newsgrafik #29134
 15.08.2014

Welcome to the ENGEL stand at Fakuma 2014  (Company news)

Barrier-free mould area, compact manufacturing cells and a high capacity for innovation: ENGEL will be celebrating 25 years of tie-bar-less technology at Fakuma 2014, which takes place in Friedrichshafen October 14 - 18. With numerous innovative applications on show, the injection moulding machine manufacturer will use the event to demonstrate how tie-bar-less machines can continue in future to meet the highest demands in terms of efficiency and cost-effectiveness.
The new tie-bar-less, all-electric ENGEL e-motion 50 TL will also be making its world premiere in Friedrichshafen. Other innovations on show at the ENGEL stands will include double technology integration and the ENGEL e-flomo closed loop temperature-control water distribution system.

Picture: Thanks to its electric control valves, the new ENGEL e-flomo temperature-control water distribution system facilitates the fully automatic adjustment of flow rates.

25 years of ENGEL tie-bar-less technology
'The clamping unit of an injection moulding machine has four tie-bars.' Since the first single-screw injection moulding machine was developed in 1956, this design principle was regarded as inviolable – but when ENGEL unveiled a tie-bar-less machine at the K 1989 plastics trade show in Düsseldorf, the innovation by the Upper Austrian company was greeted with astonishment and even ridicule; there were plenty of arguments against it. Twenty-five years on, tie-bar-less injection moulding machines represent one of ENGEL's biggest revenue sources. Underlining the outstanding success of the new design principle, more than 60,000 tie-bar-less machines have been delivered around the world. Machines offering large platen faces and free access to the mould area meet the need for high efficiency and cost-effectiveness in injection moulding production more closely than any other design. Now ENGEL is set to celebrate this success story with a special presentation in the East Foyer at Fakuma 2014.
An ENGEL victory 330/80 tech injection moulding machine fitted with energy efficient ecodrive drive technology and the new CC300 control unit will produce fittings for drainage systems – an application designed to showcase the advantages of tie-bar-less technology to best effect. Although the mould provided by ifw-Kunststofftechnik (Micheldorf, Austria) is of substantial size with its large core-pulls, it can still be attached to the 80-ton machine quickly and conveniently. “When you used a traditional machine with tie-bars, a large machine with minimum clamping force of 150 tons would be needed to fit the bulky mould. You would also need to remove a tie-bar or disassemble the core-pulls to set up the mould, which took a lot of time,” says Franz Pressl, Product Manager for tie-bar-less ENGEL victory injection moulding machines. With no tie-bars to interfere with the mould in the ENGEL victory, mould mounting platens can be used up to their edges and very large moulds can be mounted on relatively small injection moulding machines. “This enhances overall efficiency,” says Pressl. “Smaller machines require less energy, and most importantly take up less space.”
Machines with no tie-bars offer particular benefits in the production of large components with complex, three-dimensional structures as well as multi-component applications; they are also advantageous in the case of multi-cavity moulds. “Because of the pressure of costs in many sectors, the number of cavities is rising and moulds are getting bigger. Compared to mould size, though, the actual clamping force requirement has remained relatively low in the production of technical parts,” underlines Franz Pressl. “Tie-bar-less technology has enabled us to turn the tide of spiralling costs and make plastics processing firms more competitive by installing smaller machines. Even in its 25th year, tie-bar-less technology has its finger on the pulse.”

Teletronics: Higher productivity per square metre of production space
At the Teletronics section of the ENGEL stand, a new tie-bar-less and all-electric ENGEL e‑motion 50 TL will produce 15-pin plug housings from fibreglass-reinforced PBT/ASA using a two-cavity mould. “The trend towards ever higher productivity per square metre of factory space is continuing,” emphasises Heinz Rasinger, Vice President of ENGEL's Teletronics business unit. “The electronics industry also has extremely high demands as regards precision.” The 15 contact pins in the finished connector, for example, are very close together, and the moulded grid structure is equally fine with wall thicknesses and edge lengths in the region of micrometres. In this market segment, all-electric machines are the standard. To offer highly compact manufacturing cells, ENGEL combines all-electric drive technology with a tie-bar-less clamping unit in its ENGEL e-motion TL small machine range.
Having unveiled the ENGEL e-motion TL with an initial clamping force of 30 tons at K 2013, ENGEL will be upgrading the new series to include a 50-ton version at Fakuma 2014. As with the smaller variant, the new ENGEL e-motion 50 TL features a one-piece machine frame that makes the injection moulding machine lighter and more compact than comparable all-electric machines of other types. The design also guarantees very high platen parallelism and even distribution of clamping force. “The small, all-electric ENGEL e-motion TL machines are concrete proof that even after a quarter of a century, the concept of tie-bar-less injection moulding machines has room for innovation,” says Heinz Rasinger. “We believe there is a great deal of potential for tie-bar-less injection moulding machines in the electronics industry.” Many electronic components such as plug housings are parts with complex, three dimensional structures requiring bulky moulds with slide units and core-pulls but relatively low clamping force because of the somewhat small part surfaces projected. In many applications, the fact that the mould mounting platens on a tie-bar-less machine can be used up to the edges means that a smaller machine can be used than the mould size would normally dictate – and this drives up productivity per square metre of factory space.

Automotive: Technology integration opens new vistas of quality
The trend of process integration as a path to greater efficiency, safety and quality is well established. Now it is necessary to adopt a more diversified stance. The object is no longer simply to integrate process steps upstream or downstream of injection moulding, but also to combine different process technologies with one another. To produce centre console components in PC-ABS at its trade show stand, ENGEL will be using an ENGEL duo 2550/550 injection moulding machine with integrated ENGEL viper 20 robot to combine two technologies: ENGEL foammelt, the MuCell foam injection moulding process developed by Trexel of Wilmington in the USA, and ENGEL variomelt, a variothermal injection moulding process. “For the first time, this will enable us to produce thin-walled parts with very high quality surfaces and excellent fine structure reproduction at the same time in a single injection moulding step,” promises Franz Füreder, Vice President of the Automotive business unit at ENGEL.
To demonstrate the versatility of this amalgamation of processes, the sample part will have varying wall thicknesses and surface structures. The mould for the variothermal process demonstration will be supplied by ENGEL's partner Roctool (Le Bourget du Lac, France). Thanks to ENGEL foammelt the cavity, including the undercuts, is completely filled, and the component has no sink marks after cooling; meanwhile variothermal temperature control provides a high gloss finish. Away from applications aimed at car interiors, integrating ENGEL foammelt and variomelt opens up new vistas of efficiency and quality for white goods and household products.
The new design of the ENGEL duo injection moulding machine will be unveiled at Fakuma 2014. Users will benefit in particular from improved ergonomics thanks to a lower operating height and easier access to the mould and nozzle area. Other features of the new machine generation include roller rail systems for the moving platen, energy-efficient mould movement and a much cleaner mould area thanks to the discontinuation of central lubrication.
The ENGEL viper linear robot has also had a technical makeover for Fakuma, whereby it was adapted to the new CC300 control unit for ENGEL injection moulding machines. Thanks to the update, the speed, flexibility, compactness, energy efficiency and ease of use of the robots have all improved; even the standard version is fitted with a multidynamic drive package, which draws together the former load, regular and speed packages. Meanwhile the new C70 seven-inch hand-held touch terminal replaces the old C35 and C100 terminals; weighing in at 950 grams, the C70 is one of the lightest hand-held control devices of its size on the market. The sides of the robots have been adapted to the new design of the ENGEL machine control unit, ensuring a consistent operating system and uniform presentation. All robot settings can be performed using the hand-held unit or the injection moulding machine's operating panel; key setting parameters for the machine can also be displayed on the C70.

Packaging: All-electric for maximum performance
ENGEL's Packaging business unit will be presenting an all-electric injection moulding machine in Friedrichshafen. 500 ml food containers will be produced on an ENGEL e-motion 440/160 featuring a 2-cavity mould by Glaroform (Näfels, Switzerland). In-mould labelling (IML) will be used to decorate the packaging; to do this, ENGEL will collaborate with partner company BECK automation (Oberengstringen, Switzerland). “The steady enhancement of the ENGEL e-motion series is serving to establish the machines in the field of high performance applications for the packaging industry,” says Kurt Hell, Sales Manager at ENGEL Packaging.
The newest machine generation is able to achieve cycle times of well under three seconds and injection speeds of more than 500 mm per second, thereby combining maximum performance with maximum energy efficiency. The closed system for toggle lever and spindle always guarantees optimal, clean lubrication of all moving machine components. This makes the ENGEL e-motion the preferred machine type even in regulated areas such as food packaging production.

