Ultralight profilesThe international showcase of Plast2012 provides Friul Filiere (13 - C21/D18) the occasion for a livepresentation of its world-patented FFC(Foam Fiber Composite) technologythrough the display of the new OmegaEvolution extrusion line. During thedemonstrations, the new FFC ultralightcomposite is extruded as a skirtingprofile, which is the best compromisebetween the need to show the fullcharacteristics and potentials of this newmaterial and the constraints imposed byan exhibition setting. The line exhibited at the fair is equippedwith an Omega single-screw extruder,which processes a dryblend consistingof a mixture of thermoplastic materials,natural fibres and various additiveswhich is fed into the hopper andextruded directly, cutting out thepelletizing stage.The true innovative potential of FFC isthe ability to recycle not only the naturalfibre waste (jute, hemp, sugar cane, ricehusk etc.) but also, and mostimportantly, thermoset scrap, which isclassified as a special waste (rubber,urea, melamine, phenolic, MDF,coatings etc.). During the demonstrationthe skirting profile, designed in-house, isextruded using a dryblend containingrecycled coating scrap to show the highphysical, mechanical and aestheticquality of the extrudate.In recent months, there has beenspecial interest on the market in the newFFC decking profile, especially afterFriul Filiere delivered a major order to aSouth American customer, includingvarious complete lines for extruding thiskind of decking profile. Currently, WPC(Wood-Plastic Composite) deckingprofiles are widely used and theirbenefits and drawbacks are well known.This could be the reason why customersare so enthusiastic about the innovativeFFC decking profile with its improvedphysical and mechanical performancecharacteristics. Visitors to the stand find decking profilesamples toillustrating thedifferentsorts offinishes thatcan beapplied in-line: mono-material, coextrudedin FFC or PVC, embossed,printed, brushed etc. There are alsomany other samples of different types ofprofiles already made of FFC: doorframes, window profiles, wall panels,fences and more. Naturally, traditional

products are also on displaymanufactured using the company’s mostsuccessful turnkey projects: edge bandprofiles, EPS picture frames, specialcoextruded gaskets for the automotiveindustry etc.

www.friulfiliere.it

Evolution of stretch filmTo meet the demands of constant growthand development in the market forstretch film, Macchi (15 - B33/C32) hasdesigned and developed a cast line ableto produce coreless reels. This solutionallows considerable savings, includingthose resulting from the inline productionof pre-stretched film. Elimination of thecardboard core reduces the per-kilogram cost of film by 5%, while thepossibility of producing pre-stretchedfilm in-line enables higher productionspeed (over 10,000 m/min) of thinnerfilm with enhanced mechanicalproperties, without the additional costsof secondary machining processes.

These results were obtained thanks totechnology involving the use of aspecific winder (for which Macchi holdsexclusive European rights), developedin collaboration with NoEl, that enablesthe creation of coreless reels for manualor automatic use. Film in thickness from7 to 23 microns can thus be produced toprovide practical responses to a widerange of issues, from a need forlightweight film for pallets to reducedcosts for transport, storage, andcardboard disposal.Macchi cast technology enablesproduction of all these films withoutchanging system configuration.Moreover it is possible to reduce filmthickness without affecting machineproductivity: the film exits the chill rollwith a thickness of 23 microns and isthen further reduced to 12 microns byincreasing the line speed without fullypre-stretching the film.The new line was presented at a recentopen house in a demo version based on5 extruders (65-100-100-100-65 mm)

and a 2600-mm extrusionhead. It permits the productionof film in thickness from 12 to50 microns at a speed of 600m/min with an output of 1,000kg/h (23-micron film). Thecooling unit is composed of amain chill roll (diameter 1350mm) and two stabilization chillrolls, one of which featuresadjustable positioning. During Plast 2012, Macchi isshowing a 9-layer blown filmcoextrusion line in operation.The configuration againcomprises three integrated

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EXTRUSION LINES & EQUIPMENT

MACCHI

FRIUL FILIERE

platforms equipped with Plastex Barrier55 extruders and Siemens Torquemotorization feeding a COEXflex IBChead with all melt conveyi ng channels atthe same level. The inner design isbased on the dual distribution concept,first at binary partition and then withconventional spirals, to feed a 500-mmdie with automatic profile control.Multiple layers bring various benefits,from a better barrier effect for the sametotal thickness of PA and EVOH layers toimproved physical-mechanicalproperties, including thermofomability.

www.macchi.it

Thirty-year partnership for compoundingThree new compounding lines for theproduction of engineering plastics,supplied by Icma San Giorgio (13 - C29/D26), will add 30,000 tons tothe total annual production capacity ofthe Softer Group. The lines are intendedfor installation in the Forli and Ferrara(Italy) and Silao (Mexico) plants and willenable the Italian group to strengthen itspresence in the automotive andhousehold appliance sectors and also toconsolidate its role as a global supplier.The machines are three co-rotating twin-screw extruders capable ofprocessing different materials, such aspolypropylene and polyamide filled orreinforced up to 50% with glass fibre, athigh flow rates. The extruder is made ofwear-resistant steel alloys and featuresa modular design which makes itpossible to optimize maintenance costs.The significant results achieved bySofter, one of the largest independentcompounders globally, were madepossible partially thanks to its 30-yearpartnership with Icma, which over theyears has supplied high performancemachines backed by world classcustomer service. Moreover, therelaunch of the Ferrara plant (former P-Group), acquired in 2011, allows themachinery maker to participate as a

supplier in a verypositive initiative that

helps keep a centre oftechnologicalexcellence in Italy.In addition tocontributing to therecovery plan of theFerrara technologicalcentre, the newinvestment confirms theintention of Softer tomaintain Italy as aprivileged productionplatform for theEuropean markets.On the other hand,with its strategiclocation and efficientlogistic structures, Mexico is becomingthe basis for expansion towards theNAFTA countries: it will be easy tosupply companies located in the US orCanada from there as well as tocollaborate with corporations that haverelocated their production to Mexico andare looking for local partners boastingEuropean technological and quality.The range of Softer products includesthermoplastic elastomers, thermoplasticvulcanizates and engineering plastics.Thanks to its technological know-how,the group can offer innovative solutionswith a strong specialization in theautomotive, appliance, electrical-electronic, construction, footwear andsports sectors. The group has twomanufacturing plants in Italy, two furtherunits in Latin America (Mexico, Brazil)and a sales subsidiary in Germany.

