PLASTICS - coldjet.com · Monterrey, Mexico Europe ... cern for plastic part manufacturers in maintaining ... INJECTION MOLD CASE STUDY THE SOLUTION

the force of nature

Plastic Mold Cleaning & Surface Preparation using Dry Ice MicroParticles

E D I T I O NPLASTICS

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Images shown are for representative purposes only. Products may vary from the images displayed. Cold Jet is not liable for typographical errors or changes to specifications presented.

the force of nature

Introduction: Less downtime. High quality products. p3

About Cold Jet p4

We are Cold Jet p5

Cold Jet Worldwide Presence p6

What is Dry Ice Cleaning? p7

Dry Ice MicroParticles p8

Industry Overview: Plastics p9

Application Overview p10

• Automotive Mold Cleaning p10

• Deflashing & Deburring p11

• LSR & LIM Mold Cleaning p12

• Automated Surface Preparation p13

Cold Jet Solution: Plastics Edition p14

Cold Jet Innovation p15

Industry Leaders look to Cold Jet

• Case Study: Brinkmann p16

• Case Study: Marquardt p18

Cleaning Comparison p21

Automated System Solutions p22

The Right Solution for Plastic Mold Cleaning & Maintenance p23

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www.coldjet.com www.icetechworld.com


Images shown are for representative purposes only. Products may vary from the images displayed. Cold Jet is not liable for typographical errors or changes to specifications presented.

the force of nature

Less downtime. High quality products.Sustainable in-machine mold cleaning and surface preparation using dry iceMicroParticles

Dear Customer,

For plastic processors, there is a great demand to increase the productivity of their equip-ment and the quality of their parts, while maintaining healthy margins. This can be a balanc-ing act between using the most effective technology while working within a shrinking budget.

Mold cleaning remains a critical component of producing quality products. Cleaning mold cavities and vents of resin off-gasses, cured material and mold release agents can prevent a variety of molding problems: burn, sticking parts, short shots, plate-out, contamination, blemishes and flash. Mold cleaning is often delayed because traditional methods cause ex-tended downtime and often involve the use of chemicals or mechanical means harmful to employees and abrasive to the tooling, wearing away critical mold tolerances.

We at Cold Jet understand this problem and offer solutions to clean molds more often, faster, cheaper and non-abrasively, in a sustainable, environmentally responsible manner. Cold Jet Dry ice Environmental Cleaning and Surface Preparation systems afford a proven solution to accomplish these goals and increase productivity, part quality and extend the asset life of the mold.

Cold Jet also anticipates to the new trend in plastic mold cleaning, which is an integrated cleaning solution to our customers actual automated product line. Cold Jet and our systems are prepared for an easy integration to fullfill our customers automated cleaning needs.

Our dry ice technology is proven to clean molds better, while reducing cleaning time up to 75% without causing mold wear. Today, proven lean manufacturing management metho-dologies, such as 5S and TPM, are encouraging organizations to embrace maintenance as a critical business function.

The excellent cleaning capability of cleaning with dry ice MicroParticles while the mold is still in the press is an important step to make quality and productivity gains in the plastics indus-try. Cleaning with Cold Jet dry ice is an effective, environmentally responsible solution to al-low processors to do more with less time, less resources and with less impact on production.

Yours sincerely,

Steve WilsonGlobal Key Account Manager Plastics & Rubber




About Cold JetCold Jet has been pioneering the research and development of dry ice blasting and setting the standard for quality, performance and reliability in the field for more than 30 years. Since our inception in 1986, we have been recognized as the leader in dry ice technology, earning certification from the Canadian Standards Association, the German TUV and the Japanese HPGCL. And in the US, our dry ice blast systems meet all USDA, FDA and EPA guidelines.

Founded on the idea to create cost-effective, environmentally responsible and technologically advanced dry ice solutions, Cold Jet is committed to satisfying the growing worldwide demand for advanced dry ice solutions in new and innovative ways. At Cold Jet, our past is driving our future.