Medical: Process integration for safety
In the Medical section of its stand at Fakuma 2014, ENGEL will be producing drip chambers with integrated filter for blood transfusions. An ENGEL e-victory 310H/80W/50V 160 combi tri-component injection moulding machine with ecodrive and a clean room design will be used in this highly integrated production process. Each drip chamber will comprise one ABS and one PP component; in a single workstep, they will be injection moulded, fitted with the filter and joined by means of overmoulding with additional polypropylene. This high degree of integration significantly boosts efficiency in the manufacturing of multi-component hollow bodies with inlays. Conventionally, the two hollow body components are individually injection moulded; the inlay is then fitted and bonded in subsequent process steps. “Drip chambers are mass-market products that need to be manufactured economically despite the stringent demands on product safety and hygiene,” says Christoph Lhota, Vice President of ENGEL's Medical business unit, underlining the importance of the innovation. “We believe there is potential for this innovative one-shot process in other sectors too, such as the production of fuel filters in the automotive field.”
One key prerequisite in realising the integrated process is servoelectric drive technology for all movements of the index plate mould; this facilitates the synchronous control of mutually independent movements. For this application, the mould manufacturing partner is Hack Formenbau (Kirchheim, Germany).
An ENGEL easix multi-axis robot is also integrated in the manufacturing cell along with a system for total quality control. The drip chambers are inspected for seal tightness directly after injection moulding.

Technical Moulding: Efficient use of LIM multi-component processes
The main demands as regards the processing of liquid silicone (LSR) are that it must be fully automatic, waste-free, low in burrs and require no reworking. An ENGEL e-victory 200H/80W/120 combi injection moulding machine – automated with an ENGEL viper 20 linear robot – will impressively show that ENGEL system solutions not only meet these requirements fully, but also handle LIM multi-component processes securely and efficiently. A mould provided by ACH solution (Fischlham, Austria) will be used to produce sensor housings for flow measurement with integrated seals. “We can guarantee maximum precision by using servo-powered injection units,” says Leopold Praher, head of sales for elast/LIM machines at ENGEL AUSTRIA. “Normally the LSR field requires special solutions where very small injection unit volumes are involved. In this case we meet that need with a standard unit.” Developed and patented by ENGEL, iQ weight control software applied in the system recognises and automatically compensates for fluctuations in melt quantity during the actual injection process.
The tie-bar-less technology of the ENGEL e-victory machine also makes a decisive contribution to high process stability in this application, while the patented force divider evenly introduces force to the mould across the platen face. Both outer and inner cavities are thereby kept closed with precisely identical force, significantly reducing mould wear and raising product quality. On top of this, free access to the tie-bar-less machine's mould area facilitates the most effective automation concepts.

ENGEL plus: Controlled conditions
At the Fakuma event, ENGEL will devote a special presentation area to ENGEL plus, the name for its service products and optimisation tools. The main theme of the display will be intelligent mould temperature control. “Although mould temperature control has a major influence on the productivity of the manufacturing process as well as component quality, we tend to pay too little attention to this aspect,” emphasises Wolfgang Degwerth, head of the Customer Service division at ENGEL AUSTRIA. ENGEL prompted a rethink when it developed ENGEL flomo in 2010. The compact temperature-control water distribution system has manual settings and can be integrated into a machine; electronic monitoring has increased process reliability and simplified process optimisation in more than a thousand new machines to date. For Fakuma 2014, ENGEL will be taking the next step from process monitoring to process control. The newly developed ENGEL e-flomo has electric control valves that make it possible to adjust and control flow rates fully automatically; ENGEL will demonstrate this live at the trade fair. “ENGEL e-flomo keeps the temperature in the mould constant throughout the production period, even where water pressure varies,” says Degwerth. “This results in greater efficiency, process reliability and consistently high product quality.”

ENGEL at 2014: Hall A5, stand A5-5204
25 years of ENGEL tie-bar-less technology: East Foyer, stand FO-03
(Engel Austria GmbH)

Newsgrafik #28756
 15.05.2014

New ENGEL gasmelt module for Haidlmair  (Company news)

Bauer Kompressoren is ENGEL AUSTRIA's exclusive partner in the field of gas injection technology (GIT). Under the name ENGEL gasmelt, the injection moulding machine manufacturer offers complete integrated solutions for injection moulding with gas injection technology. The project with Haidlmair also demonstrates that older systems can be easily upgraded. The new GIT module was integrated into a large existing ENGEL machine.

From left to right: Klaus Mittmannsgruber, ENGEL AUSTRIA, Mario Haidlmair, Haidlmair, Raffael Kurz, Bauer Compresseurs, and Christian Wolfsberger, ENGEL AUSTRIA, with the new compressor that was integrated into a large existing ENGEL machine.

Leakage monitoring integrated as a standard
The ENGEL gasmelt process and the individual gas feeds can be controlled and monitored via the injection moulding machine's display. During mould trials, Haidlmair particularly benefits from the leakage monitoring system integrated as a standard in the ENGEL gasmelt cell. Especially in the case of large moulds with several gas injectors, being able to map the alarm messages to the control loop facilitates troubleshooting in the event of leakages and increase the availability of the system.
A specialist in moulds for drink crates, large containers, pallets and high-quality automobile components, Haidlmair already has plenty of experience with gas injection technology. Christian Wolfsberger, Technology Manager at ENGEL AUSTRIA in Schwertberg, Austria, states: "In these areas of application, the potential for increasing efficiency is particularly great. ENGEL gasmelt reduces the amount of raw material used and shortens cycle times by producing outstanding component stability and surface quality.

For more efficiency and sustainability
With key patent protection rights for the gas injection technology having expired, the process is now being given a fresh boost. Christian Wolfsberger adds: "In view of the ever increasing cost pressure at plastics processing companies and the demand for more process stability and sustainability, we see a huge amount of potential for ENGEL gasmelt. We will therefore continue to develop the technology with our partners and to make this a priority."
(Engel Austria GmbH)

Newsgrafik #28712
 09.05.2014

ENGEL at PLASTPOL 2014 in Kielce  (Company news)

Picture: The CC300 sets a new trend with its large multitouch display and central control button e-move. At PLASTPOL 2014 ENGEL will be presenting its new generation of control units in Poland for the first time.

Smart management of integrated processes: The new CC300 control unit generation will be ENGEL's main attraction at PLASTPOL 2014 from May 27 to 30. This year, ENGEL's presentation in Kielce will be bigger than ever. With four production cells at two stands plus another machine at a partner's stand the injection moulding machine manufacturer demonstrates how automated manufacturing processes can be controlled in a particularly simple and safe way.

Process integration and automation are crucial to increasing efficiency in injection moulding production. At the same time, however, they make the manufacturing processes more and more complex. Making the operation of highly-integrated and automated production processes easier, more comfortable and safer was therefore the declared goal of ENGEL in the development of its new CC300 control unit generation, which will be presented in Poland for the first time at PLASTPOL 2014. The new features include the extra-large 21" multitouch display with a new and even clearer structure, separate views for each task, which eliminate operator errors in full-feature scope, and the central control button e-move that gives the operator a feeling for the machine in spite of the multitouch functionality. By being rotated, e‑move enables all machine and robot movements to be controlled millimetre by millimetre and in a speed-sensitive manner.

"With the CC300 we are setting a new trend," says managing director of ENGEL Polska Piotr Nachiło in Warsaw. "The first users' feedback has been extremely positive." One main reason has been that the operators are able to figure out the new control unit immediately. The basic principles that operators appreciated in the previous model have been retained. In addition, user technologies that have since become standard were transferred to the demands of the injection moulding processes – for example, the intuitive gesture controls found in smartphones.

All four machines on display at the two ENGEL stands feature the CC300 machine control unit. "We invite all visitors at the fair to try out the new control concept for themselves at PLASTPOL," Piotr Nachiło states.

At its main stand in hall F ENGEL will present automotive and packaging applications, and LIM, while the special presentation in hall E is dedicated fully to the new ENGEL e-motion 30 TL injection moulding machine.
(Engel Austria GmbH)

Newsgrafik #28667
 23.04.2014

New ENGEL website online - Relaunch with added value  (Company news)

Picture: The new ENGEL website is displayed perfectly on mobile end devices as well. A global contact Network and a strong focus on applications are among the site's new features

With a clearer layout and more service features, the new ENGEL website enables
visitors to find what they need even more quickly – regardless of whether they are at accessing the site at work or via their smartphone or tablet while out and about.