www.icmasg.it

Giant corrugatorThe increasing demand for double-wallPP corrugated pipes as an alternative toconcrete or PVC pipes for seweragenetworks or drainage of rainwater hasprompted Itib Machinery (13 - C25) toinvest greater resources in developingsuitable production technology. Afterproducing the F700SH9 shuttlecorrugator, of which an exemplarwas recently put into operation atthe facilities of the Slovak

processor Plastika, the company isdeveloping its successor, F1200SH10,for pipes with inner and outer diameter,respectively, up to 1,000 and 1,200 mm,depending on applicable standards.The corrugator is composed of 10 pairsof mould halves, 6 of which are in theforming position while 1 pair is in theclosing phase, 1 pair is in the openingphase, and 2 pairs are on the returnpath. In this model, as in the previoussmaller one, the mould halves are notmoved using chain conveyors butinstead by means of a shuttletechnology, i.e., a sliding mould-holdertrolley. This solution is more suitable fora machine of such large size, reducingthe necessary number of pairs of mouldhalves, the machine footprint andinvestment costs.Each mould half is equipped with acircuit for cooling water, which is appliedunder pressure from an independentinlet-outlet point. Pipe forming is carriedout under vacuum assisted by a low-pressure blown air. In emergencysituations or in the event of a power cut-off, the F1200SH10 corrugators can bemoved backwards in order to allow freeaccess to the head, extrusion die, andthe cooling mandrel of the inner layer ofthe pipe thereby allowing any residual

material to be removed.The corrugator can achieve hourlyoutputs up to 1000 kg. Moulds ofdifferent sizes can be fitted by liftingor lowering the upper structurewhere part of the cooling andsuction systems is installed therebyaffording easy access for mouldassembly.

www.itib-machinery.com

Extrusion & thermoformingFor thermoforming applications,Amut (13 - B39/C38) introduces

the evolution of the FFG high-speedautomatic machines with steel rule diecutting: the FFG820 ADV model is inoperation with air pressure and/orvacuum forming. The toggle system forplaten stroke, with planetary rollerscrews, ensures resistance and durationof cutting efficiency for the toughest

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ITIB

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materials at high speeds, both in theforming and in the cutting stations, withan installed force of 60 tons. Greatattention has been given to flexibility anduser-friendliness, as seen in the quickmould change system in all the stations,direct connections to the utilities on themould-holding platens of the formingstation, and the electric hoist.A machine from this range has recentlybeen installed on a complete line forextrusion-thermoforming of PP sheet forhigh speed production of pots (depth 200mm) for the flower-nursery market. Onthis occasion an additional hole-punchingstation was included to make holes in thebottom of the flowerpots, while thefinished items are automatically stackedby a 3-axis handling robot. Also on display is a BA 130 twin-screwextruder for the production of WPCprofiles. The Easy Wood systemdeveloped for this application is providedas complete lines (from 300 to over 1,000kg/h) for direct extrusion, without pre-mixing of materials and additives, with upto 80% vegetable fibres in a polyolefinbase (HDPE-PP) and around 50% for PVC.The extrusion line is equipped with asingle-screw extruder and a counter-rotating twin screw extruder. The latter isconsidered the ideal machine forprocessing highly viscous compounds,such as WPC, with high percentages of

vegetable fibres.Thanks to the lowrevolution speedsand high torque ofthe screws, it ispossible to extrudeat high pressureand reduced shearkeeping the melttemperature lowso as to preventthe degradation ofvegetablecomponents. Another machineon display is an EA75 single-screwextruder for theproduction of smallpipes in special

materials for medical and automotiveapplications. Depending on screwgeometry and barrel configuration, hourlyoutputs up to 750 kg can be achieved.The pipes produced on these lines mustcomply with very strict dimensional andovalization parameters. For this reason,the lines are equipped with very accuratemeasuring and control systems fordiameter and thickness, which ensureconstant, oscillation-free production.

www.amut.it

Irrigation pipesSpecialized in the construction ofextrusion lines for the production of dripirrigation pipes, Profile Dies (13 - C05)has recently developed a new fastextrusion line for pipes with flat drippershaving the following technicalspecifications: minimum pipe thickness0.15 mm, mechanical line speed 150m/min, production speed up to 130m/min, insertion of 800 drippers perminute.The line is composed of the followingcomponents: automatic inserting unit fordrippers, gravimetric dosing units,extruder with 65- or 80-mm screw,coextruder with 20-mm screw, specialhead-die, calibration and cooling tanks,haul-offs, mechanical drilling unit,automatic winder, control panel with

high-quality components and softwarefully developed and manufactured by thecompany. The line also includes a hotrunner injection mould for drippers (up to96 cavities).Production of this new line has enabledthe company to achieve very high outputand quality standards. Another line wasdeveloped at the same time for irrigationpipes with round drippers having thefollowing technical specifications: pipediameter 16 and 20 mm, insertioncapability of up to 400 drippers perminute, production speed 80-100 m/min.

www.profiledies.com

Socketing & packaging Precisely on the occasion of Plast 2012,IPM (13 - C37/D34) celebrates its 25th

year of activity, previewing the innovativeBA 200 PP belling machine forpolypropylene pipes, operating inconnection with a fully automatedpackaging system for pipes up to 500-mm long. Considering the highproduction capacity of these belling

PROFILE DIES

AMUT

machines (up to 924 sockets per hour for50-mm diameter x 1.8 mm), end-of-linemanagement (collection, automaticpackaging and conveyance to storage ofa huge amount of pipes) is increasinglynecessary. Moreover, an automatedquality control (checking the correctposition of the automatically insertedgasket) and socket tightness checksystem is also displayed, demonstratingthat only the pipes that pass inspectionare conveyed to the automatic packagingunit. The company offers its Europeancustomers customized automatedsolutions for pipe packaging involving theuse of robots for pipe handling andpackaging into suitable supports, withautomatic forming of pallets pre-arrangedto be picked up by forklifts and stocked, orfor packing shorter pipes into cardboardboxes provided for the purpose. Thereare many requests from other regions forautomatic packaging systems for pipebundles by means of multiple straps andoptional packing into sacks (or wrappingup by film) as well as subsequentpalletization of the produced bundles inspecial cases. These are fully automatic systemsoperating in-line with extrusion(sometimes consisting of more than oneof the above-mentioned technologiescombined together) which are able topack up to 1,500 pipes per hour withlength of 150 to 3,000 mm. Furthermore,it is also possible to handle, sort and packseparately (with socketed ends havingopposite position) pipes having differentlengths but manufactured in sequence bythe same extrusion line. Another piece of equipment on displayduring the fair is the new version of the BA200 RS (Rieber System) socketingmachine, which can attain very highoutput rates thanks to the use of ovensequipped with short-wave lamps. Inaddition to their very high efficiency andexcellent energy performance, theseovens ensure better penetration as wellas direct and dynamic temperaturecontrol of the material undergoingprocessing. The direct effect is areduction of heating times and thereforeof power consumption, particularly when

the machine is not working at maximumpotential. Moreover, these ovens do notneed to be brought to temperature beforethe extrusion line is started, because theyare instantly operative. Lastly, on May 5, the eve of Plast 2012,IPM is organizing an open house at itsheadquarters to celebrate its 25 years inthe business as well as to introduce thenew (patented) INJ range for belling ofdouble-wall PP and PE corrugated pipes.The model being demonstrated (BA 1200INJ) is the largest of the range and cannotbe displayed at the fair due to its size.Together with the cutting unit, thismachine completes an extrusion linemade by Unicor and having its finaldestination in the Arabian countries. It isbe able to socket pipes in-line havingouter diameter from 315 to 1,200 mm,ensuring the dimensional stability of thesocket, even if exposed to highly variableenvironmental temperatures

www.ipm-italy.it

Optical qualityWith more than 45 years of experience,development, and in-house productionand over 95% of its products exported,