• The leader in dry ice blasting and dry ice production technology, developing superior dry ice blast cleaning systems to meet every unique cleaning application

• Committed to offering the widest selection, most reliable and dependable dry ice blasting systems, dry ice production equipment, engineered systems and nozzles on the market

• The first and largest dry ice technology company in the world, with 200+ direct employees and more than 100 contractors and distributors

• An expert team of aerospace and mechanical engineers, technical sales specialists and manufacturing, production and support personnel

• Engineering, R&D, production and assembly operation, located at our World Headquarters in Loveland, Ohio, USA

• High-tech machining and manufacturing facilities, located in Milford - Ohio, Oborniki - Poland and Bramming - Denmark - with state-of-the-art equipment and cutting-edge processes (including Electrical Discharge Machining, providing detailed machining to tolerances of only +/- 0.0001”) to ensure the highest quality precision product manufacturing

• A global presence with US Headquarters – Cold Jet LLC – located in Loveland, Ohio, European Headquarters - Cold Jet Europe bvba – located in Zellik – Belgium, Asia Headquar- ters located in Tokyo – Japan and direct sales and support of offices and technical training centres in Canada, Mexico, Germany, Spain, Denmark, Poland, China and the Middle East for local on-site testing and validate the effectiveness of dry ice cleaning on parts and specific cleaning applications

We are Cold JetThe global experts in environmentally sustainable cleaning, surface preparation and transport cooling solutions

Cold Jet pioneered dry ice blast cleaning and we are the global experts in dry ice production technology

pioneeredpioneered




Cold Jet Worldwide PresenceProviding direct global and local support via distribution channels

AmericasUSA-Cold Jet,LLC (World Headquarters)Loveland, Ohio+1 513.831.3211

Cold Jet WestRancho Cucamonga, CA

Cold Jet CanadaOntario, Canada

Cold Jet LatinoaméricaMonterrey, Mexico

EuropeCold Jet Europe bvba (European Headquarters)Zellik, Belgium+32 13 539 547

Cold Jet Deutschland GmbHWeinsheim, Germany+49 6551 9606-0

Cold Jet S.L. Spain

Icetech A/S Denmark+45 76 56 15 00

Icetech PolandPoland

OFFICES Cold Jet Sales & Service Support:AustriaBENELUXFranceIrelandPolandSwitzerlandUK

AsiaCold Jet Japan(Asia Headquarters)Tokyo, Japan+81 3 68692665

Cold Jet ChinaShanghai, China

PARTNERS

AmericasBrazilChile

Columbia

EuropeBaltic States

BulgariaCzech Republic

FinlandGreat Britain

GreeceHungary

IberiaItaly

IrelandNorway

RomaniaRussiaSerbia

SlovakiaSloveniaSwedenTurkey

Asia & OceaniaAustralia

IndiaIndonesia

JapanMalaysia

SingaporeNew Zealand

PhilippinesThailandVietnam

The strenght of Cold Jet is our global knowledge and our local presence via the Cold Jet offices and our global network of hundreds of business partners all over the world. This gives Cold Jet the ability to offer technical suppor 24 hours a day, 7 days a week.

Cold Jet = Global Presence -Local Support




How it works...Instead of abrasive media to grind surfaces (and damage them), Cold Jet uses dry ice (Solid CO2) accelerated at supersonic speeds that sublimate upon impact and lift contaminates from substrates.

What is Dry Ice Cleaning?

While pellets are most suitable when removing heavy, thick contaminants, shaved ice is ideal for cleaning delicate substrates, intricate geometries or tiny openings.

• The versatile Microparticles Series features our patented dry ice block shaving and feeder technology, providing a powerfully gentle and precise clean.

• The revolutionary Performance line features our SureFlow System, ensuring a reliable flow of dry ice pellets for a superior and efficient clean.

Patented technology for superior results:

The patented MERN nozzles make it possible to define the size of the pellets during blast cleaning. Whether pellets or finest particles - you select the correct settings during the cleaning process without any time delay.

Cold Jet nozzles feature MERN Technology used by NASA

VARIABLE FRAGMENTING MERN NOZZLE




Cold Jet’s patented, shaved dry ice MicroParticle technology provides the most thorough clean for many applications. By shaving dry ice media into the finest MicroParticles, more particles enter the air stream and strike the surface per second than traditional methods, quickly removing the contaminant and providing the fastest clean. The sugar-sized, shaved MicroParticles will enter the hardest-to-reach places and are small and delicate enough to pass through sensitive materials (like vents) for a thorough clean without worry of damaging the surface.

