inject 4.0 makes the best of your production

October | 2016

The magazine from ENGEL for the plastics industry

inject 4.0 makes the best of your productionWelcome to ENGEL’s smart factory at K 2016 Page 12

Customer proximity and quality are the foundation for success30 years of ENGEL in Asia, serving Asia Page 8

New injection units for even more precision, ergonomics and efficiencyTechTalk with Franz Pressl and Bernhard Lettner on the next machine generation Page 10

Avoid unplanned downtimeENGEL e-connect.monitor supports predictive maintenance Page 15

Dear customers and business partners,

This issue of Injection will be the last to appear during my tenure as CEO. I would therefore like to take this opportunity to thank you all for participat-ing with developments and innovations at the ENGEL Group and choosing ENGEL products and solutions over the years – the benchmark by which the success of any company is measured. Another measure of success is the capability of our employees and management team to generate added value for you as our customers, to provide you with confidence, and maintain a close partnership – all this with the final goal to ensure that our products and solutions meet your specific requirements. I have spent 35 years, in various roles, working towards these targets. As CEO, my focus has been always on the customer. This starts with product strategy. All developments – from tie-bar-less technology and dual-platen machines to integrated automation – aim to give you, our customers, something more, and above all, something better. Globalisation is not an end in itself: it is about offering and delivering ENGEL products and ser-vices quickly and cost-effectively in consistant high standard around the world – wherever you happen to be. In the field of after-sales service, we continually adapt capacity to the local demand of the respective region, train our employees and optimise our systems to steadily improve our response times. Only by meeting these and many other challenges well, can we be your strong and stable partner in the long run, and ultimately be successful. Continuity in ownership and management are values that are very impor-tant not only for us as a family-run business, but also for me personally. We have weathered tough times, such as the disastrous flooding of 2002 and the economic crisis of 2008/2009, and actually emerged stronger for these experiences. I am filled with happiness and pride to pass on the reins of such a strong company to the next generation of the owners’ family. I will remain closely connected to ENGEL. On that note, I would like to wish the management team and especially Dr. Stefan Engleder, the new CEO of the ENGEL Group, every success. The customer will remain our focus – there is no change to this central philosophy of ENGEL.I look forward to meeting many of you at the K in Düsseldorf and personally thanking you for the great times we have shared.

Dr. Peter Neumann

CEO ENGEL Holding

IMPRINTPublisher: ENGEL AUSTRIA GmbH | Ludwig- ENGEL-Straße 1, A-4311 Schwertberg, www. engelglobal.com Editorial team: Susanne Zinckgraf, ENGEL / Martin Streicher, ENGEL (responsible editor)Layout: NEUDESIGN – office for visual communication

Injection is the ENGEL customer magazine. It is published regularly in German, English, Turkish and Polish. Articles may be reprinted with the editor’s consent and reference to source. All company names, trade names, trademarks or other references to third party or ENGEL products, may in fact be registered, and thus legally protected, even if no trademark symbols are used or visible in the text or copy.

Dear customers and business partners,

There is always something exciting about something new. Some things change. New opportunities open up. From time to time there may even be a few surprises waiting for us. In this sense, especially for me, the genera-tional change in the ENGEL management will be exciting. However, one thing I can promise is that for you, our customers and partners, nothing will change in your collaboration (or relationship) with ENGEL. Our aim is to continue to be a leader in creating customer value. Customer proximity is one of the values that we live at ENGEL. This is what makes ENGEL successful and what is most important to me. To me, customer proximity not only mean responding to the current demand of the customer, but to anticipate your future requirements and translate these into products and services that allow you to successfully meet the challenges of tomorrow. ENGEL is a family business. At ENGEL, a change in management means continuity. Together with you, I want to further develop what my great-grandfather, my grandparents and my uncle Peter Neumann have built. At our booth at the K you will experience numerous innovations that were developed in close cooperation with our customers. Whether it is our new hydraulic injection units or our inject 4.0 solution for predictive maintenance – many new solutions have already been tested in real-life production en-vironments with test users, and then further optimised prior to their show premiere. Nothing will change regarding this philosophy. The generational change at ENGEL also stands for continuity as I have already headed our R & D department for four years and will be responsible for this division in my new position as CEO as well. Customer proximity is also evident at ENGEL through its local presence. Today, we are the only Western injection moulding machine manufac-turer with three production plants in Asia. We will continue following this strategy in the future and continuously strengthen our local teams. As a family business, we can make quick decisions and are independent from external investors. This allows us to plan long-term, while being able to react promptly and flexibly to dynamic markets.The change in management has been prepared for carefully over the past few years. Ever since my college days, Peter Neumann has shared his experience and his advice, and for this I am very grateful. K 2016 will be my ninth K show and my third with ENGEL. Nevertheless, K 2016 is especially exciting for me. Above all, I look forward to meeting you in person. Continuity and customer proximity at ENGEL means that I, as the CEO, will always have an open ear for you, our customers and partners.

Dr. Stefan Engleder

CTO ENGEL Holding

4_ENGEL injection-2016

“With a retention rate of 98 percent, in-house training is a critical source of trained professionals.”Johannes Höflinger, training manager at ENGEL

Top marks for ENGEL apprenticesWKOÖ competition for trainees

ENGEL AUSTRIA's apprentices are among the best in the country. The company's second-year apprentices were able to masterfully defend this reputation with

one first place and one third place at the 2016 appren-tice competition held by the Upper Austria Economic Chamber (WKOÖ). Julian Obermayr proved to be the best design engineer apprentice in Upper Austria, and Florian Wölfl took third place among the prospective mechanical engineering technicians. In the industry category, a total of 835 young men and women from 126 companies faced the scrutiny of a panel of ex-perts. “We are very proud of our young talents,” says a delighted Johannes Höflinger, training manager at ENGEL AUSTRIA. "Once again, the success of our ap-prentices confirms the quality of our training concept."More special honours were confirmed at this year’s ENGEL graduation ceremony. Freshly qualified me-chatronic technician Stefan Nöbauer and Thomas Mayrhofer completed all four vocational school classes with excellent grades, also passing their apprentice-ship examinations with distinction. The two will now undertake a three-month work placement at ENGEL’s large-scale machine plant in Shanghai before starting their professional lives in maintenance and develop-ment respectively back at ENGEL in St. Valentin.

New opportunities with multi-component technologyLSR seminar in Bangkok

Applications involving liquid silicone are rapidly gain-ing ground in southeast Asia as demands continue to rise in terms of the quality of produced parts. Which innovative technologies can provide economically fea-sible answers to the new challenges? This was the subject of an LSR seminar at the Plastics Institute of Thailand in early September, organised in Bangkok by ENGEL, Momentive Performance Materials and Elmet.

Highly satisfied with Plast Alger: Loucif Hamid, Regional Sales Man-ager (North Africa) at ENGEL, and Philippe Sterna, Managing Direc-tor at ENGEL France, pictured with Fabio Cantoni, CEO of ENGEL Partner Cantoni Stampi.

Two of the best for 2016: Florian Wölfl (left) and Julian Obermayr.