Omipa (13 - C30) is a leader in theconstruction of complete extrusion linesfor various thermoplastic materials. Thecompany is already an establishedpresence in the market for extrusion linesfor high optical quality sheets and foils inPMMA-PC-PS-MS with thickness from0.3 to 10 mm. These products aredestined for the continually growingmarket of LCD, LED and 3D screens, andalso for touch-screen technology andadvertising applications. For theautomotive industry, sanitaryapplications, food packaging, andappliances the company offers highperformance lines for the production ofsheets in PE-PP-ABS-PET withcoextrusion in up to 7 layers. In recent years, Omipa has been workingwith its clients to design and develophollow polycarbonate profiles withincreasingly innovative architecturalgeometries for application in public andprivate construction, major projects suchas stadium roofing for Olympic and othersports events, stations, shopping malls,and greenhouses.High line speed is the main feature ofextrusion lines for hollow PP profiles inthickness varying from 1.8 to 20 mm foruse in industrial and agriculturalpackaging applications (e.g., fruit boxes,containers, folders etc.) withdevelopments also in the fields of heavy-duty packaging and advertising. In hollow polypropylene profile segment,the company is developing the newFoam System, which makes it possible toreduce final product weight withoutaltering mechanical resistanceproperties. Fluctuating raw materialsprices and the need to improve existingapplications have led the company todevelop a production system for hollowPP-foam profiles, especially designed formedium-high weights, which makes itpossible to reduce raw material

34 ●

OMIPA

IPM

consumption by 20-30%, producingeconomic savings and environmentalbenefits without compromising thephysical and mechanical characteristicsof the finished product. An absolute novelty for the market is thenew range of machines, presently in thedevelopment and testing phase, for theproduction of low shrinkage EVA forencapsulation of silicon cells forphotovoltaic panels. The idea is to buildand deliver a turn-key plant, includingblend formulation. Lastly, Omipa hassuccessfully carried out tests for theproduction of hollow profiles in ABS, amaterial which has not previously beenused for these applications. Besidesmaking it possible to replace theproducts commonly used for heavypackaging, it guarantees excellentperformance even when subjected tovery low ambient temperatures.

www.omipa.it

High speed for roller shuttersSpecialized in the development ofadvanced technology for high-outputextrusion tooling of roller shutters, inwhich it boasts world leadership withspeeds of up to 12 m/min in doubleoutlet, Baruffaldi PlasticTechnology (13 - B43) is introducing a newgeneration of Combiroll andCombipack, in-line and off-lineautomatic and semi-automatic machines forassembling and packagingroller shutter profiles of allsorts and sizes up to 12 m,in single or dual outlet.These machines stand outfor sturdiness, highproduction rates, versatilityand ease of use.When it comes to punchingprofiles, even the largestand thickest ones, aninnovative punching and striking systemhas been designed to reach speeds ofup to 15 m/min with no detrimentaleffects (such as burrs, swarf or dust) on

the quality ofthe finished

products while keepingnoise levels and environmental

impact to a minimum. The new rotarypunching machine, which can handle allsorts of technical profiles includingangular ones, can run at 30 m/min, isextremely versatile and can be used in-line and off-line. Simple to operate, itcomes with height adjustment and quickchangeover tooling.The patented horizontal guillotine cuttingsystems, available with either hot or cold

blade, give a high quality cutwith no deformation of theprofile while reducingenergy consumption andmaintaining operator

comfort through noiseand dust reduction.These cutting unitsare highly versatileand customizableand can be supplied

as stand-alonemachines orintegrated intoexisting cuttingsystems. What makesthem unique is theircompact size, thespeed with which theoperator can change

the blade and thequality of theirmaterials and

components.

Moreover, thecompany has recentlyextended its productrange to covermachines forprocessing PVC andpolypropylene pipesby acquiring thePrimac brand andtechnology.

www.baruffaldi.eu

Advanced screenchangersThe capability of a company to expressits philosophy through R&D of innovativeproducts represents a fundamentalfactor in its growth and development.Finding new market opportunitiesthrough expertise gained over decadesof effort requires readiness andflexibility. Following this idea, BD Plast(15 - B23) has continuously improved itsrange of screenchangers, addressinggrowing demand in a very challengingmarket and introducing new lines ofproducts strictly embodying itstraditions. For many years the need for melt pipes,elbows and adapters for extrusion hasfound response in the company’sportfolio of products supplied to OEMsand end users. The company has understood thegrowing need to introduce a completerange of downstream equipment forextrusion lines offering services that gobeyond the engineering andconstruction of a single component. Thereference market in this regard areOEMs which can concentrate on theircore business while leaving theengineering and construction of ancillaryequipment between extruder and die inthe hands of a reliable and qualifiedpartner. Through the flexibility that hasalways distinguished it, BD Plast hasonce again demonstrated the ability towork closely with clients, producingproducts based on client’s designs orthrough their own in-house engineeringcapabilities. Participation in Plast 2012is the best opportunity to display theresults of these efforts. These include acomplete frame fitted with a 5-layer castmelt pipe group complete with heaters,wiring, and 5 different screenchangers,ranging from simple manual to hydraulictypes. In addition, a large filtration areasingle plate hydraulic screenchanger ison display together with a continuous

flow double platescreenchangerwith a newsealing systemsand protectiveguard layout.

www.bdplast.com

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BD PLAST

BARUFFALDI

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INJECTION MOULDING MACHINESLow tonnage with 2 platensThe introduction of the innovative EOSrange represents for Negri Bossi (24 - C64/D62) not just an occasion toshowcase a new low-tonnage injectionmachine range - which completelyrevolutionizes customary approachesto design, providing customers with anew concept in presses of this size -but also an opportunity to offer asolution that combines efficiency,cleanliness, energy savings andenormous versatility at a decidedlyattractive quality-price ratio. Theimpressive features of this innovativeseries - silent operation, precision, andenergy consumption levelscomparable to those achieved onelectric machines - are all on display tothe benefit of visitors.The new range is proposed with a 2-platen solution clamping unit and extremelywide tiebar spacing while also offering thelowest floor space requirements in itscategory. The need to meet the challengesof the low-tonnage press segment in aninnovative fashion has led the company tofocus strongly on product engineering andcontainment of overall dimensions withoutcompromising ergonomics, performance,efficiency, and moulding quality.EOS presses are equipped with a newcompact twin-cylinder injection unitfeaturing a practical and fast plasticizing-unit changeover system that provides easyand comprehensive access for tooling andmaintenance tasks. The clamping unitadopts a 2-platen solution with the movingplaten sliding on prismatic guides whilehydraulic oil is circulated through channelsin the fixed platen. In addition tostreamlining plant engineering, this solutionalso allows clamping and release to takeplace at high pressure using a reducedamount of fluid, thereby reducing energyconsumption. Fast low pressure movement duringopening and clamping is achieved by twopiston-corepullers with reduced cross-section, which ensure outstandingsensitivity during the mould securingphase, thereby minimising mould damageand wear. This new design, together withthe decision to support and guide themoving platen on prismatic guides, makesthis range ideal for the medical or foodsector, or for the production of any itemswhere it is important to ensure that nolubricating oils enter the mould area.The most important achievement, however,has been made in energy consumption.After years of experimentation andpractical application with servo-motors,inverters, vector inverters, andregenerative systems (for all-electric andhybrid presses), the engineers decided totake development of the inverter-controlled

variable displacement pump even further.This involved studying and mappingvariable-displacement pump efficiencycurves and actuator curves to develop apress software that ensures the bestcombination of motor rotation speed andpump capacity for each phase of themoulding cycle.