Managing consumables is important when incorporating dry ice cleaning and shaved MicroParticles will save you time and money. Due to the particle size, less compressed air is needed to propel the shaved MicroParticles to peak velocities, resulting in a much quieter clean. In addition, the improved particle coverage and particle strikes per square inch when shaving reduces the amount of dry ice required for cleaning.

MicroParticle Systemsi3 MicroClean®

• Accepts pellets, nuggets or block with patented shaved technology

• Designed for absolute precision• Easy to maintain with removable

panel design• Table-top footprint, includes

cart for mobility

vs.

SDI SelectTM 60• Uses any form of dry ice

(standard block, 3mm pellet, nugget slice, leftover scrap)

• Bypass for full 3mm pellet performance

• Clean from as low as 1.4 m³/min, using 1/3 of the compressed air and reducing noise levels and air usage

• Increase blast pressure up to 17.2 bar to clean the most stubborn contaminants

3mm pellets

Faster Because the surface is hit by more MicroParticles at a time, it is cleaned faster and more evenly

Quieter When compared to pellets or fragmented pellets, MicroParticles produce less noise, resulting in a better working environment

Safer MicroParticles minimize the risk of damage to surfaces, vents, ducts, bridges, high gloss polished forms or ejectors

Flexible Due to size, MicroParticles are able to reach areas where pellets and conventional methods can not

Economical Less power and kinetic energy are needed to accelerate MicroParticles, significantly reducing dry ice and compressed air consumption

Shaved dry ice technology - MicroParticles 3mm pellets

Dry Ice MicroParticles The finest MicroParticles for the fastest and most efficient clean




Industry Overview: Plastics Increase productivity, improve product quality

A Faster, Better CleanClean mold cavities and vents are a major concern for plastic part manufacturers in maintaining today’s high quality standards. The build-up of unwanted surface residues from either the product mix itself, mold releases or the labeling process can create various problems, ranging from product release (“knock out”) to inferior product quality and possible damage to tools.

Flash on the product also creates challenges for manufacturers. Mold halves leave a parting line in the final product, and that parting line, or flash, must be removed for product quality.

Traditional cleaning and deflashing methods involve tedious and ineffective manual processes using chemicals and hand tools. Cold Jet’s alternative cleaning process provides a non-abrasive and environmentally responsible method that allows molds and product to be cleaned in a fraction of the time, allowing increased cycles between preventive maintenance. In addition, molds can be cleaned hot and in-place, without water, chemicals or creation of secondary waste.

KEY BENEFITS APPLICATIONS• Improve product quality• Reduce scrap• Reduce production downtime• Reduce cleaning time and labor costs• Clean in-place, no disassembly required• Non-abrasive, no damage to product or equipment• Environmentally responsible; no secondary waste

PRODUCT FINISHINGDeflashing & Surface / Parting Line VentsGloss LevelingDeburring Machined Parts

GENERAL MOLD & TOOLING CLEANING

Blow Molds Compression Molds

Extrusion DiesInjection Molds

Thermoform MoldsPlastic Injection Screw BarrelsUrethane Molds and Overspill

Plate out and Off Gassing

Join industry leaders already benefiting from Cold Jet dry ice cleaning systems.

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Automotive Mold Cleaning

The SystemCold Jet’s i3 MicroClean is a non-abrasive dry ice cleaning system that extends the life of your molds by eliminating the need for harsh chemicals, wire brushes and abrasive pads. It also does not create any secondary waste. When reducing costs, improving quality and increasing productivity are vital, let Cold Jet’s dry ice cleaning solutions help you clean molds, deflash molded parts and prepare surfaces prior to painting. The Benefits

• Designed for precision applications• Low noise operation

• Easy to maintain with removable panel design• Pneumatic circuitry regulates pressure loss and

reduces moisture buildup• Minimal air/ice usage

Increased Production. Improved Quality. Extended Asset Life.Cold Jet’s Environmental Cleaning and Surface Preparation (ECaSP) systems have helped automotive molders meet stringent

industry demands: 6-Sigma, Kaizen, 5S, TPM (Total Productive Maintenance) and annual cost downs. Our systems enable

molders to optimize their manufacturing process by cleaning contaminants from cavities, vents and hard-to-reach places faster,

better and more economically than traditional methods. This can reduce cleaning times by as much as 75% and decrease

annual mold cleaning costs by as much as 45.000 euro.