ENGEL now presents its new digital look. Boasting a modern design and an extremely clear navigation structure, the new website guides its visitors intuitively to the information they want. Gerd Liebig, Group Marketing Director at ENGEL, says: "When the site was being developed, the aim was to get users where they want to be even more quickly. Our website is being used more and more, and our customers should be able to expect top-quality service
from ENGEL online too."

Solutions for specific requirements
Besides providing a detailed overview of ENGEL's product range, the new website reflects the company's strong focus on applications. Under the menu item "Business Lines", injection moulding facilities can now find possible solutions for their specific requirements. Examples include solutions for high-quality car interior design, cost-optimised thin-wall containers and electronic display screens with multifunctional surfaces. Numerous hyperlinks allow users to learn more about a topic and read press articles, while videos and animation spots make even complex machine functions and manufacturing processes easy to understand.

ENGEL has a separate area called "ENGEL plus" for its service products. For the first time ENGEL's complete range of after-sales services is presented here. The content is divided up according to various objectives, which means that even those who are not familiar with the ENGEL service products can learn a great deal about them and possibly tap into new ways of optimising potential.

Straight to the right contact
One highlight of the new website is the new global request and contact network. With just one click, visitors can contact the person responsible for a particular topic in their country. Gerd Liebig says, "This decentralised contact management system allows us to respond to online requests even more quickly and, above all, accurately."

Customer proximity is, of course, important to ENGEL online as well, and for this reason the website is available in 26 country-specific versions. This enables ENGEL to keep their customers up to date on local topics, events and job opportunities at their respective sites.

The same responsive site design has been used for every country. This ensures that the content and functions are displayed perfectly even on mobile end devices like tables PCs and smartphones.
(Engel Austria GmbH)

Newsgrafik #28608
 08.04.2014

ENGEL Deutschland Technologieforum Stuttgart continues to grow  (Company news)

Established communication hub

Picture: The ENGEL Deutschland Technologieforum Stuttgart currently has 25 employees. This year, mainly service technicians will be added to the staff.

A year after its foundation, ENGEL Deutschland Technologieforum Stuttgart is taking stock, and the results are quite positive. The number of employees has been increased sooner than planned. The service offer on site is further expanded.

The ENGEL Deutschland Technologieforum Stuttgart, which is located in Wurmberg, is ENGEL AUSTRIA's fourth sales and service branch in Germany after Nuremberg, Hagen, and Hannover. By opening the forum in April 2013, ENGEL moved significantly closer towards its customers in the southwest of Germany. "The share of technologically demanding system solutions with automation increases and requires a constantly intensified collaboration",
emphasises branch manager Claus Wilde. "With the new site we have created perfect conditions to achieve this". Thanks to its closer proximity to the market ENGEL was able to acquire a lot of new customers over the course of the past year.

Forum events and trainings attract more than 1100 participants
With its particularly large technical centre and conference area the ENGEL Deutschland Technologieforum Stuttgart endeavoured to become an information and communication hub for the injection moulding industry in the southwest of Germany. "We have achieved this goal", Wilde states. "Our events are very well attended throughout". The team in Wurmberg welcomed so far more than 700 guests to nine forum events and several workshops; plus another 400 participants of the training programme. The most sought after topics for the workshops were energy efficiency and optimised set-up. Both workshop series will be continued this year. Among the highlights in the 2014 event calendar are an automobile forum, the medical conference ENGEL med.con, as well as a large-scale machine day.

Constantly growing partner network
Another focus of the technical centre is the support of ENGEL's customers in matters regarding applications, an offer readily accepted. "We can perform elaborate fittings and experiments for customers on site, on request also in private areas, protected from sight", Wilde says. ENGEL Deutschland Technologieforum Stuttgart works closely with partner companies and institutions, such as the SKZ in Horb and the Fraunhofer Institute in Pfinztal, and is actively involved in professional associations and networks, e.g. medial mountains and Innonet. As a result, the network of partners is constantly expanding. Furthermore, ENGEL is supporting training centres in the region.

Looking for new service employees
The number of employees has already risen in the first year. Currently ENGEL employs 25 people in Wurmberg. First and foremost, additional service technicians are to be hired this year. The new ENGEL subsidiary offered a special hotline for its customers from the very start. A sale of spare parts in Wurmberg is another project for the future. "The rapid growth proves that we have struck the right path with the foundation of ENGEL Deutschland Technologieforum Stuttgart", Claus Wilde stresses. "Now we have to bring our staff, our processes, and our offer in line with the demands of the market on a continuous basis. To this end we intend to make further investments". For ENGEL Germany is the most important market. The injection moulding manufacturer generates roughly a quarter of its global turnover in this market and was able to constantly expand its market shares. The new subsidiary takes account of these developments and at the same time lays the foundation for further growth.
(Engel Austria GmbH)

27.03.2014

ENGEL restructures service offerings  (Company news)

Injection moulding machines and manufacturing cells continually need to boost their output, efficiency and flexibility. This also results in changing requirements for the machine manufacturer's service organisation. ENGEL AUSTRIA has squared up to this challenge and reorganised its service products and services under the ENGEL plus banner. The objective is to create added value for their customers and, thus, to improve their competitive advantage.

Training and service are firm features of ENGEL's system philosophy. ENGEL plus makes its service portfolio even more transparent, thus opening up optimisation potential for existing machines, robots and plants.

"We accompany our customers through the entire production plant service life", emphasises Wolfgang Degwerth, Head of ENGEL AUSTRIA's Customer Service Division. "Total Cost of Ownership is becoming increasingly important for our customers. With ENGEL plus, we ensure optimal asset health and planning security for our customers and, on request, help them keep their machinery up to date at all times."

Boosting the productivity and availability even of older systems
ENGEL plus ranges from global on-site support with spare parts logistics, remote services and a 24x7 hotline, maintenance and repair contracts at fixed prices to retrofitting options and optimisation tools, application engineering consultancy and professional training and eLearning offerings.

"Above all, the topic of retrofitting is becoming increasingly important against a background of increasing efficiency pressure," says Mr Degwerth. ENGEL offers a wide spectrum of products for a variety of tasks. Even older injection moulding machines and control unit generations can be improved in terms of energy-efficiency, shot weight constancy and maintenance overhead minimisation. At the same time, ENGEL plus allows for retroactive integration of additional process steps, technologies and automation. To fulfil the customer's specific requirements, ENGEL develops individual software solutions.

Close to the customers – anywhere in the world
More than 550 staff are employed in customer service and training at ENGEL's global plants and subsidiaries. To ensure top quality standards for our services worldwide, all ENGEL service engineers and trainers are regularly required to take part in training and testing. ENGEL also uses its online learning platform to achieve this. After all, the ENGEL service network covers the entire globe. "Short paths to our customers are very important to us," says Wolfgang Degwerth. "We are continually expanding our global service network."
(Engel Austria GmbH)

Newsgrafik #28451
 05.03.2014

ENGEL at Chinaplas 2014 in Shanghai  (Company news)

As the pressure to reduce costs continues to rise, innovation, efficiency and automation increasingly become the focus for injection moulding producers in Asia. ENGEL will be demonstrating how to successfully meet such current challenges at Chinaplas 2014, from 23rd to 26th April in Shanghai. All four highly integrated manufacturing cells on display at ENGEL's trade fair stand combine top performance with maximum energy efficiency while making clear that automation is also beneficial in terms of process technology.

ENGEL automotive: Conserving resources with higher quality components
An ENGEL duo 900 injection moulding machine with integrated ENGEL viper 20 linear robot will be the focus of the automotive exhibition. With the ENGEL foammelt technology, oil sumps are produced on the large-scale machine with a 9,000 kN clamping force. Under the ENGEL foammelt banner, ENGEL offers turnkey solutions from a single source for MuCell structural foam moulding by ENGEL partner Trexel, from Wilmington, Massachusetts (USA). For the MuCell process, which is no longer protected by licensing fees, the plastic melt is loaded with nitrogen or carbon dioxide and then injected into the mould, during which time the gas expands in the mould cavity. The use of raw materials and the component weight are thereby reduced, while at the same time the rheological properties of the melt improved. This results in dimensionally stable injection moulded parts that are free from sink marks.