www.negribossi.com

Non-standard technologyA leading manufacturer of special injectionmoulding machines, Presma (22 - B09) isdisplaying two new machines, bothupholding the “non-standard technology”slogan. One of them provides a particularlyclear expression of the company’s aim toattract visitor attention to the new range offully Italian-made presses for rubber andsilicone elastomers. In this application segment the spotlight ison the PRO 400/100, a 400-ton horizontalpress with 4-tiebar direct-piston clampingunit. Its main features are the heated steelmould-holding platens (700 x 700 mm),

with a tiebar clearance of600 x 600 mm, as wellas the movable platenequipped withsynchronized centraland side ejectors with a100-mm and 350-mmstroke, respectively. Themould approachingstroke is 600 mm andthe maximum distancebetween the platens is750 mm. The injection unit of thetwin-screw cylindermodel with stationarycarriage unit andelectrically-driven screwrevolution by motor-gearbox and frequencyinverter is a 1,000-cm³

FIFO system, with 2,000-bar specificpressure. The unit is also equipped withdouble thermo-regulated circuit for theplasticizing barrel and for the injectionbarrel + nozzle, with the possibility toremove the injection punch for cleaning.Injection stroke control involves the use ofa linear transducer. The machine is set upfor the assembly of feeding systems forrolled rubber bands and silicone blocks.Tool cleaning is accomplished by anadjustable electrically driven brush. The second machine on display isPresmall, a 6-ton all-electric mini-presswith electric coaxial drive for clamping andejection and three independent drives forthe injection unit. The machine, equippedwith touch-screen interface and dedicatedsoftware, offers quick cycle time, highprecision and very low energyconsumption. This model is particularlysuitable for micro-moulding even in cleanrooms and can be equipped with a feedingunit for rubber or both solid and liquidsilicone.

www.presma.it

NEGRI BOSSI

PRESMA

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BLOW MOULDING MACHINESZero energy After the success achievedwith the presentation of theall-electric UMA 12 SeCoEZ blow moulding machinein sequential coextrusionfor technical parts, UniloyMilacron (22 - A11/B14)continues the developmentof new models to enrich itsEnergia Zero (Zero Energy)range, the brand thatdistinguishes all thecompany’s technologieswithout hydraulic drives.The UMS 200 shuttleextrusion-blow mouldingmachine on display duringthe fair follows thisdirection: it is anintermediate model with200-kN closing force andhorizontal 710-mm carriagestroke that has already gained a highlevel of acceptance among customers. Fit to accommodate up to 12-cavitymoulds with 55-mm centre distance, themachine is already prearranged forcoextrusion configurations of up to 7layers. Engineered to easily install theIML system on both sides of the bottle(also available for double-stationversion), it finds its ideal application in thefood, detergent, and personal carepackaging industries. The application ofthe most advanced electrical andelectronic technologies, the use of latest-generation servomotors and multipledrives with energy recovery during thedeceleration phase of all movements (asit happens in Formula 1 or on hybrid cars)provide exceptionally low powerconsumption. The absolute precision of all electricmovements of UMS 200 EnergiaZero,not depending on the processingtemperature, makes it possible tomaintain a constant level of quality of theblow moulded product within narrowtolerances. The possibility of using theinnovative parison cutting device withdirect electric movement in multi-cavityproductions - typical of the food industry -makes greater precision in the cuttingphase possible than can be achievedwith traditional systems and thereforegreater process stability with productionscrap reduction. In addition to the particularly silentoperation, the absence of the hydraulicpump and the hydraulic circuit eliminatesthe risk of fluid spillage caused byleakage or breakages, while the absenceof ball screws and bearings for linearmovements removes the risk ofcontamination from lubricants and theneed for periodic maintenance, making

the machine suitable for production inclean rooms. Like other Uniloy Milacron’s machines,UMS 200 EnergiaZero is equipped with aspecial bottle take-out system (two-axismovement, fully electric servomotordriven). Bottles are dropped on a linearconveyor system and then released toone side of the machine also in thedouble-carriage version. The eliminationof the traditional bottle conveyors allowsa dramatic reduction of footprint andbetter accessibility to the machine for aquick mould change.

www.uniloy.com

All-electric blowThe absolute innovation introduced byMeccanoplastica (22 - A19/B22) isMipet-1P, an all-electric single-cavitymachine for in-line 2-step stretch-blowmoulding of PETpreforms.

Manufactured at theSpanish branch inBarcelona, during theexhibition the machine isequipped with a mould toproduce 750-ml bottlesstarting from model 28/410preforms (weight 38 g).Designed for using bothstandard and specialpreforms to produce PETbottles of up to 2.5 litres, themachine can reach atightness strength (at 10bar) of 450 kg with a 140-mm max openingstroke. Its peculiar innovativefeature is the high speed ofthe production cycle, thanksto the prompt responses ofthe all-electric drive.Another all-electricmachine is HL 350 for 2-

station continuous extrusion-blowmoulding, designed to producecontainers having a volume of up to 3litres. The machine can reach 6 tons ofmould clamping force with a carriagestroke in the two versions of 350 and 400mm, respectively. Its innovative feature isthe hydrostatic-pneumatic system usedfor the clamping phase, actuated by abrushless electric motor. During the fairthe machine is running equipped withtriple-parison extrusion head (120-mmcentre distance) to produce 350-mlHDPE oval-shaped cosmetic bottles(weight 30 g).Finally, JET55/L, an all-electric 3-stationinjection-blow moulding machine, hasbeen designed to produce smallcontainers up to a 250-ml volume and

can achieve 55 tons oftotal clamping force

(50 for injectionand 5 for

blowing). During

UNILOY

MECCANOPLASTICA

theexhibitionthe machine isequipped with aset of 18-cavitymoulds to produce 10-mlHDPE bottles (weight 5 g).This is currently the only all-electric injection-blowmoulding machine inoperation anywhere in theworld. The absence ofpollutant or noise emissionsmakes it particularly suitablefor pharmaceuticalapplications, where there is acritical need for clean roomwork with very stricttolerances.