INSTRUMENT PANELS

DOOR HANDLES

AIR INTAKE

HEAD LIGHTS

FRONT GRILL

BUMPER

GEARS

TAIL LIGHTS

WHEEL COVERS

RUNNING BOARDS

Mold Cleaning Textured PP

Mold Cleaning & Deflashing ABS

Mold Cleaning PEI

Mold Cleaning PC

Mold Cleaning ABS

Mold Cleaning & Deflashing RIM

Mold Cleaning PEEK

Mold Cleaning PC

Mold Cleaning ABS

Mold Cleaning PBT

i3 w/ #13865-256 Nozzle

i3 w/ #13865-256 Nozzle

i3 w/ #13865-256 Nozzlei3 w/ #13865-256 Nozzle

i3 w/ #13865-256 Nozzle

i3 w/ #13865-256 Nozzle

i3 w/ #13865-506 Nozzle

Aero 80FP w/ 323-S1 Nozzle




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i3 w/ #13865-506 Nozzle


Deflashing & Deburring

The SystemWhen it comes to product finishing, Cold Jet’s i3 MicroClean systems can be used to deburr or deflash products manually or robotically - or can be integrated into your manufacturing process. The i3 MicroClean utilizes Cold Jet’s patented MicroParticle technology to create a greater flux density of dry ice particles, resulting in a faster, more uniform burr or flash removal without causing part damage. Cold Jet’s i3 MicroClean systems are often integrated into fully automated production cells.

The Benefits• Designed for precision applications

• MicroParticle technology• Low noise operation

• Safe operation• Increased blast pressure

• Continuous, consistent particle flow• No ice clogging

• Minimal air/ice usage• Pulse-free cleaning

• Easy to maintain with removable panel design

Surface Preparation SolutionCold Jet’s Environmental Cleaning and Surface Preparation (ECaSP) systems were developed to improve quality and lower

operating costs for manufacturers with parts that have flash or burrs. Our automated systems eliminate the need for manual

deflashing or deburring, thus improving part quality, increasing productivity and lowering cost. Our systems can safely remove

flash and burrs from a variety of materials: PEEK, PBT, Acetal, Nylon, LCP, ABS, UHMWPE, Nitinol, etc. without causing part

surface damage.

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LSR & LIM Mold Cleaning

The SystemCold Jet’s i3 MicroClean is a non-abrasive cleaning system that extends the life of a mold by eliminating the need for harsh chemicals, wire brushes and abrasive pads. Dry ice cleaning is faster and more effective than traditional methods. The small particle size of the patented shaved dry ice i3 MicroClean system also enables molders to clean a variety of mold surface finishes, including matte or textured surfaces.

The Benefits• Designed for precision applications

• Low noise operation• Easy to maintain with removable panel design

• Pneumatic circuitry regulates pressure loss and reduces moisture buildup

• Minimal air/ice usage

Increased Production. Improved Quality. Extended Asset Life.Cold Jet’s Environmental Cleaning and Surface Preparation (ECaSP) systems have helped Liquid Silicone Rubber (LSR) and Liquid Injection Molded (LSM) Silicone Elastomer molders meet stringent industry demands. Because silicones flash very easily, molds for these high performance thermoset elastomers are manufactured to critical tolerances, often +/- .0002 inches. Protecting the critical dimensions on parting lines and sealing surfaces, as well as the mold surface finish is vital. It is also important to keep the vents open in order to evacuate the air out of the mold prior to injection – this helps to produce high quality molded parts.

With Cold Jet dry ice cleaning, you can clean molds in the machine at processing temperature (typically 250-400 degrees Fahrenheit), without causing mold wear – thus, increasing production capacity and improving product quality.