The manufacturing cell makes it clear how the optimized cooperation between the injection moulding machine and the robot opens up new potential for efficiency. Thanks to the complete integration of the control unit, the injection moulding machine and the robot access the same database and can precisely coordinate their move sequences. For example, the robot can enter the mould area during the mould opening movement, which frequently reduces cycle times.

"Automation is increasingly becoming an integrative process that enables extremely economical production processes and guarantees a constant high level of product quality," states Gero Willmeroth, Sales and Service Manager of ENGEL Machinery Shanghai. "With intelligent automation concepts we can clearly increase the competitiveness of our customers. The demand for automated system solutions continues to increase in Asia."

ENGEL teletronics: Maximum efficiency for even the smallest precisions components
In the electronic and telecommunication sectors, it is necessary to combine energy efficiency with maximum precision and flexibility. And yet, as the demands for quality increase, part sizes are decreasing. In order to meet these requirements while keeping costs low, ENGEL has expanded its ENGEL e-motion series of all-electric injection moulding machines with a small, tie-bar-less variety. As the first injection moulding machine developed in Europe, the ENGEL e-motion 30 TL with a clamping force of 300 kN is capable of producing optical lenses for mobile devices with a maximum form deviation of just a few µm. Equipped with an 8-cavity mould and an integrated ENGEL viper 6 robot, it will demonstrate this at Chinaplas 2014.

For the small, tie-bar-less ENGEL e-motion machine, a new frame concept was developed that enables a really light and very short machine design. With a length of only 3 metres, the ENGEL e-motion 30 TL is the shortest 30-tonne machine with all-electric drive technology on the market. In addition, the barrier-free mould space allows for comparatively large moulds. Both aspects greatly reduce the footprint of the plant, which is an important efficiency factor, especially in clean room production.

ENGEL packaging: Fully electric for maximum performance
The business unit ENGEL packaging will also be presenting an all-electric injection moulding machine in Shanghai. 500 ml food containers will be produced on an ENGEL e-motion 440/160 featuring a 2-cavity mould by Glaroform (Näfels/Switzerland). The containers will be decorated using in-mould labelling (IML). The high-performance IML automation comes from BECK automation (Oberengstringen/Switzerland), and the foils from Viappiani (Mailand/Italy). The auxiliary equipment partners are Piovan of S. Maria di Sala in Italy and ef cooling (Dällikon/Switzerland).

The ongoing development of the ENGEL e-motion series has increasingly established these machines in the area of high-performance applications in the packaging industry. The newest machine generation is able to achieve cycle times easily under 3 seconds and injection speeds of more than 500 mm per second, thereby combining maximum performance with maximum energy efficiency. The closed system for toggle lever and spindle always guarantees optimal, clean lubrication of all moving machine components. This makes the ENGEL e motion even in regulated production areas – for example, in the production of food packaging – the preferred type of machine.

ENGEL medical: tie-bar-less technology saves space in the clean room
Petri dishes belong to the standard consumables in biochemical laboratories. In order to be able to optically analyze the micro-organisms and cells grown in the dishes, the plastic dishes must have a high level of transparency, optical clarity and a flat bottom. An ENGEL victory 1350/300 injection moulding machine will meet this challenge at Chinaplas. In an 4+4-cavity mould by Plastisud (Castelnaudary/France) eight upper and lower parts of the petri dishes will be produced out of polystyrene in every cycle. The parts are removed in pairs fully automatically, fitted together, stacked and prepared for packaging. ENGEL achieves such a high level of process integration together with its systems partner Hekuma (Eching/Germany). In medical technology, automation plays a decisive role in achieving high levels of process and product safety. That is because manual interventions represent the greatest risk of contamination in the clean room.
Thanks to ENGEL bar-tie-less technology, this manufacturing cell even fits within a small area. On the one hand because, thanks to the barrier-free clamping unit, the large mould fits in comparatively small machines. And on the other hand because the automation can be placed very close to the mould. The handling arm can directly access the mould area from the side.

CC 300: New ENGEL control unit simplifies complex processes
Process integration and automation are crucial to increasing efficiency in injection moulding production. At the same time, however, they make the manufacturing processes more and more complex. Making the operation of highly-integrated and automated production processes easier, more comfortable and safer was therefore the declared goal of ENGEL in the development of its new control unit generation CC 300, which will be presented in Asia for the first time at Chinaplas 2014. The new features include the extra-large 21" multitouch display with a new and clearer structure, separate views for each task, which eliminate operator errors in full-feature scope, and the central control button e-move that gives the operator a feeling for the machine in spite of the multitouch functionality. By being rotated, e-move enables all machine and robot movements to be controlled millimetre by millimetre and in a speed-sensitive manner.

"We're setting a new trend with the CC 300," says Gero Willmeroth. "The feedback from our test operators has been extremely positive." One main reason has been that the operators are able to figure out the new control unit immediately. The basic principles that operators appreciated in the previous model have been retained. In addition, user technologies that have since become standard were transferred to the demands of the injection moulding processes – for example, the intuitive gesture controls found in smartphones.

"The control unit of the manufacturing cell has long since become an important factor in efficiency," Willmeroth stresses. "With our new CC 300 we can support our clients in maximizing the full potential of integrated system solutions while increasing process safety at the same time, even when the level of qualifications of the employees are low.”

ENGEL plus: Intelligent service products maximise productivity and efficiency
Under the ENGEL plus banner, ENGEL showcases its service products and services at Chinaplas 2014 in a separate exhibition area. The main focus is on ENGEL flomo and ENGEL e factory 2.

The ENGEL flomo electronic temperature control water distributor continually monitors all cooling and temperature control circuits, thus making maintenance-intensive cooling water distribution manifolds with sight glasses redundant. With its vortex sensors, the ENGEL flomo requires no moving parts and water filters. All the components are made of premium stainless steel. ENGEL flomo is one of the smallest manually configurable water distribution devices with electronic monitoring on the market, and can thus be mounted very close to the mould. This reduces heat loss.

With ENGEL e-factory 2, ENGEL sets new standards in production data acquisition. Thanks to the enhanced set of features, the new release of ENGEL's MES solution can be connected directly to ERP systems such as SAP – even injection molding machines of different brands can now be integrated. Production figures can be observed conveniently in real time from the desk in order to counteract deviations immediately. This results in higher productivity and efficiency in the injection molding production.

From injection moulding machines and automation, process technology and mould planning, to training and service, ENGEL offers optimized, turnkey system solutions around the world for the specific needs of individual business sectors and national markets. Local production in Asia ensures the fast and flexible adaption of injection moulding machines and system solutions while also guaranteeing short delivery times. ENGEL is the only western injection moulding machine manufacturer with two production plants in Asia.

ENGEL at Chinaplas 2014 in Shanghai: Hall E3 Stand E01
(Engel Austria GmbH)

Newsgrafik #28407
 26.02.2014

ENGEL Machinery Korea delivers 5000th machine  (Company news)

5000 injection moulding machines have been built by ENGEL AUSTRIA's production facility in South Korea since being established in 2001. The "milestone" machine – an ENGEL victory with ecodrive – was delivered at the beginning of 2014.

Customer proximity reduces delivery times
ENGEL pursed a global presence from early on and established its own production plants in regions with strong growth potential. Today, ENGEL is the only European injection moulding machine manufacturer with two production plants in Asia. The plant for injection moulding machines in the small and medium clamping force segment is located in Pyungtaek City (Korea), while ENGEL builds large-scale machines for the Asian markets in Shanghai (China). The assembly capacity at the two locations has been substantially increased in the past two years. Thanks to application-orientated system solutions from a single source, ENGEL has attained a leading position in Asia, too. Local customers benefit from flexible alterations to their machines and system solutions for their specific requirements, as well as from short delivery times. "Our project running times are constantly getting shorter", confirms Gerhard Zebe, President of Global Operations Mechanicals at Flextronics, based in Zhuhai, South China. "ENGEL adheres to the delivery times we demand and fulfills individual equipment requests in Asia. As a company with global production, we value partners that also have a global presence and provide the same quality and service worldwide. And this is precisely what we appreciate about ENGEL."

Energy efficiency drives competition
Flextronics is a leading end to end supply chain solutions company that employs a staff of 200,000 in more than 30 countries. ENGEL is a preferred supplier in its injection moulding sector. All told, ENGEL has thus far delivered nearly 400 injection moulding machines and integrated manufacturing cells with automation and process technology to the group. The new ENGEL victory machine is destined for the site in Malaysia.