Turnkey solutions requiredPlast Alger fair in Algeria

ENGEL has made a third appearance at Plast Alger in Algiers, Algeria – and once again the event was a resounding success. “The calibre of visitors to the trade fair in Algiers is very high,” says Philippe Sterna, Manag-ing Director at ENGEL France who is also responsible for sales in Algeria. “Demand for turnkey solutions was particularly high at the trade event,” reports Mr. Sterna. “Our wide-ranging experience in application technology is a central factor for clients when making a decision, as is our technological expertise.” In Algeria, ENGEL solutions are mainly deployed in the pharmaceutical, cosmetics and food packaging sectors.

ENGEL worldwide. around the corner.

ENGEL injection-2016_5

“Our clients know we have amassed a wealth of experience in multi-com-ponent processes around the world, and they are turning to us increasingly for integrated solutions.”Aram Tongurai, Managing Director at ENGEL Machinery (Thailand)

From left: Christoph Hinteregger, President of the HTL Bregenz board of trustees, Rudolf Reichart, workshop instructor at HTL Bregenz, Klaus Mittmannsgruber, Regional Sales Manager at ENGEL, Christoph Steger, Chief Sales Officer at ENGEL, Jörg Maninger, head of plastics engineering department at HTL Bregenz, Claudia Vögel, Director of HTL Bregenz and students.

Students learning on ENGEL machineMachine loaned to HTL Bregenz

ENGEL is supporting the study of plastics engineering at HTL Bregenz by loaning an ENGEL e-victory injection moulding machine with linear robot to the higher techni-cal college. The machine, which was handed over in a special ceremony, was soon being used by students.The on-loan machine was presented to the school as part of a celebratory event and students put it into operation shortly after the event. “Practical learning is extremely important to us,” says Claudia Vögel, Director of the HTL Bregenz. “The excellent cooperation we have established with the industry has contributed decisively to the high standards of our trainee program and the excellent reputation of our graduates.”

LSR experts in southeast Asia: Leopold Praher of ENGEL AUSTRIA, Paul Fattinger of Elmet, Jason Hsieh and Tatinan Thaikhrew of Mo-mentive, Aram Tongurai of ENGEL Machinery (Thailand) and Oliver Franssen of Momentive.

Maximum efficiency in fitting productionIranplast in Tehran

The production of fittings places particular demands on injection moulding technology: the mould is generally very large due to the core-pulls, while the clamping force requirement is relatively small. ENGEL provides efficient solutions for these applications with its ENGEL victory and e-victory series of tie-bar-less injection moulding machines. In mid-April Varzidehkar, ENGEL’s distribu-tion partner in Iran, demonstrated what this means in practical terms at Iran Plast in Tehran, where the focus was on turnkey solutions. ENGEL’s partner ifw, which specialises in high-tech moulds for fittings, also at-tended the Tehran event.

Following a series of successful events in China and Korea, the partner companies have made their debut in southeast Asia. “As quality requirements rise, the focus is switching to integrated processes. Multi-component processes with thermoplastic/silicone compounds, for example, are new territory for many processing firms in the re-gion,” says Aram Tongurai, Managing Director at ENGEL Machinery (Thailand). Speakers used sample parts and videos to highlight current projects and illustrate new possibilities such as sensor housings for flow measurement with an integrated LSR seal. After the presentations, the experts were available for individual discussion; attendees brought along sample parts, CAD drawings and product ideas for this purpose.

The new production plant will also be used for the final exams of apprentices in Vorarlberg specialising in plastics moulding and plastics engineering. “I am sure the trainees are delighted with the ENGEL machine,” says Klaus Mittmannsgruber, Regional Sales Manager at ENGEL. "Most of our students already use ENGEL injection moulding machines in the companies where they complete their practical training, and can now take their examinations in a control environment they are familiar with".


“The properties of Liquid-metal materials are fasci-nating to anyone working with plastics or metals. Now we have to find ways to make use of them.”Heinz Rasinger, Vice President, EN-GEL teletronics

Preview

K 2016, Düsseldorf, Germany, October 19th to 26th

MuCell – Success with little pressure, Schwertberg, Austria, November 22nd to 23rd

Composites Europe, Düsseldorf, Germany, November 29th to December 1st

Expoplast, Montreal, Canada, November 30th to December 1st

Plast Eurasia, Istanbul, Turkey, December 7th to 10th

Integration means low unit costsMedical Seminar in Kazakhstan

In June, ENGEL invited participants to a medical semi-nar in the Worldhotel Saltanat in Almaty, Kazakhstan, together with its distribution partner Textima Export Im-port. Many plastics processing businesses in the region took the opportunity to discuss current requirements and trends, learn more about innovative technologies, exchange experiences and establish new contacts. Kebo and Motan Colortronic presented their solutions alongside ENGEL, addressing in their presentations such themes as choosing a mould manufacturer, clean room concepts and injection moulding machines for medical usage. In the process, it became clear that the interplay of individual components in a manufacturing cell was just as important as hygiene, precision and high performance. Videos and sample parts were used to present current clean room applications. During the seminar, a tie-bar-less ENGEL victory machine was used to produce Petri dishes, one-shot production of drip chambers with integrated filters was demonstrated on an ENGEL e-victory hybrid machine and needle

Rolf Saß (left), Managing Director at ENGEL Deutschland, handed over the injection moulding machine to Professor Hopmann at Poly-mer Optics Days 2016. (Picture: IKV/Fröls)

Strong interest in LiquidmetalHannover Messe 2016

With its completely new material characteristics and abil-ity to be injection moulded, Liquidmetal revolutionises the fabrication of high-quality metal components. At the Hannover Messe this spring, ENGEL demonstrated the potential of the new material class.

Liquidmetal components are extremely hard, yet highly elastic at the same time; with a low specific weight, they are corrosion-resistant and biocompatible. This range of characteristics predestines the new mate-

rials for use in precision and functional compo-nents that are subjected to high mechanical stress-es. Visitors to the stand at the trade fair represented a wide range of sectors, from medical engineering

to the electronics, automotive, aerospace and sports equipment industries.

holders for insulin pens were produced on an all-electric ENGEL e-motion high performance machine. Common to all of these applications is the fact that very low unit costs are possible through process integration and automation.

Research into optical componentsENGEL machine for IKV technology centre

A new all-electric ENGEL e-motion 160 injection mould-ing machine was recently supplied to the plastics pro-cessing institute (IKV) of RWTH Aachen University. The machine, which supports high precision injection moulding and injection-compression moulding tech-niques, was specifically designed to meet the needs of optical component production. The IKV research programme includes innovative approaches to pro-cess control for the multi-layer formation of thick-walled optical components, with the aim of improving optical reproduction accuracy and reducing cycle times.

Professor Christian Hopmann, who heads the institute, thanked Engel for providing the state-of-the-art injection moulding machine: “We are very pleased that this ma-chine has enabled us to expand our activity in the area of injection moulding for optical components. ENGEL has been supporting our efforts for quite some time. This is a significant step forward for our work in terms of efficiency and precision.”


"In North America the automotive industry is again the growth and innovation driver," says Füreder. "Auto sales figures are at a high level. On top of that, many processors are modernising their machine pools." And as to ENGEL’s plans for this important market, Mark Sankovitch, Presi-dent ENGEL North America, comments: “ENGEL has committed substantial, ongoing resources to tackle the unique challenges in the dynamic automotive injection moulding industry here in North America – and the co-operation with Tech Centers is just one of the initiatives to support our customers.”