www.meccanoplastica.com

Advanced generationIn the new Advancegeneration of extrusion-blowmoulding machines,developed by Techne(Graham PackagingCompany Italia), the “fully-electric” concept has beenpushed beyond normal limitsthanks to innovative featuressuch as kinetic energyrecovery during machineslowdown cycles. During eachstep of the production cycle,kinetic energy is stored andthen fed back into the networkin the subsequent step,producing energy savings.The final result offers a rangeof machines with an overallenergy consumption of 0.31kWh per 1 kg of extrudedmaterial, with a 37% saving inreal terms if compared toconventional machines.The flexibility concept wasthen developed, bearing inmind that nowadays themarket requires machinescapable of handling differentkinds of productionprocesses. In order tomanage this important issue,the mould clamping systemaccommodates a range ofcontainers starting from smallsingle-serving capacity up to20-litre industrial tanks. Thesame concept has been

applied to the handling devicefor calibration nozzles, withthe aim to precisely andconstantly cut large diameternecks, and conventional onesfrom multi-cavity moulds.The project is completed bythe energy saving extrusionsection with high quality rawmaterial plasticizing, heatingand stabilization time, and fineadjustment of parisonthickness. The extrusionplatform includes a widerange of models and sizes inorder to cover the mostsuitable production choice interms of both hourly outputand extruded material. Ofcourse the multilayer andmulti-cavity platforms (up to 6layers and 80 cavities throughthe neck-to-neck technology)are available as well as theoption for production ofaseptic containers. Modularity is a unique specialfeature of the Advance range:machines are built withconfiguration capacity of up to4 shuttles, with high outputvolumes in limited floor-space,making use of conventionalunits. For limited productionoutput, machines can run with2 shuttles only or bereconfigured with differentcavity platforms.The production cycle hasbeen drastically reducedthanks to solutions which offer15% increases in productivityfor small containers, and over25% for industrial tanks. Thepicture is completed by theIML feature, with just one labelapplication robot serving twoshuttles, which allows quickapplication time and high-precision label placement.

www.technespa.com

TECHNE (GRAHAM PACKAGING)

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OTHER MACHINERYThirty years of pad printingPrecisely in concurrence withPlast 2012, Tosh (22 - B25)celebrates thirty years of activity inthe field of pad printing. This is aunique opportunity to thankcustomers, suppliers,representatives and all those whohave believed in the company andits products. In addition, theexhibition provides an occasion tolearn more about possible goalsfor the future, thanks to thecompany’s expertise andprofessionalism.Founded in May 1982, thecompany quickly established aleadership role in pad printing notonly in Italy but also in theinternational marketplace.Passion, solution-basedmotivation, and design ingenuitymade the name Tosh well knownamong the most satisfied andsuccessful users of pad printingtechnology worldwide. Gainingleverage from the economic boomof the Eighties, the Logica Serieswas designed and developed.This line of pad printing machinesintroduced the clearly innovativetechnological component of an all-electric operating cycle with digitalcontrol of all axes of motion. Thechoice not to design the systemsaround the traditional pneumatic driveproved to be a winning one. This isattested by thousands of machines sold todate in a dynamic and expanding market.Parallel to the advancements in the areaof machine design, the company workedto develop a complete line ofconsumables specifically developed forpad printing. Here, a second winningchoice was made with the decision toproduce, in addition to pads of any shapeand hardness, printing inks, clichés andaccessories, thus acquiring the capabilityto provide customers with products thattruly meet their requirements.Continuing along the same path andencouraged by satisfied customers, theNineties saw the company expand outsideof Italy and Europe to other countriesaround the world. New countries broughtnew opportunities, leading to thedevelopment of more sophisticated,application-specific, highly automated padprinting machines. These years were alsocharacterized by the proliferation ofhermetically sealed systems that have allbut eliminated the old open inkwellsystems of the past making pad printingincreasingly production-friendly.The first decade of the new millenniumreaffirmed pad printing as an essentialtechnique for decoration of a seemingly

infinite number of products. Niche marketsdeveloped as companies sought todifferentiate their products. At the turn ofthe century, Tosh was routinely providingcustomers with solutions that wereinconceivable only a few years earlier.During this decade the companyrecognized the need to divide its Logicarange into two distinct lines - High Speedand Flexible - to meet the specific needsof those customers seeking to make

investments in technology thatensures concrete advantages inan increasingly challengingeconomic environment.In these last two years the range ofmachines has continued to growvia the advent of Logica Platformand Logica Cartesio. Both of thesesolutions come “sized to fit” andwill serve the customers well asthey continue to expand thehorizons of the pad printingprocess. Last but not least, incontrast to most competitors, whenTosh says “made in Italy”, it meansusing 100% Italian design andcomponents, in the full Italian style.

www.tosh.it

Alternative rotomouldingSome materials currently availableon the market have not yet foundtheir best use in rotationalmoulding because of a lack ofadequate automation and processcontrol in the conventionalprocess. Recent experimentscarried out by Persico (22 - A23)have been focused precisely in thisdirection.One of these experiments regardsthe production of PA6 componentsstarting from caprolactam chipswhich are polymerized through

anionic addition. The company hasdesigned a material preparation plant forthis application in which the raw materials(caprolactam+activator, andcaprolactam+catalyst) are melted in twoseparate tanks where specially designedstirrers uniformly blend the additives. Thematerial in liquid state is mixed in anantechamber and pumped into rotatingmoulds heated at the proper temperature

TOSH

PERSICO

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for polymerization. Material solidificationoccurs through a chemical reaction andnot by cooling inside the mould. This being a chemical process, it is vital tocontrol and monitor the processingtemperature inside the mould. OnLeonardo, the first fully-automatedrotomoulding machine, the heatingelements consist of a series of resistorsapplied directly to the mould surface. Thisfeature allows for uniform heattransmission and precise, instantaneouscontrol of process temperature, which isrequired for effective completion of thechemical reaction inside the mould. The second experiment was focused ontransparent polycarbonate processing, inwhich a newly developed version of theLeonardo machine with electric heatinguses a vacuum technique. This processalso requires precise mould temperaturecontrol in addition to rotation speedshigher than in conventional rotomoulding.As is well known, one of the problems ofpolycarbonate moulding is the presence oftiny air bubbles trapped on the outside andinside surface of the moulded part duringsintering. If the bubbles are not eliminated,they negatively affect the mechanicalproperties of the material as well as itsaesthetic appearance. The classicapproach to removing the bubbles is toprocess the material at a much highertemperature and for a longer time than istheoretically necessary to melt thepolymer. The higher temperatureincreases melt fluidity and, by keeping thematerial in this state for a sufficiently longtime, the bubbles can be “reabsorbed” bythe polymer. To overcome this technological limitation,Persico carried out some tests comparingthe results of different samples mouldedunder the same processing conditions butwith a different internal mould pressure.Thanks to the Leonardo machine, besidescontrolling the mould temperature directlyand precisely, it is easy to monitor internaltemperature and even pressurize anddepressurize the cavity of the rotatingmould. Testing revealed that a vacuum techniqueleads to the complete removal of thebubbles both on the outside surface and

inside the wall. In addition, the mouldsurface was subjected to a specialtreatment, and some adjustments indesign and construction have produced asignificant improvement in moulded partquality.

www.persico.com

Wood-imitation embossing in registerThe market shows great interest inlaminated materials and coverings forproduction of wood-grain flooring,composed of a substrate encapsulatingseveral PVC film layers filled with highpercentages of calcium carbonate andpossibly reinforced with glass fibre,laminated to a printed film, which can bereinforced or non-reinforced (extensible)and perfectly imitates wood.Progress in printing techniques, includingdigital printing, makes it possible to obtainvery high quality imitations of any kind ofnatural material. For example, prints canbe produced that perfectly reproducecolours, shades, and grains of any kind ofwood. But this is not sufficient to give anacceptable appearance to the product, asits surface is glossy and smooth to thetouch, which is absolutely unnatural andfar from the real appearance of a naturalmaterial.