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Automated Surface Prep

The SystemThe IceTech COMBI 75 is an automated, non-abrasive cleaning system that prepares the surface of molded parts prior to painting. The fully automated COMBI 75 will produce on demand up to 165 lbs (75 kg) per hour of consistent, high density dry ice using liquid CO2 and electric power. The IceTech COMBI 75 continuously produces dry ice pellets directly into the hopper of the dry ice blasting unit. From there, the dry ice pellets are tranported through a distribution system to one or more blasting applicator or robot.

COMBI 75 The Benefits• Ability to integrate with robotic controls

• Reduce consumable costs through just-in-time manufacturingwith no storage waste

• Superior cleaning performance• Reduce labor and associated costs

Reducing operating costs & increase production Cold Jet’s Automated Environmental Cleaning and Surface Preparation (ECaSP) systems were developed to improve quality

and lower operating costs for manufacturers with paint lines. Our automated systems eliminate the need for powerwashing

or chemical cleaning prior to painting, thus saving companies up to 50% on their cleaning operating costs. Our systems can

safely remove a variety of contaminants from the parts, including oil, dust, release agents, finger prints, etc. without causing

part surface damage.

CO2

PELLET OUTLET FOR EXTERNAL USE

INTEGRATED MACHINE




Clean mold cavities and vents are a major con-cern for plastic part manufacturers in maintaining today’s high industry standards. Cold Jet has de-veloped an all new Plastics Edition – a com-prehensive application solution that provides ac-cessories to best clean mold cavities and vents in the press at operating temperatures and also deflashes/deburs parts, thus reducing production costs, minimizing downtime and improving quality.

When precision counts, the single hose electric i3 MicroClean featuring Cold Jet’s patented shaved MicroParticle technology is your best choice. This environmentally responsible system enables you to safely clean delicate surfaces and complex cavities and crevices that other machines can’t reach— with-out surface abrasion, disassembly or harmful sec-ondary waste.

The new Aero 40FP & Aero 80FP – Plastics Edition is a full pressure dry ice cleaning system packaged with accessories that will provide the best clean for your environment. The Aero 40FP & 80FP is a Performance Class machine utilizing our advanced SureFlow pellet

technology, featuring an isolated, insulated hopper with advanced agitation, internal pressure regulator, full pressure dosing system, coated aluminum rotor and is equipped with plastics-friendly accessories. The Aero 40FP & 80FP – Plastics Edition improves quality, increases productivity and reduces cost for the end user. The Aero 40FP-80FP use the Aerotech Nozzles for a faster and more aggressive cleaning.

Our Industrial line- for lighter industrial environ-ments- existing out of the Elite 20, Xtreme 40 and Xcel 6 feature a stainless steel frame. It comes stan-dard with quick disconnects making it very mobile. When coupled with the IT3 Nozzle Kit – is very versa-tile and will handle a lot of different air supply situa-tions.

Whether you choose a Cold Jet pellet or shaved ice technology system, the Cold Jet experts assists you in make the right equipment choice, fully adapted to your cleaning application needs and aligned with your budget.

Cold Jet Solution: Plastics Edition Setting a new standard in plastic mold cleaning





Cold Jet Innovation

Cold Jet has the widest selection of nozzles. Our MERN nozzles are designed for advanced performance offering the most flexibility for any application. They won’t clog, and can be adjusted for aggressive or sensitive cleaning. The patented MERN nozzles make it possible to define the size of the pellets during blast cleaning.

0 = PELLETMaximum aggression for removing the toughest contaminants

1= MEDIUM FRAGMENTINGAggression with control

2= FINE FRAGMENTINGPower and precision

3 = EXTRA FINE FRAGMENTINGGentle cleaning on delicate substrates

Our engineering (aerospace and mechanical) and production experts collaborate to ensure the best product design, implementation and reliability based on our customer’s needs.

Sealed LidEliminates Moisture

Stainless Steel Insulated, Isolated Hopper

Reduces Sublimation & EnsuresReliable Feed Rate

Advanced Radial Feeding System

Aerodynamic Loading Reduces Wearon Pads & Rotor

Enhanced SureFlow SystemConsistent and Continuous Blasting

Hopper VibratorsKeeps Dry Ice Fluidized

Tilt-out HopperAn Automatic Tilt-out Hopper to Quickly & Easily Unload and Preserve Unused Ice

Cold Jet’s Patented Nozzle Technology for Superior Cleaning Results

Cold Jet nozzles feature MERN Technology

used by NASA





Brinkmann GmbHREDUCED TIME REQUIREMENTS AND COST;INCREASED JOB SAFETY AND ENVIRONMENTAL PROTECTION

INJECTION MOLD CASE STUDY

COMPANYBrinkmann Formenbau GmbH www.brinkmann-formenbau.de

APPLICATIONCleaning injection molds and punching tools

COLD JET SYSTEMi3 MicroClean®

BENEFITSOptimized maintenance and repair of injection molds and punching tools.