New players, challenging targets and more lightweight technologiesWhen it comes to future production strategies, the focus is mainly on one topic: Industry 4.0. "The automotive industry is extremely open to this topic," says Füreder. Accordingly, the presentation given by Dr. Stefan En-gleder, CTO of ENGEL, was warmly received. He spoke about the advancements in digitalisation which offer new opportunities to manufacturers. Intelligent assistance systems and the new condition monitoring solutions from ENGEL's inject 4.0 program will assist processors to further increase the quality reproducibility of manu-factured parts. In addition vehicles are being increasingly equipped with driving assistance systems and this places new demands on manufacturers, as Drew Winter from WardsAutomotive clearly stated in his lecture. Another challenge he named was changes in the provider structure caused by new players such as Tesla and Google as well as the growing significance of energy efficiency. Haig Stoddard, also from WardsAutomotive, indicated that there is still a lot of effort necessary for manufacturers to meet 2025 CAFE stan-dards. Larry Gros from ExxonMobil closed the discussion

on this subject with a global energy outlook. Jim Moore from Magna, and Steve Jarzynski from Hi-Tech Mold & Engineering presented their solutions to fulfil the require-ments and speed up development of plastic car parts.“ENGEL recognizes the critical nature of the 2025 CAFE standards and is developing technologies to aid OEMs in reaching these increasing requirements,” explains Wolf-gang Degwerth, Vice President ENGEL North America. Lightweight technologies are the key solutions for reduc-ing the weight of vehicles and thus their consumption. Therefore, a number of presentations showed new de-velopments, trends and best practices in this area: Pal Swaminathan from Lanxess, Levi Kishbaugh from Trexel, Srikanth Pilla from the University of Clemson and Peter Egger from the ENGEL centre for lightweight composite technologies. Lightweight construction was also a pre-dominant topic in the ensuing panel discussion. "Just as in Europe, universities in North America are paving the way for applications in lightweight technologies – often in collaboration with Tier 1 suppliers," says Michael Fischer, Sales Manager of Technologies at ENGEL, who moderated the discussion.

Local capacity for customer trials and demonstrations At the conclusion of the presentations, the conference participants were invited to the SA Engineering Tech-nology Center to delve deeper into the technological possibilities. Five machine exhibits there demonstrated how to raise productivity and efficiency in production by means of customised solutions. Besides SA Engineering, ENGEL collaborates with Hi-Tech Mold & Engineering in the Detroit area in order to provide automotive customers with machines for trials, presentations and development projects.

At the end of June, ENGEL hosted the first ENGEL trend.scaut event in North America. It took place in Livonia near Detroit and participants not only came from the USA but also from Canada and Mexico. "It was definitely the right decision to take our au-tomotive conference to manufacturers," sums up Franz Füreder, Vice President of the Automotive Business Unit at ENGEL. "On site we can discuss local requirements much better. The automotive experts certainly left the conference with concrete suggestions to face their individual challenges."

trend.scaut America: Automotive industry drives growth and innovation


30 years of ENGEL in Asia, serving Asia In Shanghai this spring, ENGEL celebrated its 30th anniversary in Asia along with customers and partners. As Europe’s first injection moulding machine manufacturer, ENGEL established a sales office in Hong Kong in 1986 – and to this day, it remains the only company producing machines at multiple plants in Asia. Customer proximity, quality and a profound understanding of the local requirements – this is what ENGEL views as the foundation for its consistent and sustained success.

After founding ENGEL Machinery Hong Kong, devel-opment advanced at a rapid pace. To meet the rising demand, additional sales offices, service centres and subsidiaries have been opened in Singapore, Korea, China, India, Thailand and most recently Vietnam; there are also numerous representative agencies.

ENGEL continues to build its presence and expand production capacity in Asia. In 2001, the production plant for low and medium clamp force injection mould-ing machines was opened in Pyungtaek City, South Korea. Since 2007, large-size machines have been produced in Shanghai. Both plants produce for the local markets. “Thanks to vast markets, which are de-veloping rapidly in many respects, Asia is key to the global success of ENGEL. The region is also driving the growth of our locations in Austria,” emphasises Dr. Christoph Steger, Chief Sales Officer at ENGEL. "Our early efforts in Asia secured access to the major electronics companies that have grown internationally from their base in Asia. Back then and still today, these companies place great value in having partners and suppliers that are located close to their headquarters and production facilities."

Local production ensures short delivery timesLocal production guarantees short delivery times for ENGEL's customers and ensures that the injection moulding machines, robots and system solutions can be flexibly adapted to the specific requirements of the Asian markets. ENGEL achieves 85 percent of its turnover in Asia with local production. The field of teletronics is still one of the strongest sources of revenue. However, the automotive industry now accounts for an even larger proportion of sales. Other important target areas are the packaging and medical industries, which are both profiting from the strong population growth and increasing prosperity. In addition to the major multinational companies, more and more local plastics processors are join-ing ENGEL's customer base in Asia. "We observe an increasing specialisation among the small producers and suppliers," says Robert Bodingbauer, President at ENGEL Machinery Korea. “There is a trend towards higher quality, and a need to produce that standard of quality quickly and cost effectively. Therefore the focus is moving to overall efficiency, life-cycle costs


and ultimately the latest developments in technology."ENGEL’s success story in Asia is closely tied with the name of Robert Bodingbauer. In 1986 Mr. Bod-ingbauer, who was based in Korea at the time, went to Hong Kong for ENGEL to promote the steady ex-pansion of a sales and service network across Asia. ENGEL started out with four employees in Asia; today the company has more than 500 staff members in China alone, with over 180 in Korea.

Top quality worldwideIt has always been top priority for ENGEL to deliver the same high quality worldwide. Therefore, the same strict quality standards are applied in the Asian factories as in Austria; a machine produced in Asia cannot be distinguished from one of the same type produced in Austria. "The demand for high-quality products and in-novative technologies will continue to secure the future success of ENGEL in Asia," as Robert Bodingbauer is convinced. Overall, the requirements for quality are continually increasing, although at a different pace in each individual country market. China is definitely one of the forerunners in this respect.

As a system expert, with great expertise in automa-tion, most inquiries ENGEL receives in Asia are for technologically sophisticated applications. The pro-portion of system solutions that ENGEL delivers as a single-source provider, which include automation, process technology and additional peripherals, is ris-ing. "In China, robots are increasingly becoming fixed components of an injection moulding machine in many areas. The production of high-quality components requires reproducible cycle times that can only be achieved with the help of automation," explains Gero Willmeroth, Sales and Service President of ENGEL Machinery Shanghai. Willmeroth has also been living in Asia for many years, and both he and Robert Bod-ingbauer stand for ENGEL's long-term commitment and continuity in Asia.

WINTEC subsidiary brand reaches new target groupIn 2014, ENGEL set another milestone for its strategy in Asia with the foundation of its WINTEC subsidiary in

Changzhou, China. The goal of the subsidiary brand is to manufacture high-quality injection moulding ma-chines in Asia for standard applications. "Standard products also place high demands on quality and process stability," emphasises Peter Auinger, CEO WINTEC. "But they usually require a smaller range of

options and fewer individual solutions. That is where the difference lies compared to injection moulding machines of the ENGEL brand. However, as far as quality is concerned, we make no compromises. This is why we are in a position to offer durable and reliable injection moulding machines for standard applications.”Quality and customer proximity also form a common thread at WINTEC. The company has established a new production plant in Changzhou. Independent of ENGEL, the subsidiary company is building its own sales and service infrastructure.