Currently, this problem is addressed bysubjecting the material, after the baselayer and printed sheet have beenlaminated together, to an embossingprocess that imprints relief into thesurface, creating tactile irregularities thatmake the product more similar to itsnatural counterpart. However, suchtechniques do not provide satisfactoryresults since the engraved roll createsrelief that does not correspond to theprinted pattern. Thus, grain, knots, andother printed features of the wood have nocorresponding features in the embossedrelief.This drawback can only be overcome byperforming embossing in registerdiscontinuously, thus making it a slowprocess. Furthermore, the embossingpress, working offline, is expensive andcumbersome. Since laminates are, bynature, economical products, the processneeds to be simplified and as cheap aspossible. It is thus necessary to carry outembossing in a continuous process, i.e.,directly on laminated film instead of onpre-cut panels, something hithertoconsidered infeasible. Specific patent-pending systems havebeen invented and are presented at thefair by Rodolfo Comerio (11 - C42). Theaim is to offer an effective, fast, and

RODOLFO COMERIO

42 ●

economical technology forembossing in register (orsynchronized embossing) ofsingle-layer or laminated sheetcomposed as describedabove.

www.comerio.it

Insulating panelsEarly in 2011, Saip (11 - A73)and Dow Chemicalestablished a new company inSpain, CeDePa (Centro deDesarrollo del Panel enContinuo), located in Tudela(Navarre). It is a new, one-of-a-kind, state-of-the-artindustrial-scale developmentcentre for thermal insulationpolyure6thane panelsproduced with continuouslamination process. Dedicatedtechnical resources and acomplete network of experts inequipment, chemical systems,process engineering, andapplications assist teams fromdifferent companies toconfidentially develop,prototype, and test innovativeand most effective solutions. CeDePa builds on years ofexperience in this industry ofthe two partners, who havedecided to jointly invest in thisinitiative as they both believethat the combination of theirrespective expertise inchemical and mechanicalproduction processes andtechnology is a decisive factorfor rapid innovation and theenduring success forcustomers and the industry asa whole. The new company isalso open to external R&D andtechnology centres,universities, qualitycertification organizations, andother external playersinterested in innovation andsustainability in this industry.A state-of-the-art industrial-scale line has been installed at

CeDePa and is fully devotedto testing and prototyping. Ithas been conceived to allowSaip and Dow customers, andthe construction industry as awhole, to accelerate thedevelopment of novelsolutions for themanufacturing of polyurethanepanels for thermal insulationand to accelerate thediscovery and availabilityacross the industry of novelsolutions to help increaseenergy efficiency throughenhanced thermal insulation ofbuildings while also simplifyingand accelerating theirconstruction, durability andsafety including fireperformance, and final usercomfort.The line, with a length of 135m, includes the whole range ofproduction equipment from thesteel uncoiling section to thewrapping section: roll formingsection for corrugated and flatsteel facing profiles with aquick profile changeoversystem; primer equipment forsteel facing treatment; flexiblefacing, EPS and mineral woolprocessing equipment; multi-stream, high-pressurefoam dispensing machine (9components); double pressconveyor with operatingtemperature up to 70°C (panelthickness processing range upto 240 mm); handling sectioncomplete with coolingequipment, stacking and panelbundle wrapping; state-of-the-art line process control andsupervision system (over 100parameters constantlymonitored); up to 16 camerasmonitoring and recording theproduction and trial process.

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www.saipequipment.it

Shuttle rotomouldingAs a supplier of solutionsfor all rotational mouldingneeds, RotomachineryGroup (22 - C10) isintroducing a new shuttlemachine with 3 stations,where each carriageenters the ovenindependently. The clientdemanded maximumflexibility for the productionof huge tanks (capacity upto 40,000 litres) requiringlong cycle times forhandling the moulds andmoulded parts. Thepresence of the additionalcarriage has brilliantlyresolved these problems, allowingoptimization of resource use (operatorsand equipment): each arm (with a mouldor group of moulds) can be put intooperation totally independent of theothers, either sporadically or continuously.The insulation system for the walls of thecooking chamber allows high efficiencyeven with low production volumes. Thesynergy between Rotomachinery Group’sItalian and Canadian research teams hasled to noticeable progress in the efficiencyof hot air circulation inside the mouldingchamber. And the results can be appliedto any type of plant in the range(independent arm machines, shuttlemachines, and rock-and-rollmachines).Tests carried out on a new typeof hot air blower and a betterperforming directional airhandling system have proven asignificant reduction in cycletimes and lower energyconsumption thanks toincreased heat exchange in theoven. The goal of reducedconsumption is constantlypursued with tests of newinsulating materials and auto-adaptive cycle managementthanks to software thatautomatically determinesoptimal cooking and coolingtimes and verifies the best

combination of the moulds based on thespecific programmed recipe.

www.rotomachinerygroup.com

Digital decorationIn 2012 GMC is introducing the innovativeD-HDT system for direct printing of digitalimages on plastic containers. The specialfeature of the system is the ability to printdigital images using dry thermoplastictoner, applying them subsequently to themoulding process. The system permits thedecoration of plastic pails or jars withdifferent geometries: truncated-cones,cylinders, and objects with oval, round or

square bases with orwithout handles. The new system wasdeveloped in response tospecific demand in theprinting market forreduced production timeswith respect to thetraditional thermaltransfer. This is achievedthanks to the immediatedecoration of the objectand simultaneous checkof the final result, reducinglabour costs because theentire process can bemanaged by a singleoperator.Based on mechanical and

software innovation, D-HDT makes itpossible to set up a single line to printdigital images and apply them tocontainers, simplifying processmanagement, improving cycle time (warm-up time 5 min; print launch time 30sec) and increasing productivity. Rolls ofvariable length (from 1,600 up to 7,000 m)can be used to decorate as many as 450seventeen-litre pails or 650 three-litre pailsper hour. Thanks to the innovativetechnology of the print controller andprocess electronics, the printing processoffers excellent performance in terms ofconsistently accurate colour reproduction,simplicity of use, and operational economy.