Cleaned injection molds in just 45 minutes.

Cleaned areas with difficult access, without further disassembly.

Improved job safety while remaining environmentally responsible.

“WITH THE i3 MICROCLEAN, WE CAN CLEAN DIFFICULT TO ACCESS AREAS; SO THAT WE CAN CLEAN INJECTION MOLDS AND PUNCHING TOOLS WITHOUT FURTHER DISASSEMBLY.“

THE SITUATIONBrinkmann Formenbau GmbH manufactures in the Lower Saxony city of Mühlen, Germany, with approximately 50 employees who spray-cast, stamp and foam tools for the automotive, agriculture, sanitary and medical industries. Tools with a total weight of 27 ton is no challenge for the company. The company provides services ranging from the development and design of various innovative products via rapid prototyping to designing and manufacturing tools and the injection molded products.

With continuous CAD and CAM technology, in combination with modern machine park, the injection molding tools are developed and implemented by the first sampling to series production stage in close consultation with the customer. The product portfolio is completed by the possibility of tool procurement and project planning in the Asian market. To ensure the functionality of both the tools from Germany and the Far East – as well as from foreign tools – the company offers also a maintenance and repair service.

THE TASK“When we receive the tools for maintenance, they are usually very dirty and first need to be cleaned,”

Industry leaders look to Cold Jet:

said Roman Baev, Assembly Department Employee at Brinkmann Formenbau. “Deliveries are made especially for large tools disassembled, but dismantling work is also required. Until recently, we cleaned with mold cleaners and solvents as well as ultrasonic bath because the delicate surfaces and contours of the forms should not get any scratches or other traces. Cleaning this way required a lot of time. To clean a larger form with sliders, we needed two or three co-workers to spend six hours and still, the result was sometimes lacking. In addition, the cleaning agents gave off an unpleasant odor.”

THE COLD JET SOLUTIONIt is therefore not surprising that the workshop manager at Brinkmann Formenbau searched for an alternative cleaning method – and found the right solution with an innovative i³ MicroClean dry ice cleaning system from Cold Jet. Cold Jet’s cleaning medium is pressed block carbon dioxide as a recaptured by-product of chemical or industrial processes; therefore, it is environmentally responsible CO2 which does not contribute to the greenhouse effect. For cleaning the smallest areas, odorless MicroParticles





Industry leaders look to Cold Jet:

are scraped off the dry ice block via Cold Jet’s patented technology. MicroParticles provide a finer blast cleaning, allowing gentle yet highly effective treatment for easy-to-damage surfaces when compared with conventional dry ice pellets. Cold Jet’s i3 MicroClean system operates quieter than a dry ice pellet system.

“A Cold Jet employee came to our company and demonstrated the device,” said Baev. “We could work on our own with the system and it was impressive how quickly and thoroughly the contaminant was removed. After we decided to move forward with the i3 MicroClean, several of our employees were trained on the system.”

THE RESULTSThe compact i3 MicroClean system is at Brinkmann Formenbau, placed on a transport cart so it can be driven comfortably to the cleaned forms. The employees work with two different blast nozzles: a fan nozzle at 2.2 cm (0.88”) blast swath is used to clean large areas and the round nozzle is used to remove stubborn contaminants and dirt from undercuts, edges and corners.

“The mobility makes our work much easier,” said Baev. “We connect the i3 MicroClean to the air pressure and power supply, connect the integrated grounding cable and it is ready to blast. We can also clean difficult areas to access. We can clean injection molds and punching tools without further disassembly.

An ergonomically designed applicator with an integrated LED light provides optimum illumination of the areas to

be cleaned. Air pressure and the amount of dry ice can be individually adapted to the respective surface and the degree of contamination; therefore, a more economical possible use of compressed air and dry ice is ensured. An optimal result with all tools and forms is also achieved.