Its tie-bar-less technology makes the ENGEL victory a preferred machine type. "Tie-bar-less technology helps to keep floor space for our manufacturing cells to a minimum," says Gerhard Zebe. "Additionally, the ENGEL victory machines work extremely precisely without losing any stability during the course of their entire service lives." The latest delivered ENGEL victory machines are equipped with the ecodrive energy-saving option, just like the new "milestone" machine. "Sustainability is very important to our business", adds Zebe.

Mutual goals provide incentive – on both sides
The delivery of the 5000th machine from Korean production was actually celebrated twice. First with the staff in Korea, and shortly afterwards together with the customer at ENGEL's head offices in Schwertberg, Austria. Dr Peter Neumann, CEO of ENGEL Holding, thus had the opportunity to thank Flextronics for their trust and long-standing partnership. "Vigorous innovation, combined with sustainable operations, is what characterises the global activities of both Flextronics and ENGEL", emphasises Peter Neumann. "Building on these shared values, our close cooperation continually provides new impetus contributing to the on-going development of both companies."
(Engel Austria GmbH)

Newsgrafik #28355
 13.02.2014

ENGEL appoints new managing director in Scandinavia  (Company news)

Picture: Jens Thor Hansen

ENGEL has appointed a new managing director for Sweden, Denmark and Norway. Jens Thor Hansen is an experienced plastics expert for these strategically important markets.

Having previously been the managing director at a plastics-processing company specialising in clean room production, Jens Thor Hansen has gained extensive experience in this area over the last six years. All told, the 49-year-old plastics technology engineer has worked in management positions for medical technology and raw material companies for 25 years. "Medical technology is one of our important growth markets in Scandinavia, and we will benefit hugely from Mr Hansen's experience", remarks Dr Christoph Steger, CSO ENGEL Holding GmbH, Austria. "In addition to this, our continued growth in Scandinavia depends to a great extent on providing efficient solutions for innovative applications. And this is precisely ENGEL's strength, as well as that of the Scandinavian industry."

Ralf Godbey, the previous managing director of ENGEL in Scandinavia left the Group at the end of 2013. "We thank Mr Godbey for his great commitment in the past few years", says Christoph Steger. "Under his leadership, ENGEL gained a strong foothold in Northern Europe. Based on where we are already, I am convinced that we will be able to solidify our market presence in Denmark, Sweden and Norway."

ENGEL is represented by subsidiaries in Solrød Strand, Denmark, and Jönköping, Sweden, as well as a sales and service office in Hobøl near Oslo, Norway.
(Engel Austria GmbH)

Newsgrafik #28302
 30.01.2014

New managing director for ENGEL in Mexico  (Company news)

Hector Moreno has become ENGEL de Mexico S.A. de C.V.'s new Managing director, replacing Peter Auinger, who will be filling a new role within the ENGEL Group in Asia.

Hector Moreno is a qualified engineer and has many years of sales experience in the Plastics industry in Mexico. Before joining ENGEL he has been in charge of another European machine builder's Mexican sales for 18 years.

Dr Peter Neumann, CEO of ENGEL Holding in Austria, remarks: "We're delighted to have found a very experienced expert for this strategically important market. Mr Moreno is equally passionate about sales and engineering, and we're sure that, together with his team, he will continue the success story of ENGEL in Mexico." Among other things, his objectives include the further strengthening of system sales and the further expansion of the local service
network, which already saw very strong growth while Peter Auinger was still in charge.

Peter Neumann adds: "We would like to thank Mr Auinger for his excellent work. ENGEL has been able to make a disproportionately large contribution to the strong growth in the Mexican injection moulding industry and increase its market share continuously over the last few years." Investments by international car companies have more than anything else made the market so dynamic, but investments in the packaging, telecommunications and the consumer electronics industries have also played a major role.

ENGEL AUSTRIA has had a subsidiary in Mexico since 1996. In 2010, the premises were moved from Mexico City to Querétaro and significantly expanded. Querétaro is one of the country's most important centres for the plastics industry. ENGEL de Mexico is not just a sales and service site with an extensive spare parts warehouse, but also a training site. The large, well equipped technical centre is used for seminars and conferences as well as for customer tests and mould trials.
(Engel Austria GmbH)

Newsgrafik #28258
 27.01.2014

Energy efficiency for updating  (Company news)

Rising energy prices and the demand for more sustainability often make manu-facturing systems that have been used for many years seem even older. ENGEL's new retrofit solution ecodriveR is reasonably priced, can be fitted with little hassle and reduces the energy required by existing hydraulic injec-tion moulding machines by up to 50 %, increasing their cost-effectiveness sig-nificantly as a result.

ENGEL has been a leading developer of energy-efficient drive concepts for many years now. ENGEL set a new energy efficiency benchmark for all injection moulding machines, including hydraulic models, when it launched its servo-hydraulic system, ecodrive, in 2008. Consisting of a servomotor and a fixed displacement pump, this drive solution saves lost energy among other things. Without an energy saving option, lost energy builds up when a machine is idle and traditionally accounts for a large proportion of its total energy consumption.

Low cost, great effect
ecodriveR means hydraulic injection moulding machines with an asynchronous motor and electric-hydraulic variable capacity pumps (EHVs) can now be controlled according to de-mand as well. This is achieved through the installation of a frequency converter that adjusts the speed of the pump drive to the amount of energy required. ecodriveR is set using a sim-ple interface of the machine control unit, Wolfgang Degwerth, head of ENGEL AUSTRIA's customer service division, states: "Since a machine's hydraulic system remains the same when it is retrofitted, ecodriveR allows us to adapt older injection moulding machines to the requirements of modern production companies quite quickly and at a relatively low cost. The first few uses have shown that, depending on the application, it can reduce the energy re-quired by machines by up to 50 % without affecting the cycle time, part quality or reproduci-bility standards.“

Less energy, heat and noise
As with the ecodrive principle, the drives of an injection moulding machine with the retrofitted ecodriveR are only active when the machine is in movement, such as during mould opening and closing, plasticising and injecting. During the post injection pressure and plasticising phases, the speed is reduced, and during cooling, the drives come to a complete standstill and do not use any energy at all.

In addition to the significantly lower drive energy levels, both ecodrive and ecodriveR offer other advantages. For example, the reduction in the amount of heat released is particularly noticeable. Normally, the excess energy is converted into heat and emitted into the atmos-phere and the hydraulic oil. Both of these effects are almost completely eliminated when ecodrive or ecodriveR is used, which lowers the cooling capacity considerably and increases the lifespan of the hydraulic oil. One ergonomic advantage of the two systems is the reduced noise emissions, which are a consequence of lower average motor speeds.

Smaller footprints
The saving potential depends on different factors. Machine size and cycle time play a crucial role among other things. If, for example, POM technical parts with a shot weight of 109 g and a cycle time of 78.3 seconds are made on an ENGEL victory 330/125 injection moulding ma-chine that has been energetically optimised with the ecodriveR system, 3.7 kWh of energy will be saved every hour, which means 46 % less will be consumed compared to a machine that has not been updated. The 3.2 kWh/h drive energy reduction and the fact that the cool-ing/filter motor uses 0.5 kWh/h less energy make a major contribution here. If the machine is in operation for 6000 hours per year, the amount of electricity it uses will be cut by 22,200 kWh overall, which equates to six tonnes of carbon dioxide.

The retrofit option ecodriveR can be added to any ENGEL hydraulic injection moulding ma-chine with three or fewer asynchronous motors and electro-hydraulic variable capacity pumps. In many countries, this investment is supported by funds from the public sector.
(Engel Austria GmbH)

Newsgrafik #28184
 08.01.2014

More than 300 Participants at LSR Seminars in China  (Company news)

With more than 300 participants, the LSR-seminars, to which ENGEL, Dow Corning and Elmet issued invitations in mid-December and which were held in Shanghai and Dongguan, were a huge success. Intelligent system solutions that process liquid silicone rubber (LSR) for the highest efficiency and lowest unit costs, were the focus of lectures and live demonstration.

"The demand for high-end solutions to process LSR is rapidly increasing in China", according to Gero Willmeroth, Head of Sales and Service at ENGEL Machinery Shanghai. "It is even essential for mass products to adapt production lines individually to the products, the quantities, and the materials. This is the only way to competitively produce over the long term." ENGEL and its system partners provide turnkey systems from a single source, because only when all system components and materials are perfectly matched from the beginning can the efficiency potential be exploited to the maximum. ENGEL, Elmet and Dow Corning demonstrated how this looks in practice, producing sealing rings on an ENGEL victory 110 injection moulding machine. The manufacturing cell was equipped with a mould manufactured by
Elmet, and injection unit, feeding units, and metering pumps especially developed for LSR processing.