Dual training exported to ChinaWith three production plants altogether, the ENGEL Group in Asia has a great need for qualified profes-sionals. In order to secure them for the long term, ENGEL Machinery Shanghai started its own training programme two years ago. An apprentice workshop has been built at the large-size machine manufactur-ing plant in China, modeled after the award-winning apprentice workshop at the company headquarters in Schwertberg, Austria. By setting up a dual vocational training programme, ENGEL is emerging as a pioneer in China.


A new generation takes shape – this could be read on the ENGEL web site and in the current advertising campaign long before the start of the K trade fair. We asked Bernhard Lettner and Franz Pressl, the product managers for the ENGEL duo and ENGEL victory machines, about the secret behind them.

Mr Lettner, Mr Pressl, please don't keep us in sus-pense. What is up with the new generation?BERNHARD LETTNER: Essentially we are talking about even more, two generations – the ENGEL vic-

tory and ENGEL duo. We have developed completely new injection units for these two hydraulic series and have also re-vised the design of the machines at vari-ous points. We will present the results for the first time at the K and are keen to find out how our visitors react. With their new features, the machines achieve even higher levels of precision, ergonomics and efficiency. This will be made clear at our stand.

What does this development mean for ENGEL and the plastics industry? FRANZ PRESSL: The injection unit, to-gether with the clamping unit, form the heart of every injection moulding machine as these two central elements are respon-sible for their performance and efficiency.

One could say that the ENGEL victory and ENGEL duo are almost completely new injection moulding

machines. Injection units are not, after all, enhanced in a trade-fair cycle of every three years. What we are presenting in Düsseldorf is based on many years of development work. LETTNER: This development is also so important because the ENGEL victory and ENGEL duo are the two best-selling ENGEL injection moulding machines worldwide. ENGEL has also worked continuously and consistently on making its hydraulic machines fit for future requirements. The choice of hydraulic, hybrid or all-electric is not a question of philosophy, but depends on the individual requirements of the process and re-spective parts class. What counts are the unit costs. For the production of technical parts, for example, a hydraulic machine equipped with energy-efficient drive technology is often the first choice.

When one works on something for a longer period of time, a lot of experience is usually incorporated...PRESSL: That is exactly how you should see things. The R&D teams and we as product managers work very closely together with colleagues in application technology, in service and in the business units and also visit our customers regularly. We learn a lot from the market and take all this information into account in

ENGEL victory and ENGEL duo with new injection units

For even more precision, ergonomics and efficiency

Bernhard Lettner (left) and Franz Pressl (right)


our developmental work. We often incorporate specific customer wishes and ideas in the standard versions of our new products. On top of that, ENGEL is well-known for delivering answers to very individual and industry or country-specific requirements.

How is it possible to take individual requirements into consideration in the case of injection units, which do not only consist of the customised screw?LETTNER: Through the size range, for example. Based on our long experience with the previous injection units, we have restructured the sizes of the units and also optimised their performance data, such as injection pressure, injection speed and plasticising capacity, for current and future requirements. We are therefore now able to meet the needs of our customers even more specifically than before regarding the injection units when designing machines.

More precision, ergonomics and efficiency – you said this right at the beginning. Let us start with precision. What has happened in this respect? PRESSL: The new injection units permit, at the same screw speed, better plasticising capacities and higher process stability. The controls for this are the tem-perature and pressure in the barrel. Special attention was paid in development to temperature control of the feed throat cooling. 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. We now achieve a significantly better en-ergy efficiency both during cooling and heating of the feed throat. The revised piston design also helps us to improve controllability of the pressures. LETTNER: Precision also always has something to do with variations in ambient conditions and the raw material, and these fluctuations need to be taken into consideration. We have, thanks to our iQ weight control software, been able to detect deviations and compen-sate for them in the same shot in our electric injection moulding machines for some time now. In this way it is possible to prevent rejects and increase productivity actively. This intelligent assistance system is now in

use in more than 1000 machines. Together with our new injection units, we will now present a new version at the K that can also be used in injection moulding ma-chines with hydraulic injection units.

The second important value is ergonomics. How does the new generation make life easier for processors? LETTNER: The main point here is the design of the new machines. We have rearranged the layout of the electri-cal cabinets and pumps in the ENGEL duo, reducing the footprint in some versions. Even more importantly, the machines have been designed so that it is easier to access their components. The new panels now consist of two parts and are equipped with integrated handles. They are very quick to open, which, for example, saves time when servicing the pumps. PRESSL: We have also implemented a big improve-ment in efficiency for changing the barrel on the ma-chine. When the barrel is removed, it can now be put down outside the machine without any need for ad-ditional equipment because we have equipped them with sturdy feet. No special tools are needed to remove or install the barrels, and even with the big units, all that is necessary is to loosen or tighten a few screws. We have also redesigned the electrical interfaces of the barrel heater to improve compatibility and ergonomics. It is therefore now much easier and quicker to change the barrels, which means shorter downtimes. We have applied the principle of quick mould clamping to the barrel.

Various factors play a role in efficiency. For ex-ample, set-up times, rejects and energy.PRESSL: The changes in the feed throat already men-tioned contribute to very high energy efficiency. We investigated the energy flows, for example from heated barrel to cooled feed throat, and were able to make important improvements. On the other hand, we also have ecodrive. These ENGEL servohydraulics, which have proven their worth in many years of use, belong to the standard equipment of the new machine models. Using ecodrive, the pumps work on a need-related basis. The side effects of this are that the machines run more quietly and that the hydraulic oil does not heat up as much, which reduces the workload for cooling.

When can the new machines be ordered? LETTNER: The sales start is at the K. 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.


On its exhibition stand, ENGEL demonstrates how the potential of smart machine can be utilised in practice with the manufacture of the inject 4.0 logo.

With the help of the networking and integration of pro-duction systems, the systematic utilisation of machines, process and production data and the use of decentral-ised, intelligent assistance systems, the manufacturing processes in a smart factory continuously optimise themselves, making it possible to react very flexibly to constantly changing requirements. The result is greater efficiency, productivity, machine availability and quality.ENGEL is making it possible to actually experience the smart factory at K 2016. For all three areas – smart machine, smart production and smart service – is able to support processors, using existing solutions, to tackle the new challenges in their processes. In-dustry 4.0 is nothing new for ENGEL – it has been in practice, in many areas, for a long time, and ENGEL continuously develops its inject 4.0 programme. At ENGEL, experience meets innovation.

smart machine: compensating for any fluctuationsThe human-machine interface will play an increasingly important role in tomorrow's factory. As processes become increasingly complex because of greater

smart machine, smart service and smart production are the three pillars of the smart factory.

inject 4.0 makes the best of your production

inject 4.0 is ENGEL's answer to the challenges of the Fourth Industrial Revolution. At K 2016, ENGEL presents a comprehensive range of well estab-lished as well as brand new solutions for the smart factory.