“For earlier cleaning tasks, two or three people needed several hours and now, we can do it in just 45 minutes – and completely without chemicals,” said Baev. “We are not only significantly more economical, but have also shown improvements in labor and towards the environment.”

“FOR EARLIER CLEANING TASKS, TWO OR THREE PEOPLE NEEDED SEVERAL HOURS AND NOW, WE CAN DO IT IN JUST 45 MINUTES - AND COMPLETELY WITHOUT CHEMICALS.”

BEFORE AFTER




Industry leaders look to Cold Jet: Marquardt GmbH

CLEANING INJECTION MOLDS WITH SMALL MICRO DRY ICE PARTICLES - RELIABLE PROCESS TO INCREASE PRODUCTIVITY


COMPANYMarquardt GmbHwww.marquardt.com

APPLICATIONCleaning injection molds

COLD JET SYSTEMi3 MicroClean®

BENEFITS• 95% less cleaning equals less machine downtime• A cleaning time of 4 hours is reduced to 5-10 minutes with

Cold Jet dry ice cleaning• Significantly increased productivity• Optimized process reliability • Complete optimization of production process

“THE MACHINE GETS ADJUSTED AND THE CLEANING WORK GETS DONE WITHIN FIVE TO TEN MINUTES. COMPARED TO THE FOUR HOURS WE HAD BEFORE, THE PRODUCTIVITY INCREASED SIGNIFICANTLY.”

THE SITUATIONIn the production process of injection molded parts, the tool cleaning is a crucial but unproductive step. Marquardt solved this issue with an innovative dry ice cleaning system. The system reduces cleaning time and machine downtime by 95% while improving process security.

In every vehicle from well-known automotive suppliers you can find mechatronic or electromechanical Marquardt GmbH parts. A Rietheim based, independent, family company, Marquardt GmbH is the international leader in supplying driving systems and control panels. In addition to vehicles, you can find Marquardt products in control and operating panels in household equipment and other industries. Marquardt is also the world leader in electric tool switches. The company employes 8,500 employees in 14 locations and 10 countries.Annually, Marquardt invests 10% of its turnover into research and development.

THE PROBLEMModern development tools, simultaneous engineering and effective experimentation are equally important in high-modern injection molding. With 100 machines, the company produces around 3,000 different products. There was one step in the work process that was still done manually: the cleaning of the injection molds.

“Clean tools are a must for the product quality,” explains Dieter Stais, product manager of Marquardt for Riethem-Weilheim. “Contaminants cause damaged parts and waste. Therefore we clean in fixed cycles.”

For manual cleaning, the tools needed to be removed, installed and aligned again. That’s why they had a production downtime of 4 hours. In addition, the cleaning was not guaranteed, reliable and became staff related. It could also not be excluded, as the mechanical cleaning could lead to damage or increased wear on the tools. This process needed to be optimized.





THE SOLUTIONThe solution was the innovative dry ice cleaning system: The Cold Jet i3 MicroClean-S4.

”The theme of dry ice cleaning was actually already closed,” said Dieter Stais. “The reason for that was a Cold Jet competitor came by with his equipment and asked us to try it. Dry ice cleaning with pellets didn’t function and the machines couldn’t be adjusted to our needs. With Cold Jet, the representative did some testing on the injection molds and adjusted the system to our needs.”

To make sure the system was the best solution, Marquardt tested the equipment for 4 weeks.

With the MicroClean system, the carbon dioxide comes in the form of ice blocks. The blocks are made of carbon dioxide which is captured as a by-product in chemical or industrial processes. It is reclaimed CO2 and does not contribute to the greenhouse effect. This by-product is created with, for example, the brewing of beer, and can be ordered as a standard industrial gas over the corresponding trade. For cleaning, micro-particles are scrapped of the dry ice block with the patented shaved ice technology. These particles have, in comparison to pellets, a more refined blasting swath, allowing a more smooth and effective treatment. At the same time, the i3 MicroClean-S4 operates much quieter.

“With this dry ice cleaning technique, we can clean our injection molds hot in the press and without disassembly,” reported the production manager.