Fully automatic, wastefree, and virtually free of burrs
"The main demands with regard to LSR processing are that it must be fully automatic, waste-free, low in burrs, and require no reworking", explains Leopold Praher, Sales Manager Elast/LIM at ENGEL AUSTRIA. "In many cases, ENGEL victory injection moulding machines, with the tie-bar-less clamping unit, offer significant benefits for LSR applications. The excellent accessibility and the space available in the mould area are unique. Very often, smaller injection moulding machines can be used than the mould size would normally require, which saves costs in both investment and operation."

During the lectures, the organisers went into detail on the requirements, potentials, and trends of LSR processing. "Multi-component applications, such as hard/soft combinations for baby products, will significantly increase in China," says Dr. Hans-Peter Wolf, Global Re-search and Development Manager for Silicone Rubber at Dow Corning. In his lecture, he presented innovative raw materials from the Xiameter product range that are preparing the way. In two lectures, Leopold Praher presented injection moulding solutions for processing LSR as well as solid silicone, and Paul Fattinger, Sales Manager at Elmet in Asia, explained special mould concepts, LSR pumps, and mixing units.

Individual solutions with short delivery times
At the end of the Shanghai seminar, the participants had the opportunity to visit ENGEL's production plant. ENGEL is building largescale machines of the ENGEL duo series on-site. Injection moulding machines with low and medium clamping forces, such as those in the ENGEL victory series, are produced for the Asian market in Korea. ENGEL is the only western injection moulding machine manufacturer in Asia with two production plants. "Thanks to decentralised production in Asia, we can assure our customers of short lead times and accommodation of the injection moulding machines and turnkey solutions to the specific requirements on site", says Gero Willmeroth.
(Engel Austria GmbH)

Newsgrafik #28129
 16.12.2013

Intelligent solutions minimise unit costs  (Company news)

At Interplastica 2014, January 28 through 31 in Moscow, Russia, ENGEL will be demonstrating, at its stand in Hall 3, how innovative injection moulding technology and intelligent options can substantially improve the overall efficiency of manufacturing cells. Two automated plants set out to prove this: a tie-bar-less ENGEL victory tech injection moulding machine with an ENGEL viper 6 robot will produce technical parts, while an all-electric ENGEL e-motion injection moulding machine with integrated in-mould labelling will create premium packaging.

Large moulds on a small machine
"ENGEL victory type injection moulding machines have been in heavy demand in Russia for several years", emphasises Olaf Kassek, the CEO of OOO ENGEL in Moscow. "The reason: thanks to their tie-bar-less clamping unit, they enable much lower unit costs in many applications." With the ENGEL victory 500/90 tech, which will produce geometrically complex technical parts at the fair, ENGEL will be demonstrating how to leverage further efficiency potentials beyond this. This system solution represents the state of the art in injection moulding engineering, featuring an integrated ENGEL viper 6 robot, an ENGEL flomo temperature control water distributor, integrated oil maintenance and the ENGEL e service.24 service package.
The efficiency potential that the use of a tie-bar-less machine opens up for geometrically complex parts- and multiple-component products is huge. Moulds for these applications are typically bulky due to the core-pulls and slides, although the clamping force required is typically relatively low. Because the ENGEL victory machines can fully use the mould fixing platens up to the edge, a far smaller injection moulding machine can be used in many cases than the mould size would normally require. This keeps both investment outlay and operating costs low. On top of this, the barrier-free clamping unit facilitates mould changes and automation. Thanks to the integration of the ENGEL viper robot with the injection moulding machine's control unit, the machine and the robot access the same database and coordinate their move sequences. This reduces the cycle time in many applications. Thanks to the pervasive control philosophy, the robot can also be reliably and safely controlled by less skilled staff.

ENGEL flomo and oil maintenance reduce maintenance overhead
The ENGEL flomo and oil maintenance products used in the manufacturing cell exhibited at the fair also contribute towards low operating costs. The ENGEL flomo electronic temperature control water distributor continually monitors all cooling and temperature control circuits, thus making maintenance-intensive cooling water distribution manifolds with sight glasses redundant. With its vortex sensors, the ENGEL flomo requires no moving parts and water filters. All the components are made of premium stainless steel. ENGEL flomo is one of the smallest manually configurable water distribution devices with electronic monitoring on the market, and can thus be mounted very close to the mould. This reduces heat loss.
Far lower repair costs, more system availability and improved operating safety – these are the benefits that ENGEL oil maintenance offers. A cellulose cartridge with a 3 μm fine filter continually removes particulate soiling, condensed water and oil degradation products. This keeps the quality and viscosity of the hydraulic oil constant throughout the machine's service life.
The ENGEL e-service.24 package also contributes towards ensuring maximum availability of the manufacturing cell. ENGEL service engineers can use a remote connection, after ap-proval by the customer, in order to access the machine data in realtime, and immediately start troubleshooting following an error message. The ENGEL team can give the machine operators on site specific instructions and explanations by audio, video or text conferencing. Many problems can easily be resolved over the Internet in this manner, and plastics manufacturers can avoid a costly and timeconsuming service call on-site. At Interplastica in Moscow, Russia, ENGEL will be showing how ENGEL e-service.24 can also be used within the enterprise for greater data transparency and continuous process optimisation.

Maximum performance and lowest possible energy consumption
ENGEL's second manufacturing cell at Interplastica is dedicated to manufacturers of premium plastic packaging. 500 ml containers will be produced at the fair on an all-electric ENGEL e-motion 440/160 injection moulding machine featuring a 2-cavity mould by Glaroform (Näfels/Switzerland). The containers will be decorated using in-mould labelling.
"All-electric ENGEL e-motion injection moulding machines are increasingly being deployed in high-performance applications in the packaging industry", says Olaf Kassek. "The consistent ongoing development of this model series is what makes this possible." The latest generation of ENGEL e motion injection moulding machines achieves cycle times of well under 3 seconds and injection speeds of more than 500 mm per second, a performance class that was long the domain of hydraulic accu machines. “We can now combine top performance with maximum energy efficiency thanks to all-electric drive technology”, says Kassek.

ENGEL at Interplastica 2014: Hall 3, Stand B09
(Engel Austria GmbH)

Newsgrafik #28112
 11.12.2013

ENGEL at Saudi PPPP 2014  (Company news)

Picture: ENGEL e-cap injection moulding machine

ENGEL will be demonstrating how maximum output, consistent quality and permanent availability can be combined with excellent efficiency levels through perfect cooperation between an injection moulding machine, a mould, automation, application technology and support at the Saudi Plastics and Petrochem exhibition taking place from 17th to 20th February 2014 in Riyadh, Saudi Arabia.

Perfectly tailored to specific requirements
ENGEL will be focusing on the packaging and building industries over the four days and will be presenting four examples of application:

-Caps: The all-electric ENGEL e-cap injection moulding machine is designed to produce extremely high performance levels and achieves cycle times of under three seconds. The ENGEL e-cap can be used to manufacture both standard drink caps and special caps for the cosmetics, cleaning and food industries. Andreas Leitner, ENGEL's Middle East sales director says: "29/25 caps are definitely becoming more and more popular for water. We've already completed a number of projects for this new, lighter cap type in co-operation with a well-known Swiss mould manufacturer and have had some very good experience with the ENGEL e-cap along the way."
-Thin-walled containers: The all-electric ENGEL e-motion injection moulding machine turns thin-walled containers that meet high-tech requirements into low-cost products. ENGEL packaging turnkey solutions help processing companies to conserve energy and raw materials, and to integrate various process steps by incorporating techniques such as in-mould labelling. ENGEL works with system partners who are also leaders in their respective fields here, and some of these partners will be exhibiting in cooperation with ENGEL in Riyadh. Those joining ENGEL at the trade fair include Swiss IML expert BECK automation and Otto Hofstetter, which is also Swiss and a leading producer of moulds for thin-wall applications.
-Pallets: ENGEL helps plastics processing companies to follow the trend of switching to plastic pallets early with flexible system concepts based on its large yet compact ENGEL duo machine. In doing so, ENGEL creates systems from a wide technology spectrum, in order to reduce pallet weight and optimise part handling. The system partners ENGEL works with in this area will also be at the Saudi PPPP in Riyadh, which means even very sophisticated turnkey solutions will be able to be worked out during the exhibition.
-Fittings: When large moulds with lots of core pulls and sliders are used, as the production of fittings requires, for example, the tiebarless ENGEL victory machine keeps both the investment and the operating costs low. In addition, the barrier-free clamping unit fa-cilitates automation and enables moulds to be changed more quickly. Irrespective of whether it's the increasingly popular PPR that's being used or PVC and CPVC, which are difficult to process, ENGEL will adapt the plasticising unit to the individual requirements of the materials being processed, and therefore enhance the efficiency of the whole system as well.