integration and automation, their management and control must become simpler and more intuitive. Self-adapting, decentralised systems increase process capability and quality, without the machine operator having to acquire additional expert knowledge. For example, the iQ software products from ENGEL continually analyse critical process parameters in order to identify and immediately compensate for deviations, even before rejects are produced. While iQ weight con-trol keeps the injected melt volume constant throughout the injection moulding process, the iQ clamp control software determines the mould breathing to continually readjust the clamping force. Even if the environmental conditions change, or the granulate quality fluctuates, the software solutions keep the process constant and consistently ensure high product quality. With the new iQ flow control, temperature control also comes into focus (page 16).During K 2016, ENGEL will demonstrate how the po-tential of smart machine can be optimally utilized in practice with the manufacture of inject 4.0 logos on an all-electric, tie-bar-less ENGEL e-motion 80 TL injection moulding machine.


smart production: high vertical and horizontal data integrationENGEL's exhibition stand at K 2016 will be a regular small business with seven highly integrated and au-tomated production cells, plus the iQ demonstration injection moulding machine. All production cells are networked using ENGEL e-factory, allowing the current condition of the individual injection moulding machine, their utilisation and output, to be viewed and analysed from a central computer. The MES (Manufacturing Ex-ecution System) of ENGEL has a modular design. The solution is adapted exactly to the processor's individual requirements and is able to grow flexibly with the system according to demand. An energy module that allows the detailed presentation, analysis and optimisation of power consumption is new at the K 2016. It enables ENGEL e-factory to control the start-up of the injection moulding machines and production cells automatically, and reliably avoid any energy peaks. The electricity costs of the machinery are therefore reduced. In many businesses, ENGEL has already developed the basis for consistently tracking individual products through their entire development process, right down to the raw materials. inject 4.0 will make traceability even simpler in the future. The inject 4.0 logos manu-factured by ENGEL on the exhibition stand are each marked with an individually generated QR code. Visitors to the exhibition will be able to get information about when, and under what process conditions, the injection moulded part was manufactured, even after K 2016, by using the QR code on the internet.

smart service: condition-based, predictive maintenanceTo increase the availability of injection moulding ma-chines and manufacturing cells, smart service relies on direct access, remote maintenance and a view into the future. The new ENGEL e-connect.monitor will make it possible to analyse the condition of process-critical core machine components during operation, and reli-ably predict the risk of failure (page 15). Whereas smart machine and smart production solu-tions fall largely within the processor's responsibility, there are several benefits of smart service if ENGEL, as the supplier, is able to access certain data approved by the customer. Mutual trust is important for this but is not enough by far. For data transfer, ENGEL consistently uses state-of-the-art safety technologies, and has its systems checked regularly by independent experts. Furthermore, ENGEL, jointly with its customers and partners, is working to establish OPC UA (Open Plat-form Communication Unified Architecture) as a mode for shared information in the plastics sector, even in the field of condition monitoring. The communication protocol offers great flexibility with its service-based and scalable structure, independent of any platform. In addition, safety features are already an integral part of the architecture.

smart machine: the intelligent assistance systems of the iQ product family, such as iQ weight control, balance out any process fluctuations before any rejects are produced.

smart service: the new ENGEL e-connect.monitor makes it possible to analyse the condition of process-critical machine components during operation,and create a reliable forecast of failure.

smart production: ENGEL e-factory enables the processor to view the entire production process from a central computer.


e-connect customer portal: fit for the smart factory

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, ENGEL 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 as-signed to different halls or departments online.

Status of critical components available onlineNow that the new e-connect.monitor smart service solution has been integrated into the customer portal, the status of critical machine components is avail-able online as well. Condition-based predictive main-tenance 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 devel-oped 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 indus-trial revolution head-on. ENGEL is continually developing new prod-ucts and services for the smart factory. The e-connect portal is

ideally equipped for handling additional requirements, whenever they may arise.

Customers and ENGEL on the same pageService 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 respon-sible 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 de-scriptions 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.


Maintenance staff face an enormous challenge every day. They are expected to guarantee very high availability of the production equipment, while at the same time reduce the costs for maintenance and keep a stock of spare parts. Common maintenance strategies do not completely fulfil these requirements. Because mainte-nance staff do not know exactly what condition the ma-chine is in, components susceptible to wear are often re-placed at predetermined intervals. This reduces machine availability and cost-efficiency, because in many cases the replacement takes place sooner than necessary, and therefore too often. But waiting until a component fails means risking longer downtime, delivery problems and collateral damage to adjacent machine parts. Industry 4.0 now opens up new opportunities through the increased networking of production systems and the systematic utilisation of machine data. The vision of a status-bases, predictive maintenance strategy becomes reality at the ENGEL exhibit at K 2016.

Monitor the screw status during operationThe plasticizing screw of an injection moulding machine no longer needs to be removed in order to assess its condition. To measure wear-relevant parameters during operation, ENGEL has developed a measuring system based on the latest, easy to install, sensor technology. The measurements only take a few minutes, whereas before, the assessment of the screw on a large injec-tion moulding machine often meant the planning of two entire workdays of downtime for the removal, cleaning and measurement of the screw.

The measurement data are analysed using mathemati-cal models and documented so that a reliable forecast of the remaining service life can be made based on the results of repeated measurements. This forecast al-lows maintenance staff to replace the screw at the right time, and to plan the necessary machine downtime in advance. The new screw can be ordered in advance, with delivery just in time for the scheduled maintenance. Thus ENGEL e-connect.monitor reduces the downtime of the production cell and eliminates the need for an in-house stock of spare parts. In the long term, regular condition monitoring aids in process optimisation. Analysing the wear parameters makes it possible to recognise critical process settings that increase the wear of specific components, which can then be avoided by adapting the process corre-spondingly.

Keep an eye on the spindlesThe ENGEL e-connect.monitor is particularly beneficial for process-critical machine components that mainte-nance staff are not constantly focused on. These in-clude the spindles that actuate the axial movements in electrical injection moulding machines. Since there are multiple spindles operating in each machine, and the failure of only one brings the entire production cell to a standstill, condition monitoring of the ball screw drives is done continuously. In future, the data captured by the sensors is transmitted, in real time, to the ENGEL econ-nect customer portal where it is automatically analysed with the help of mathematical and physical models.

The plasticizing screw no longer needs to be removed in order to assess its condition. Within only a few minutes, the sensors of the new ENGEL e-connect.monitor measure the wear-relevant parameters during operation.

Avoid unplanned downtime

Hello machine, how are you doing today? – In the future, injection moulding proces-sors will get more and more answers when they ask this question. The new ENGEL e-connect.monitor makes it possible to check the status of process-critical machine components during operation, analyse the data online, and make a reliable prognosis concerning the remaining service life. At K 2016, ENGEL is demonstrating how this can help avoid unplanned machine downtime, reduce maintenance costs, and even optimise processes with the example of plasticising screws and spindles. ENGEL econnect.monitor expands the ENGEL inject 4.0 programme and sets the next mile-stone on the way to the smart factory.

16_ENGEL injection-201616_ENGEL injection-2016

Fewer rejects and greater energy efficiency

To mark K 2016, ENGEL has consolidated its systems expertise by expanding its range of intelligent peripherals. The new integrated temperature control solutions include the electronic ENGEL e-flomo temperature control water manifold system, temperature control units with speed-controlled pumps and the new iQ flow control software. Together, they improve the stability of injection moulding processes, re-duce rejects and increase energy efficiency.