The new system conserves allthe characteristics of thetraditional system, such asmaximum printing area (1,200 x300 mm), resolution (1,800 x 600dpi equivalent) with pantonecolour calibration, a commercialprint engine model that is widelydistributed and serviced all overthe world to ensure clients fullfreedom and autonomy inacquiring and managingconsumables. The new systemis characterized by a quick sizechangeover, absence ofmandrels, reduced maintenance,and easy management.

www.gmcprinting.com

SAIP surl- via Bressanella, 13 - 22044 Romanò d’Inverigo - Como - Italy - tel. +39 031.605762 - fax +39 031.606934 - www.saipequipment.it - infosaip@saipequipment.it

EQUIPMENT AND TECHNOLOGY WITH VALUE ADDED SOLUTIONS

FOR POLYURETHANE FOAMS PROCESSINGVisit us at STAND A73 - HALL 11

IMPIANTI E TECNOLOGIE

PER LA LAVORAZIONE

DI POLIURETANI ESPANSI

ROTOMACHINERY GROUP

FROM THE FILE TO THE CONTAINER (GMC)

44 ●

ANCILLARY EQUIPMENT & COMPONENTSInnovative approach to dryingThe Eureka project has been developedby Moretto (22 - A33/B34) to significantlyreduce energy consumption and improveperformance in drying systems. Itincludes three exclusive technologies:the new X MAX modular dryers, theFlowmatik control device and the OTXhoppers.The modularity of X MAX dryers makes itpossible to create large drying systemswith capacity of up to 20,000 m3/h. Theunits can be configured from aminimum of 3 to a maximum of10 with up to 32 dryinghoppers, with no need forair pressure or coolingwater. The result is afaster, consistent andgentle dehumidification ofhygroscopic materials,ensuring a significantreduction in energyconsumption. The main feature ofthis multi-bed systemis the capability ofmaintaining a consistent anduniform dew point during the process.High efficiency levels can thus beachieved with total operating flexibility.The individual units are rotated forregeneration: while one dryer is beingregenerated, the other units are inoperation, guaranteeing constantperformance. The variable airflow adjustsautomatically depending on processrequirements, thus preventing thermalstresses and viscosity variations in thepolymer.Flowmatic is an automatic integratedsystem for process air distribution inmulti-hopper systems. It supplies thecorrect quantity of air needed by thehoppers. This technology manages thesystem by adjusting the individualhoppers and process variables. Themachine uses only the process airneeded, which is calculated on the basisof the quantity and type of polymer to behandled. This produces excellent resultsin terms of minimizing consumption.The proprietary OTX hopper has aninnovative geometry which resolves theproblem of non-uniform material fallingflows and results in more efficientmanagement of the drying phase,keeping the process inside the hopperunder control. The particular hopperconfiguration provides homogeneousairflow and temperature, thus ensuringoptimal treatment of the granule with aconsiderable reduction in energy costs incomparison with conventional hoppers.The high impact Spyro finish, besidesproviding this new hopper with itsdistinctive look, also makes it more

resistant than those using standardlinings.

www.moretto.com

Cooling & thermoregulationThe new range of Raca Plus Energychillers is now complete with theinnovations to be introduced byFrigosystem (15 - B30, 24 - D40) duringthe fair. This series boasts successfulworldwide installations: many customershave already attained the benefits of theecological R410 gas, saving an average of35% energy compared to the traditionalR407. These chillers are also appreciatedfor their highly reliable technology and theflexibility of application.

However, the company continues toenlarge and enrich its range of

products to better address theneeds of its customers. Inits quest to stay ahead ofcompetitors, the newseries will include modelsfrom 50 to 1,200 kW ofnominal cooling power, allwith multi-circuit and multi-compressor systems. Themax ambient temperaturerange will move from 43 to45°C without options. Thefree-cooling system,integrated or not, has beenoptimized too, and willconsequently reduce theenergy consumption in themost favourable climaticconditions. i-Remote is thename of the newlyintroduced control system,a local and remotesupervision system,applicable also to the mostcomplex cooling plants.

Innovations are also announcedon Kite air and water chillers, purpose-built and engineered for blown filmextrusion and already valued by German,Italian and North American customers.The technical focus remains on energysavings, R410 efficiency and flowvariations, with constant and precisecontrol of process temperature. The rangenow offers units with 1-2-3 cold air outletsand heat regulated water connections forextruder utilities.On the temperature controllers, thecompany is presenting the new i-Heatingunits, with a new-generation controlsystem. In 2011 Frigosystem was namednumber one Italian manufacturer oftemperature control units, with more than150 models in its catalogue and 2,800produced units: water or diathermic oil,

simple solutions or sophisticatedtechnologies, but always

and totally “made inItaly” with an excellentquality-price ratio.

www.frigosystem.it

Band granulatorsBand granulators fromSagitta (11 - C06) aresuitable for dicing nonvulcanized rubbercompounds of anytype, natural or

synthetic, as well asthermoplastics, linoleum,

cellulose, and silicone.Feeding extruders and moulding

machines with granules instead ofFRIGOSYSTEM

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MORETTO

strips offers severaladvantages, such as theability to blend differentcompounds thus obtainingbetter product quality, lesspulsation in extruder screws,energy savings, andautomatic operation.Many solvent manufacturerstake advantage of bandgranulators because thedissolving times can bereduced considerably bymeans of granules (5x5 or3x3 mm). The use of the GR450 S2 model isrecommended forprocessors who often havechanges of compounds orcolours. On this machine thecutting unit moves forward for easycleaning.Sagitta delivers machines with workingwidth of 135-235-430-620-830 mm forgranules of 3x3, 5x5, 8x8, 10x10 and15x15 mm. Toothed feeding disc-cylinders are available for very hardmaterials in order to prevent slippage.Hardened metal knives can be suppliedfor granulating very abrasive compounds.The hourly output capacity ranges from300 to 10,000 kg according to themachine model and granule size.Machines with or without automaticpowdering equipment are available.Furthermore, the delivery programincludes pneumatic conveyance ofgranules and de-powdering systems aswell as de-packing powder feedingequipment.Sagitta also produces other rubberprocessing machines: horizontal splittingmachine to divide elastomer sheets (maxwidth 550 mm, max thickness 60 mm,minimum thickness 0.2 mm); automaticmachine for trimming and cuttingelastomer gaskets placed on rotatingspindle and trimmed with extremeprecision by lance tooling; automaticmachine to cut elastomer sleeves onrotating spindles into rings by means ofspecial knives; automatic machine to cutextruded elastomer profiles and hoses byelectronically-controlled revolving circularknives.

www.sagitta.it

In-line recoveryAmong the innovative proposalsintroduced by Tria (15 - C26, 24 -C55/D50), a special emphasis is put onthe evolution of JM grinders, devoted toin-line recovery of injection mouldingscrap. Following sales of more than4,000 units, the company decided to sumup in these machines the Blue Linedesign philosophy that it has developedin recent years. This vision has led to thoroughgoingresearch into performance whilemaintaining flexibility of use, compliance

with standards and legislation, advancedergonomic solutions, and managementeconomy combined with constructivequality to ensure a medium-term returnon investment.The aims which have served asguidelines in renewing the JM range maybe summarized as follows: low noiselevel (below 80 dBA) for in-line grinding;low energy consumption (max 700 W)with motor power reduced by 20% whileensuring the same performance;ergonomic design and reliability withsimplified access to the hopper andfunnel, and a 27% reduction in footprint.Similar design standards and solutionshave also been applied to other widelyused machine ranges, Series 30 and 42,

which are proposed in updatedversions.As for large-sized machines, arevamped version of the Series80 (rotor diameter 620 mm) ison display for grinding in-line(thermoforming and film scrap)and off-line (extrusion andrecycle). A new counter-knife securing systemhas been designed for thewatertight grinding chamber;moreover it is possible to fitstationary or rotary discs andthree different shafts, includinga forged one for wet grinding orextrusion spurges.A further innovation on displayis the CR K high speed forcedloader for film fluff, designed in

cooperation with major manufacturers ofcast film lines. Equipped with visualwarnings and video cam for internalmonitoring, its special design allows it tointegrate with any type of extruder.