Efficient turnkey solutions from one source
When selling a system to a customer, ENGEL supplies the injection moulding machine, the automation, the mould project engineering, the process technologies and its services from a single source, which enables efficiency potential to be exploited in the best possible manner. The Austrian-based machine builder's dense network of subsidiaries, offices and service locations ensures that it is always close to its customers – regardless of where they are in the world. At the same time, ENGEL's cost- and time-efficient support is aided by intelligent Internet-based software solutions.

ENGEL at Saudi PPPP 2014: stand 417-2, hall 2
(Engel Austria GmbH)

Newsgrafik #28071
 03.12.2013

ENGEL Appoints New Chief Sales Officer  (Company news)

Picture: Dr. Christoph Steger has been appointed newly CSO of the ENGEL Group.

Christian Pum, CSO of the ENGEL Holding GmbH in Schwertberg/Austria, has decided to resign from his position and will leave the company at the end of this year to accept new challenges in a different industry. Dr. Christoph Steger, former Vice President for ENGEL’s Business Unit packaging, has been appointed as the new CSO.
Christian Pum joined ENGEL in 1991 and has been CSO since 2006. During his time as CSO, Mr. Pum contributed significantly to the worldwide success of ENGEL. „We thank Mr. Pum for his great achievements and his commitment“, highlights Dr. Peter Neumann, CEO of the ENGEL Holding. „We regret to inform you of his departure, but of course we respect his decision and wish him good luck and all the best in his new challenges.“
Dr. Christoph Steger takes over all responsibilities from Christian Pum effective immediately. Mr. Steger joined ENGEL at the beginning of 2012 and had since lead the Business Unit packaging with great success. Under the leadership of Christoph Steger, ENGEL packaging has experienced a continuous substantial growth, providing injection moulding solutions to the plastic packaging sector.
Together with Dr. Peter Neumann, third-generation-member of the ENGEL family holding, now the fourth generation in management with Dr. Christoph Steger and Dr. Stefan Engleder (CTO) bears operational responsibility. Since its foundation in 1945, ENGEL has been 100 percent family-owned.
(Engel Austria GmbH)

Newsgrafik #28016
 21.11.2013

ENGEL at Swiss Plastics 2014  (Company news)

Maximum precision and reliability levels combined with a tiny footprint: At the Swiss Plastics trade fair that takes place in Lucerne from 21st to 23rd January 2014, ENGEL will be demonstrating how even very sophisticated applications can be realised efficiently and economically using innovative injection moulding technology.

Picture: ENGEL e-motion 30 TL injection moulding machine

Three-component hollow bodies with inlays in one step
ENGEL is setting a new trend in the manufacture of three-component hollow bodies with inlays. At its stand in hall 1 (A 1001), the company will be producing drip chambers for blood transfusions with an integrated filter in just one work step. An ENGEL e-victory 160 combi three-component injection moulding machine with an integrated ENGEL easix multi-axis robot will be used to make the chambers in a 4-cavity mould manufactured by Hack Formenbau, a mould making firm in Kirchheim, Germany. The chambers will consist of a PS and a PP component, which will be injection moulded simultaneously. The filter will then be mounted straight away in the same mould and joined by means of overmoulding with another PP. The cycle time will be 14 seconds.
One key prerequisite for realising the integrated process is servo-electric drive technology for all movements of the index plate mould. This enables mutually independent movements to be controlled synchronously. The high-precision platen parallelism setting on the tie-bar-less hybrid machine provides a high level of mould protection.

All-electric, highly precise and tie-bar-less
By combining the benefits of ENGEL tie-bar-less technology and all-electric drive technology, the new ENGEL e-motion 30 TL injection moulding machine brilliantly meets the needs of the electronics industry in the low clamping force segment. Outstanding precision, extremely low energy consumption levels and maximum flexibility are all essential here. ENGEL will also be producing 60-pin board-to-board connectors in a 16-cavity mould on its new smallest injection moulding machine at Swiss Plastics 2014. This is an application that requires very high precision levels, as the distance between the pins is just 0.5 mm.

Even complex processes can be kept safely under control
Another ENGEL highlight being showcased at Swiss Plastics 2014 is its new CC 300 generation of control units. Smartphones served as the example when the interface for these was being developed. In addition to allowing a machine to be operated, the central control element, e-move, gives a feel for the machine back to the operator. This unique combination means the new ENGEL control unit is able to ensure that even complex processes are controlled easily, efficiently and reliably.
ENGEL doesn't just supply injection moulding machines and robots all over the world; instead it concentrates on providing highly integrated and automated turnkey solutions from a single source. It is only when all the components in a manufacturing cell are perfectly coordinated from the outset that efficiency potential can be fully exploited and new applications with extremely low unit costs can be realised.

ENGEL at Swiss Plastics 2014: stand A 1001, hall 1
(Engel Austria GmbH)

Newsgrafik #27948
 05.11.2013

K 2013 huge success for ENGEL AUSTRIA  (Company news)

K 2013 exceeds ENGEL AUSTRIA's expectations. Spotlighting the topics of system integration and automation, ENGEL's total of 25 machine exhibits focused on the future buzz topics of the global injection moulding industry, attracting many new customers in the process. Visitors were excited above all about the new ENGEL CC 300 control unit generation, which takes the overall efficiency of the system to another dimension.

"At K 2013, we experienced a totally positive willingness to invest", said Dr. Peter Neumann, CEO of the ENGEL Group after concluding a successful week at the fair. "Our forecasts were more than fulfilled. The investment climate is excellent internationally. And we were really pleased to see that the upward trend in North America was reinforced at K 2013. This is not only evidenced by the willingness of North American companies to invest, but also by the clear trend towards high-tech products."

CC 300 control unit generation sets a new trend
The ENGEL booth in Hall 15 was well visited throughout. Many trade fair visitors took this opportunity to try out the new control unit generation by ENGEL AUSTRIA at first hand. They experienced a totally new control solution that still looked familiar at first glance. "Devices like our smartphones, which we use every day, acted as the role models for developing the user interface," Dr. Neumann reports. "At the same time, the central control element, e-move, helps us give a feel for the machine back to the operators. With this unique combination, the CC 300 sets a new trend for the entire industry."
As process integration and automation increases, the complexity of the production process rises, and this poses increasingly tough challenges for control technology. The more intuitive and convenient the control unit is, the more safely and efficiently the production system can work. "The control unit has become an important factor of efficiency in integrated and automated system solutions," says Peter Neumann.

Development live: Near-production solutions for lightweight composites
Of all the industry-specific solutions on display, it was the automotive exhibits that attracted the majority of visitors to the ENGEL trade fair booth. Focusing on lightweight design technologies, ENGEL gave trade fair visitors a sneak preview of current research projects. For example, ENGEL, in collaboration with partner ZF-Friedrichshafen, has established another milestone in the form of the first one-shot process for the production of composite brake pedals in Düsseldorf, and in two different ways. Firstly, the production cell displayed at the fair, which is nearly production-ready, achieved previously unknown productivity figures, and secondly with the geometrically and load-optimised component, which proves that fibre composite materials can also replace steel in safety-relevant areas.

But it was not only the automotive applications at the ENGEL booth that made the extent clear to which process integration and automation can offer a competitive advantage. ENGEL takes this one step further: after all, training and service are fixed components of ENGEL's system philosophy. Under the ENGEL plus banner, the machine manufacturer showcased its service products and services at K 2013 in a separate exhibition area. In great demand: the new ENGEL protect and ENGEL protect+ maintenance packages, which make maintenance costs for injection moulding machines and system solutions calculable from the start.

“Our aim is to lead the field globally when it comes to creating customer benefit,” says Peter Neumann. The visitors at K 2013 experienced at first hand that ENGEL keeps its promises.
(Engel Austria GmbH)

Newsgrafik #27927
 31.10.2013

Keeping control of maintenance costs  (Company news)

ENGEL AUSTRIA is setting new standards in the maintenance of injection moulding machines thanks to ENGEL protect and ENGEL protect+. The two service packages insure plastics processing firms against repair costs while significantly improving the availability of machinery and systems.