Automatically regulating pump capacityThe majority of reject parts produced by injection moulding firms around the world are the result of tem-perature control errors. With this in mind, temperature control has been a central focus of product and tech-nology development at ENGEL for many years. For K 2010, the machine manufacturer launched ENGEL flomo, an electronic temperature control water mani-fold system. Replacing high-maintenance cooling water distributors, the system monitors and documents all cooling and temperature control circuits linked to the injection mould. Moreover, the ENGEL e-flomo devel-opment facilitates automatic regulation of the flow rate or temperature difference. ENGEL is taking the next step at K 2016. ENGEL eflomo and the temperature control unit merge at controller level to form a single unit. With the help of the new iQ flow control software, the pump speed is automati-cally adapted to current requirements based on the measurement values determined by ENGEL e-flomo. While ENGEL e-flomo reduces the risk of rejection by enhancing process stability, less energy is required for temperature control thanks to automatic speed control. Since the pump operates according to need rather

than at maximum output all the time, stress on moving parts is reduced and temperature control units have a longer service life. At its stand, ENGEL will present its new temperature control solution in conjunction with temperature control units made by HB-THERM of St. Gallen, Switzerland, which are sold by ENGEL as an integrated solution.

OPC-UA for maximum data securityThe iQ flow control software not only determines the ideal speed in each case, but also makes it possible to operate the ENGEL e-flomo and temperature control unit as an integrated system. All temperature control parameters are set, monitored and logged centrally on the display of the injection moulding machine; the ideal operating point for each temperature regulating device is automatically calculated and set. The CC300 control unit of the ENGEL injection moulding machine and the temperature control unit communicate via OPC-UA. Based on the complete range of functions of OPC-UA, ENGEL has defined a communications model for temperature control units. The strategy is to open this model to allow integration of temperature control units from different suppliers in the future.


ENGEL eflomo and temperature control unit merge at controller level to form a single unit. With the help of the new iQ flow control software, the pump speed is adapted automatically to current requirements.

OPC - UA


In its new design, the ENGEL e-speed now achieves even greater dynamics, precision and energy efficiency.

At K 2016 in Dusseldorf from October 19 to 26, ENGEL will once more underscore is global claim to technological leadership. All applications on display generate high customer benefits thanks to their innovative process technologies, custom-built man-ufacturing concepts and intelligent control technology.

ENGEL to present latest technologies at K

With their innovative drive concept, the injection mould-ing machines of the ENGEL e-speed series guarantee high efficiency at continuous high-speed operation, even with high shot weights and high clamping forces. But ENGEL takes this one step further at K 2016. Thanks to IML integration, long thin-walled packaging can be produced ready-to-fill with injection moulding. For the production of cartridges for the construction and DIY retail sector, an ENGEL espeed 500/90 injection mould-ing machine is being combined with IML automation from Beck Automation. The 16-cavity mould comes from Otto Hofstetter and the system partner for the labels is Verstraete in mould labels. For the first time it is possible to decorate cartridges using IML technology, with the extreme length-to-diameter-ratio requiring specific IML solutions.

Hall 15, Stand C58

Teletronics: process integration with extreme thin-wall technology

Whether notebooks, tablets or smartphones, when it comes to producing handheld devices, the key to less weight and more stability lies in using innova-tive composite materials for the housing. The goal

of a development cooperation project between ENGEL, Bond-Laminates (LANXESS group) and LEONHARD KURZ is to also significantly increase production efficiency. At K 2016, the three partner companies are introduc-ing the revolutionary result of their collaboration: the injection moulding of an extremely robust, fit-for-purpose housing with a sophisticated surface decoration in extreme thin-wall technology. The highly automated production cell was specially designed for the material combination of continuous fibre reinforced thermoplastic preforms and IMD films. It integrates three processing technologies: ENGEL or-ganomelt, ENGEL variomelt and In Mould Decoration (IMD). The heart of the production cell is an ENGEL insert 500V/130 single injection moulding machine with a roll-to-roll IMD unit, an ENGEL easix six-axis robot and an infrared oven.

The housings have a wall thickness of only 0.6 mm.

Infrared ovens for preheating fibre-reinforced semi-finished prod-ucts extend the range of products for peripheral systems stemming from ENGEL's own development and production.

The cartridge production makes optimal use of the ad-vantages of the hybrid machine, which has an elec-tric 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 injec-tion performance. Very short cycle times are achieved despite the relatively high total shot weight of 800 grams.

Packaging: high performance in a new dimension

The cartridge production makes optimal use of the advantages of the hybrid machine.


In-situ polymerisation of εcaprolactam opens up new opportunities in the production of fibre-reinforced com-posite components with a thermoplastic matrix. It makes it possible to achieve highly efficient processes and flexibly designed composite components. Starting with dry, preformed reinforcing fabrics (preforms),

With DecoJect, the desired surface characteristics can be achieved via the film.

Increasingly, IMD technologies are replacing painting in the production of car interiors in order to combine a high quality surface finish with a high degree of flex-ibility for small batch sizes and low unit costs. ENGEL, together with its partners and the DecoJect film-based solution, presents the next development step at K 2016: the combination of injection moulding with IMG (in-mould graining) in a roll-to-roll process. Unlike conventional IMD processes, the paint is not simply transferred from the film onto the component. Instead, the film is punched out and stays on the component. This way, in addition to colour and pattern, surface structure and haptics also come into play. At its exhibition stand, ENGEL will present the DecoJect technology in a fully automated production

The new ENGEL easiCell integrates robots and processing units within a compact space.

the in-situ method combines the polymerisation and moulding process in a single injection moulding machine. Since the presentation of the first prototype machine four years ago, ENGEL has continuously optimised the system components and developed a completely new reactive aggregate that can be combined with different types of ENGEL injection moulding machines. The new unit also differs markedly from the 2012 prototype from a technological viewpoint. As the only provider on the mar-ket, ENGEL can melt and process the solid monomer in a just-in-time manner. The advantages are a significantly shorter material dwell time, a reduced thermal load, and thus increased product quality. Representating the wide range of possible applications, fibre-reinforced shovels are being produced on an ENGEL v-duo 1560/700.

Technical moulding: in-situ polymerisation and injection moulding combined

n-situ polymerisation of εcaprolactam opens up new possibilities for the production of fibre-reinforced composite components.

cell for the first time. On an ENGEL duo 5160/1000 injec-tion moulding machine, sample parts simulating large door panels will be produced. A ready-to-fit component leaves the production cell every 60 seconds. Only the very close interdisciplinary cooperation of many partner companies has paved the way for DecoJect. Besides ENGEL, the project involves the following com-panies: Benecke-Kaliko (Continental Group), Georg Kaufmann Formenbau, the Galvanoform Gesellschaft für Galvanoplastik, hot runner manufacturer HRSflow, ICO SYSTEM international and Borealis. ENGEL made a significant contribution to the high cost efficiency and flexibility of the process with its automation expertise. Together with a laser station for the fine trimming of the film, the ENGEL easix robot is integrated in an extremely compact space in an ENGEL easiCell.

Automotive: DecoJect brings colour, structure and haptics into play

In developing the ENGEL v-duo series, ENGEL has tailored a compara-tively compact and energy-efficient injection moulding machine specifi-cally for fibre-composite applications..


Up to 500 bristles can be moulded with the single-component process.