www.triaplastics.com

Sprue-pickers & driersThe sprue-picker manipulators in the AVPrange, suitable for on-board use withinjection moulding machines, have beendesigned by Dega (24 - D14) to pick-upsprues or parts (with grip device andvacuum generator) from the mould area.Amortized pneumatic cylinders and largesolenoid valves permit a considerablereduction of the extraction cycle times. Thanks to the programming softwaredesigned by the sister company DegaAutomation, the manual control allowsconstant and accurate monitoring of allcycle times, with visualization of eachmovement on the display. The selectionof standard programs is easy and fast:there are 4 pre-set programs in thememory which can be called up andmodified at any time. Moreover, it ispossible to create new programs andstore them in memory. The operatingfunctions, such as vacuum circuit, partgrip verification, and part pick-up from themoveable and fixed platen, are easilyselected by a key on the hand-heldcontrol.For small batch dehumidification with astable process quality, Dega isintroducing the latest version of its DD60-R, a small dehumidifier with a 60-m3/h rotor which is positioned in acontainer that rotates, divided into 3different compartments, each specializedin a different function: processing,regeneration and cooling. With thissystem, the processed air exits the rotoralways at the highest level of dew point,eliminating the rippling effect observed inconventional systems.When it is dried, industrial compressedair (6-15 bar) has a dew point of 3-5°C.When it expands to atmosphericpressure, the dew point falls naturally

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TRIA

to -20 or -28°C. With the Series AC micro-dehumidifier it is possible to reachan average and constant dew point ofeven -18°C. Hence, for small batches itbecomes convenient to adopt thissolution because similar results areachieved, per unit of energy consumed,as with traditional dehumidifiers, with theadvantages of small space requirements,temperature control managed by specificsoftware, micrometric control of the airflow at low pressure, insulated hopperwith rolling cover, and air diffuserpositioned in the socket adapter.

www.dega-plastics.com

Quality firstThe latest innovative solutions introducedby Doss Visual Solutions (11 - A31) inthe field of artificial vision systems andindustrial automation include Migl II,which makes it possible to sort complexand irregular parts with length up to 600mm and width up to 200 mm. Linearcameras and laser measurementsystems collect all the data necessary forrepeatable quality control. The point-to-point laser acquires the real partthickness and the cameras carry out bothsurface (on two sides) and dimensionalchecks. The machine can be equipped withloading and unloading robots. A turnoversystem has been developed specificallyfor 180° flipping of any type of part ormaterial. All sorting data are saved to adatabase that can easily be accessed bythe operator and statistics can bearranged in tables that can be exportedwhenever needed.Designed for the sorting of large gasketsup to 200-400 mm (in two versions), theDuet machine is composed of a firstrobot, guided by a camera, which picksup the parts directly from a bin: 2 differentcameras frame the scene from twodifferent viewpoints and send back to thePC all the information about the XYZposition of the part to be picked up. Therobot then places the part on aback-lit plate fordimensionalcheck; asecondrobot rotatesthe part andpasses it infront of acamera forinspection ofthe entireexternalsurface. Thesoftwaredetects

stains, rings, scratches, tears, flash ormissing material. Depending on theoutcome, the robotized arm places thepart into the bin for good parts or thescrap bin.

www.doss.it

Nozzles & controllersInnovations introduced by Thermoplay(24 - D34) for injection systems include anew nozzle for multi-cavity moulds usedfor manufacturing tubular-shaped parts,which contributes to the elimination oftraditional “tunnel” sprues normally used inthese applications. Injection is direct in theannular cavity wall. The nozzle structureallows easy machining of the injectionsystem housing in the mould. In addition the nozzle is provided with adouble sealing ring preventing materialleakage. The thermal profile of the nozzlebody and the isolation of the tip from theforming matrix make it possible to useprocess parameters aligned with thosesuggested by plastics manufacturers. Theextraction operation helps create a defect-free injection point thanks to the lateralinjection. Another innovative injection systemenvisages that the nozzle, with or withoutthe shut-off group, can be mounted atdifferent inclinations and assembled to themanifold ensuring perfect perpendicularityto the injection platen. An innovativesystem of joints that distributes expansioninside the manifold enables the use ofnozzles without minimum lengthconstraints depending on distance fromthe centring element. The system issupplied prewired in variousconfigurations based on specific needsand equipped with conditioning andelectrical circuit, and pneumatic/hydraulicsystem, simplifying handling andinstallation of the system in the mould.Thermoplay also introduces a newsequential controller designed to optimizethe molding process in criticalapplications. Each shut-off valve isdetected and controlled by the

system, so the end product isfree of welding lines,

DEGA s.p.a.Largo del Lavoro 4 - 6 - 8

25040 CLUSANE SUL LAGO (BS)Tel. +39 030 989595 - Fax +39 030 989596

Email: info@dega-plastics.comwww.dega-plastics.com

www.pubblicitab

elotti.it

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DOSS

thus meeting the most strict qualitystandards. Technical characteristicsinclude: sequential control of pneumaticand hydraulic shut-off valve systems,automatic and manual test operation forfunction testing of each valve, maximumconfiguration 16 valves, mobile high-resolution touch-screen unit andshockproof case, temperature control ofconditioning circuits.

www.thermoplay.com

Strategic maintenanceToday more than ever,maintenance is recognized as astrategic asset for anycompany. An accuratemaintenance strategy,together with the use ofsystem components thatenable reduction in overalloperating costs, is fundamentalin optimizing machine functionand plant operation in theplastics processing industry.Even though service processesoften play a secondary role inthe production system,Wamgroup (11 - B92) offersnew specializedcomponents aiming atoptimizing processes,improving performance, andensuring high safety standardsfor both personnel andequipment.The new VHS pressure reliefvalve, manufactured from engineeringpolymers, relieves any excess pressureoccurring during silos filling or generatedby physical or chemical reactions that maytake place inside containers. The valveconveys dust emissions to a collectionspoint to ensure constant safety in the workarea. Reliability in operation coupled witheasy maintenance make the VHS valve aone-of-a-kind component fully compliant

with environmental protectionregulations.

Reduction in maintenancetime and costs also plays

a key role for Torex,another Wamgroupcompany, which hasdeveloped VAR, a

drum-type diverter valvefor pneumatic conveyingsystems. This valve, withstandard inflatableseals, has beenspecifically designed to

minimize maintenanceand considerably extend

the product life cycle.Distinctive features ofdiverter valves are

specific anti-abrasivecoatings designed for theplastics industry and aparticularly maintenance-friendly design.

Finally, the GT pipe couplings,developed to join plain pipe ends ofpneumatic conveying lines in a safe,quick and rigid way, help reduceinstallation costs as compared to weldedjunctions, at the same time ensuringgreater flexibility of use, work safety andno pressure drop along the pneumaticline.

www.wamgroup.com

HALL 13 - STAND C05

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THERMOPLAY

WAMGROUP