“Calculating maintenance costs is not easy, especially where injection moulding machines are used for a lot of different products and the requirements keep changing,” points out Wolfgang Degwerth, head of the Customer Service Division at ENGEL AUSTRIA. “With our new service packages, we are enabling customers to plan reliably from the start.”
Where clients sign up to ENGEL protect, ENGEL pledges to rectify at no additional cost all damage to production systems supplied by ENGEL not caused by wear or operation. Spares, transport and technical services are included, regardless of whether these are rendered on site or over the phone. ENGEL protect+ goes a step further and even includes expendable parts (the only exception to this being components subject to plasticising wear). From now on, plastics processing companies can therefore guard against unpleasant surprises.
Since the two service packages make quotations and ordering processes superfluous, proc-essing firms also save time. One call to ENGEL is all that's required for the required parts and resources to be scheduled automatically. At the same time, the customer benefits from their supplier's fast pace of innovation. New developments and insights are continually feed-ing in to the process, ensuring systems run at maximum output and availability for years.

A big plus for security, for the life of a machine
Known as ENGEL plus, the comprehensive range of maintenance-oriented products and services also include the upgradable ecodriveR energy-saving option, the flomo temperature-controlling water distribution system, oil maintenance, the e-service.24 remote maintenance tool and the e-factory 2 MES solution as well as training and e-learning options.
(Engel Austria GmbH)

Newsgrafik #27838
 09.10.2013

Engel Press conference – K 2013  (Company news)

With 25 exhibits – 12 of which will presented at our own stand in hall 15 (B42/C58) – ENGEL will open the door to new applications, set new efficiency records and provide
answers to the big challenges of the future at K 2013.
Learn more about our K highlights and about the latest developments and projects offered by ENGEL.
We invite you to attend the ENGEL press conference on the first day of the fair: Wednesday, 16th October 2013, 12.30 to 1.30 pm, Room 16, CCD South (1st floor).
Please note that we have changed the room compared with the previous announcement!
The language of the conference will be English. All press materials will be available in English and German.
Please register until 11th October at susanne.zinckgraf@engel.at.
We look forward to welcoming you in Düsseldorf!
(ENGEL Austria GmbH)

Newsgrafik #27818
 04.10.2013

ENGEL invests again in Schwertberg  (Company news)

Picture: Turning heads on Ludwig-Engel-Strasse in Schwertberg: work will soon commence in ENGEL AUSTRIA's new assembly hall.

ENGEL AUSTRIA is continuing to expand its main base in Schwertberg. Just 18 months on from the southwards expansion, a new assembly hall has been opened at the northern end of the factory site. This will increase the number of spaces for machines to be accepted by clients.
“The volume of our orders is going up around the world, so we have to address this expansion by continuing to invest in our sites,” emphasises Dr. Peter Neumann, CEO of ENGEL Holding. In the past two business years, ENGEL has invested some €50 million just to expand and modernise its Austrian plants in Schwertberg, St. Valentin and Dietach.

More spaces for large machines
Every year, the production facility in Schwertberg produces more than 2,000 injection moulding machines – and the number is rising. For some time now, there has been a shortage of machine spaces for client acceptance on the site. In particular, large injection moulding machines have had to be transported to the St. Valentin plant for initial start-up.
Thanks to the new building, sufficient spaces are now available at the plant. Designed for machines weighing up to 40 tons, the new assembly hall also addresses the trend towards larger injection moulding machines. ENGEL now produces machines with clamping force of up to 650 tons in Schwertberg. One of the biggest machines manufactured on the site is the new ENGEL e-speed high performance hybrid machine.
The new structure was completed in a construction period of just seven months. Only companies based in the local region were contracted to carry out planning and construction work.

ENGEL open day attracts more than 5,000 visitors
To mark the opening of the new assembly hall, ENGEL organised an open day. At the end of September, more than 5,000 guests from across the region took the chance to have a look behind the scenes of the ultra-modern production hall for injection moulding machines in Schwertberg. “Investing in our buildings is not just about expanding capacity but also about modernising and improving working conditions in every instance,” says Peter Neumann.
Visitors to the plant could see for themselves exactly what he means.
(ENGEL AUSTRIA GmbH)

Newsgrafik #27719
 12.09.2013

ENGEL e-learning boosts efficiency in training  (Company news)

If you want to be successful in the market, you need to ensure that your employees are top fit at all times. This explains why training programs are an integral part of ENGEL's system philosophy. At the worldwide training centres, the injection moulding machine builder and automation expert offers seminars and workshops that are attended annually by more than 3000 participants. With its new online program, ENGEL is now extending its training portfolio and thus making ongoing training more efficient and easily accessible.

A knowledge advantage is a competitive advantage. Despite this, participation in training events is often reduced to a few isolated dates in many companies. To give customers access to seminars and training sessions with very little time and cost overhead, ENGEL is taking a new approach in the dissemination of knowledge. ENGEL's internet-based e learning platform is now available at any time and any place, whether just for a few minutes between tasks, or for a multiple-hour power training session. The content can be adjusted flexibly to meet individual requirements, and everyone can learn at their own speed.

ENGEL e-learning is organised in three sections:

- ENGEL e-learning first steps teaches basic skills and compact injection moulding know-how. The workings of an injection moulding machine and process control are intuitively explained, as are the various machine types and processing technologies. To test your own knowledge, even the basic module includes tests, which you can also take online.

- ENGEL e-learning standard seminars cover a wide range of topics, from EOB (ENGEL operator basics) to TPQ (Process and quality control), and the content is no different from the material taught at the ENGEL training centres. Online participants also have access to the original training manuals via the online platform. Our e-learning seminars are a particularly efficient alternative if you are unable to take place in a taught event for reasons of time or geography. At the same time, this program helps to refresh your acquired knowledge, and lets you take exams to acquire performance certificates. The final exam can be repeated any number of times, and you can follow your learning success in an intuitive test protocol.

- ENGEL e-learning competence assessment combines test questions from 19 plastics processing and robotics topics. It is useful as a regular performance check and supports a continual build-up of knowledge and skills. The test report can be used as the basis for needs-driven planning of training measures, and serve as an annual module in knowledge and skills management.

The modules include videos and simulations for intuitive teaching of complex topics, and were compiled to reflect the latest educational methods. Companies can generate additional, enterprise-specific content for their staff, and configure the platform to match their corporate design. ENGEL e-learning is currently available in German and English. More languages are in preparation.

Globally at the same level – in real-time
Feedback from initial applications on the new learning platform has been extremely positive. "Thanks to the skills check, we now have a comprehensive, holistic picture of our machine setters," says, for example, Richard Hiebler, the Managing Director of Richard Hiebler GmbH in Stainz, Austria, summing up. "The platform provides the basis for continually improving our setters' qualifications. We can now create a needs-driven training plan." Oswald Krassnegger, the Head of Injection Moulding at MACO in Salzburg, above all emphasises the benefits for international companies: "We have globally uniform and exacting staff skill requirements. The ENGEL e-learning platform supports our global knowledge management perfectly."

Multiply tested and mature
One major benefit for the users of the ENGEL e-learning platform is that this is not a new product, but a mature and multiply tested tool. For more than two years, some 3500 ENGEL staff have worked intensively with the e-learning platform. After all, ENGEL is also increasingly relying on web-based training internally. "Thanks to ENGEL e-learning, our service technicians and sales staff around the globe are always up-to-date", says Robert Brandstetter, Head of Training at ENGEL AUSTRIA in Schwertberg. "Our trainers also regularly check their knowledge; this is the only way that we can guarantee uniformly high quality standards of our training offerings worldwide."

ENGEL AUSTRIA started at a very early stage to deploy and develop modern knowledge dissemination methods to secure a competitive advantage for our customers. The milestones include the virt-mould simulation program which gives users the ability to install injection moulding machine control units on a PC for training and test purposes, live training via the internet (ENGEL e-trainer live) and, last but not least, the ENGEL e-learning platform.
(Engel Austria GmbH)

Newsgrafik #27279
 23.07.2013

drinktec 2013 - Engel Austria GmbH  (drinktec 2013)

Visit Engel Austria GmbH at drinktec 2013 in München, September 16 – 20, Hall B3 Stand 238

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