Medical: single-component interdental brushes with up to 500 bristles

"scrub!" – that is the name of a new interdental brush that pheneo is soon introducing to the market. It will celebrate its exclusive preview at K 2016 because its production process is also a world first. Up to 500 bristles can be moulded directly in single-component injection mould-ing together with the core and the grip. At the fair, the cleanroom version of an all-electric ENGEL e-motion 170/100 T injection moulding machine is being used to process a three-component compound. The eight cavity high-performance precision mould, which is extremely delicate in the bristle area, comes from Hack Formen-bau. Hekuma is responsible for the automation. The presentation showcases a highly integrated, automated production cell which includes camera inspection. To completely fill eight cavities with up to 500 bristles each, at a total shot weight of only 1.93 grams, not only places extremely high demands on the mould, but also

on the injection moulding machine. In order to com-pensate for fluctuations in the ambient conditions or raw material, the iQ products from ENGEL's inject 4.0 programme come into play.

Packaging: integrated injection blow moulding in up to 96 cavities

Injection blow moulding makes it possible to achieve economical production of ready to use small contain-ers in a single step. Previously, however, the number of possible cavities was limited. Together with its system

partners Foboha and Alpla Werke Alwin Lehner, ENGEL has succeeded in developing the integrated process further, for use with multi-cavity moulds, thus reducing cycle times significantly. Based on cube technology, upscaling to up to 96 cavities is possible without com-promising cycle time and accuracy. This significantly reduces unit costs for high production output. Polypropylene containers are being produced on an all-electric ENGEL e-motion 740/220 T WP injection moulding machine in an 8-cavity cube mould built as a proof-of-principle prototype. System partner for the blow moulding technology is Bauer Compressors. As an integrated part of the process, the gas pressure can be controlled via the CC300 control unit of the ENGEL injection moulding machine.

Technical moulding: tie-bar-less for efficient LSR processes

The importance of multi-component technology is grow-ing with increasing momentum in LSR (Liquid Silicone Rubber) processing. In many applications, only the in-tegrated injection moulding process makes it possible to bond thermoplastics and silicone together in stable layers. Pressure reservoir diaphragms used in pressure compensation vessels are an example of this. At K 2016, ENGEL is producing these two-component parts of PBT and LSR on an ENGEL victory 200H/200L/160 combi injection moulding machine with integrated ENGEL viper 40 linear robot. The mould and the LSR metering pumps come from ENGEL's partner Elmet. The LSR is a product delivered by Wacker Silicones. Producing two-component parts makes optimal use of the efficiency potential of the ENGEL victory machine's tie-bar-less clamping unit. The bulky mould extends right up to the edge of the mould mounting platen, and

therefore fits on a comparatively compact 160 ton injec-tion moulding machine.

Up to 96 containers per shot can be produced in the injection blow moulding process.

Virtually flash-, waste- and rework-free, the fully automated pro-cessing of LSR is the prerequisite to the economical production of high-tech liquid silicone products .

Up to 96 containers per shot can be produced in the injection blow moulding process.


Thanks to a swivel arm and innova-tive lightweight construction tech-nology, ENGEL’s new servo sprue picker combines high dynamics with low energy consumption and even lower maintenance costs.

ENGEL expands automation range

Productivity and efficiency depend in no small part on having the ideal automation concept. ENGEL is expanding its range of robots to ensure that both integrated sys-tem solutions for injection moulding and standalone robot cells can be adapted even more precisely to specific requirements. A new servo sprue picker and a SCARA ver-sion of the ENGEL easix will be added to complete the range on different ends of the spectrum.

Servo sprue picker for enhanced dynamics and cost-effectivenessThe new servo sprue picker ENGEL e-pic B is based on the technology of the ENGEL epic Z pick-and-place robot introduced in 2014. To benefit from high dynam-ics, compact design and low energy consumption, ENGEL has developed a brand new kinematic system that combines linear movements with a swivel arm. In contrast to the ENGEL e-pic Z, the new servo sprue picker operates without a Z-axis: it can instead be ro-tated by as much as 110° on the actual pedestal, which means it requires very little space. Another advantage is the reduction in maintenance costs with the absence of an axis. As in the case of the ENGEL e-pic Z, the swivel arm of the servo sprue picker is made of an in-novative composite material that minimises the mass moved while raising dynamism and energy efficiency.

The ENGEL e-pic B was de-signed to manipulate weights of up to 1 kg and work with injection moulding machines with clamping forces of 600 to 2,200 kN. On machines of this size range the installation is made easy and there are no machine specific adapta-tions required – e.g. a pedes-tal for height adjustment. The user-programmable RC16 control unit, introduced with the ENGEL e-pic Z, ensures ample flexibility for the servo sprue picker; it can be inte-grated into the CC300 con-trol unit of ENGEL injection moulding machines. In addi-tion, the servo sprue picker has a EUROMAP 67 interface as standard. The ENGEL e-pic B repre-sents an extremely cost-effective choice wherever sprues need to be removed very quickly and injection moulded parts either fall freely from the machine or are removed manually.

ENGEL easix SCARA model offers faster pick-and-placeIn terms of pick-and-place, the loading of grippers, conveyor tracking, stacking and palletising, four-axis SCARA robots are frequently superior to the larger six-axis robots: they perform more picks per minute and are also cheaper to purchase. Expansion of the ENGEL easix range of industrial robots to include a four-axis version means automation concepts that are even more accurately tailored. As with the six-axis robots in the ENGEL easix series, SCARA robots, which are based on Stäubli technol-ogy, can be integrated fully into the CC300 control unit of ENGEL injection moulding machines. Rather than communicate with an injection moulding ma-chine, the robot directly accesses its database as an integral system component. Since the machine and robot automatically coordinate their movements, overall efficiency is increased; the downtime that normally results from communication interfaces is also avoided. Even where process flows are highly complex, move-ments of the injection moulding machine and robot within the CC300 environment can be synchronised via the machine’s display. Several multi-axis and linear robots can be integrated in one machine control unit simultaneously. ENGEL robots can be connected not only via the CC300 control unit of an injection mould-ing machine, but also with each other. With its ability to network multiple robots into a standalone solution, ENGEL is a pioneer in the plastics industry.

ENGEL easix, now with four axes: SCARA robots frequently achieve greater dynamics in pick-and-place, loading of grippers, conveyor tracking, stacking and palletising.


ENGEL Plasticizing Systems: closer to the customer

More than 20 years’ experience: Günther Klammer heads Plasticizing Systems division.

In the Plasticizing Systems division, all efforts lead to increased benefits for customers: ENGEL’s plasticiz-

ing solutions are targeted to fulfill the customer’s individual requirements while guaranteeing unbeat-

able quality and fast delivery times.

The plasticizing unit is key to the quality and performance of injection moulding ma-chines. 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-ef-fectiveness of a machine. To respond even better to individual requirements of clients, ENGEL has reorganised its Plasticizing Systems division.

Demands on plasticizing units are rising: innovative additives and higher filler content, economising on weight and material, tighter dimensional tolerances and in-creasing requirements for higher surface quality. All these factors are constantly driving develop-ment. “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 com-

ponents,” 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 and support from a single sourceThe recently established process of Concurrent Devel-opment 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 in-teraction with other components of an injection mould-ing 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 re-searching the complex physi-cal 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 annu-ally – a figure set to double by 2020. With this in mind, ENGEL is investing 17 million euros in new machine tools, heat treatment equipment and material flows. A fully integrated CAx process chain will raise produc-tivity even further.

K 2016: stronger performance, shorter cycle timesAt the K 2016 trade fair in Düsseldorf this October, the Plasticizing Systems division will demonstrate its increased capabilities at a special Expert Corner on the ENGEL stand. Among the exhibits on display will be two new screws for the automobile and packaging indus-tries. Developed using innovative simulation models, the automotive screw with optimised non-return valve underwent extensive practical testing with selected clients. Unprecedented performance values are now possible in the manufacture of bumpers and interior parts from PP/PC blends and ABS using ENGEL duo injection moulding machines. The design of the new barrier screw for high performance applications in the packaging industry was enhanced with the aim of re-ducing cycle times. The new screws release their full potential when com-bined with the extensively modified injection units which ENGEL will also be unveiling to a global audience at K 2016.


Ultra-efficient lightweight designSuK Kunstofftechnik GmbH in Kierspe produces around 30 million housing parts each year for door locks, which are mainly found in BMW and Daimler models, but also in VW, Ford and PSA. The platform strategy of the automotive groups causes the volumes of individual components to rise, presenting suppliers with new challenges in certain areas: they have to combine excellent product quality with production that meets the highest standards of efficiency and availability.

Every day, 400 pallets packed with high quality plastic parts leave the plant. In 2007 Martin Witulski purchased the plastics processing firm Schütrumpf & Kückelhaus (founded in 1973), whereupon he renamed it SuK and embarked on a consistent path of growth. After several expansions, a completely new and significantly larger plant was acquired in Kierspe at the end of 2010. The next major phase of expansion is planned for the coming year. Even in 2009, when many processing businesses reported falling sales, SuK grew by more than 30 per-cent. The company achieved turnover of 21.3 million euros in the last financial year with 133 employees. SuK has focused on technologically sophisticated parts from the outset. As processes are continuously opti-

mised, potential efficiencies are identified and quality is enhanced. "There is no future in simple parts in Germany as a location for industry. We have to specialise here," believes Managing Direc-tor Witulski. The door lock components are quite clearly one of the company's spe-

cialities. Another speciality is multi-component parts, which are produced for customers in the automotive, electronics and plant engineering sectors.

The plant has 52 injection moulding machines. Five of them fully utilised around the clock, seven days a week, producing lock components for BMW and Daimler. SuK customers are leading manufacturers of automo-tive lock systems. SuK has been an integral part of the BMW and Daimler project since 2011. Kierspe devel-oped the pre-series moulds, and was heavily involved in optimising the design and processes before series production commenced in April 2014.

Lighter yet dimensionally constantIn terms of product development, the challenge was to reduce component weight compared to previous models while further reducing unit costs. The weight had to be reduced by means of MuCell. "Even in earlier roles I was developing MuCell processes for automo-tive customers”, says Witulski. At that time we were the first in Germany to get a MuCell system from Trexel." Today, SuK buys the production cells as a complete package from ENGEL, including tailor-made automa-tion solutions. Each lock module consists of three individual parts: the 'housing', the inner cover and the external cover. All three parts are geometrically complex, although the inner and outer lock covers are particularly demanding, as this is where the mandrels and the bushings sit that are required for mounting the door lock. Let's take the

MuCell reduces the component weight by ten percent.


example of Daimler. Two step mandrels, one large and one small, are inserted into the mould and overmoulded with PBT in the MuCell process. The manufacturing cell for this comprises an ENGEL victory 180 injection moulding machine, a 2+2-cavity mould – in which two parts are formed for the left and right door in paral-lel –, two ENGEL viper robots – sizes 6 and 40 – and an automatic box changing system. A fully automated process is the precondition for highly efficient series production. For each shot, the smaller ENGEL viper 6 positions four small and four large step mandrels on the lay plate. Here the large ENGEL viper 40 picks up the entire set, places the metal inserts in the cavities and takes the four finished parts. The quality of finished parts is also checked as part of the ongoing process. There are sensors in the gripper that monitor the end of the flow path of the component.

Saving valuable secondsAutomation is one key to the high efficiency of the process; reproducible component quality is another. Foam injection moulding ensures that even tight areas and undercuts are reliably filled. Moreover, the cooled components do not show any sink marks or warpage. "Dimensional stability is required for automated as-sembly," explains Production Manager Sven Wieland. "Another point is even more important, however. If the parts are not a perfect fit, this can result in unwelcome noises that are unacceptable these days."Last but not least, the precision of the injection moulding machine's clamping unit also contributes to high repro-ducibility. However, the decision to opt for a tie-bar-less ENGEL victory machine was taken for quite different reasons. "Tie-bar-less technology has enabled us to use a significantly smaller machine and thereby keep our investment and operating costs low," reports Rainer Heller, technical manager at SuK. The automation also benefits from barrier-free access to the closing unit.

"The fact that the robot can access the mould area from the side shortens the cycle time by 2 to 3 seconds," according to Wieland. "If we have to plan a contingency of two to three seconds in any new enquiry, we might not even get shortlisted."The example of door lock component production shows how many different efficiency factors have to be con-sidered to be successful in large-scale, automotive production. "For every application we decide together with ENGEL what the ideal solution should be like”, stresses Witulski. “The fact that ENGEL is a family-run business is an advantage for us. The channels are short, and our contacts at the Hagen subsidiary have considerable scope to make decisions."

Focus on Industry 4.0Early on, Martin Witulski started thinking about the time after his retirement from professional life to ensure long-term success. Many possibilities were evaluated, and the company was finally sold to Luxshare two years ago. Based in Dongguan, China, Luxshare focuses on cable assembly and connectors with the goal of expanding the automotive division further. "Our techno-logical expertise is an important add-on for Luxshare," says Witulski. "For us, it is now much easier to work the very rapidly developing Chinese automotive market."SuK and Luxshare now tackle many new challenges together. Witulski has no doubt MuCell will continue to grow in importance worldwide. In terms of flexibility, SuK is happy to look beyond the confines of its own sector. "An online mail order company can supply to Berlin and the surrounding area within two hours. We want to learn that lesson. Aside from quality, speed will be decisive in terms of competitiveness in the future." Industry 4.0 should help with this in mind. "We want our customers to be able to view the status of their orders online at any time. Another project will be about monitoring our production via smartphone."

From left to right: Managing Director Martin Witulski, Production Manager Sven Wieland, Technical Manager Rainer Heller, Christof Born from ENGEL Deutsch-land, Commercial Manager Gabriele Taferner and Production Manager Kyriakos Schoinas.

Barrier-free access to the mould area makes manual intervention easier.

An ENGEL viper 40 and an ENGEL viper 6 robot working hand in hand.

A new generation takes shape.

Take the proven and tested, make it even better and explore something new – that is what makes ENGEL and their customers so successful. Following our claim be the fi rst, we will present a new generation of injection moulding machines setting new standards at K 2016. For now, we will entice you with this: We do not compromise on energy efficiency, ergonomics or precision. Do you want to know more? Meet us at stand C58 in hall 15, starting October 19.

Visit us

at K 2016

in Düsseldorf,

Germany

Hall 15

Stand C58

www.engelglobal.com

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inject 4.0 makes the best of your production