This is possible, on one hand, as blast pressure and ice volume are adjustable. On the other hand, there are different high performance nozzles. For the cleaning of

wide areas a nozzle with a blast swath of 2.2 cm would be appropriate. The low flow round nozzle guarantees a punctual and reliable removal of persistent dirt. The cleaning of difficult-to-reach areas and undercuts are done with a 90° angled nozzle. In addition, a rotary union allows the nozzle to turn 360° and to reach all areas. During the work, the ergonomically designed applicator with integrated LED-light gives optimal illumination for the areas that need to be cleaned.

THE RESULTSTo clean, the mobile and compact device can be easily moved to the injection molds and then connected to the compressed air supply and the static cable.

“The machine gets adjusted and the cleaning work gets done within five to ten minutes,” said Dieter Stais. “Compared to the four hours we had before, the productivity is increased significantly.”

The i3 MicroClean reduces cleaning time up to 95%; therefore, it paid for itself within a very short time. This is an aspect the people at Marquardt were very pleased with. Another aspect is the optimzed process reliability.

“Unlike manual cleaning, we can certainly remove contaminants with dry ice cleaning,” said the production manager. “This also results in a contribution to the overall optimization of our production process.”

“UNLIKE MANUAL CLEANING, WE CAN CERTAINLY REMOVE CONTAMINANTS WITH DRY ICE CLEANING,” SAID THE PRODUCTION MANAGER. “THIS ALSO RESULTS IN A CONTRIBUTION TO THE OVERALL OPTIMIZATION OF OUR PRODUCTION PROCESS.”

BEFORE AFTER

Due to the big succes of cleaning injection molds with the Cold Jet i3 MicroClean, by end of 2016,

5 production facilities worldwide of Marquardt (and more to follow) will apply the i3 MicroClean in their

cleaning process, to save time and money!




“If you need to clean 96 cavities by hand, it is not only time consuming but also hard to reach each crevice and angle, ” said Hans Kolb, Process Engineer at Hans Geiger. “Cleaning by hand in the machine was not very effective.

Depending on the mold, 20 man-hours and up to 2 employees were needed. In addition, there was always the risk of damaging the mold, thereby reducing the lifespan of the equipment and tools needed to be replaced.”




Variables Production Maximum, Mold Cycle time, Profit per preform, … Not taken in consideration: Savings by labor cost, Reduced repair costs, Extended equipment life time.

Cleaning Comparison Dry Ice Cleaning compared to manual Cleaning - Example: Injection Molds

BEFORE

AFTER

Mold Cleaning 48 Cavity IMM 96 Cavity IMM 144 Cavity IMMProduction maximum (Hours/Year) 8.400 8.400 8.400

Time saving per week with CJ 1.5 2.0 2.5

Time saving with CJ per year 78 104 130

Efficiency improvement with CJ 0.9% 1.2% 1.5%

Extra hours production 78 104 130

Mold cycles per hour 360 360 360

Extra preforms made per year 1.347.840 3.594.240 6.739.200

Profit per preform 0.003 0.003 0.003

Profit per year from extra production 4.044 euro 10.783 euro 20.218 euro

Payback-time per IMM in months 89 33 18

Payback-time per 5 IMM in months 18 7 4




Automated System Solutions Customer-centric solutions based on innovative proprietary technologies

Easy System IntegrationCold Jet creates on demand automated cleaning stations within a continuous manufacturing process (either existing or new) for applications requiring repetitive dry ice cleaning.

Currently, Cold Jet senses an increasing demand for automated system solutions for both online and offline cleaning in the plastic & rubber indus-try. The market is changing and more companies are moving to integrated cleaning solutions with an on-site dry ice production. Cold Jet’s auto-mated surface prepartion improves quality and lowers operating costs for manufacturers with paint lines. For more than 30 years, Cold Jet has provided custom, engineered dry ice cleaning and produc-tion systems to world-class companies. Begin your research today as you may only need mini-mal customization to interface a Cold Jet solution into your production environment.

• The dry ice pellets available for blasting are always freshly produced

• The CO2 consumption is reduced since only the dry ice quantity required is produced

• The dry ice is produced directly into the blasting unit

FULLY AUTOMATED MACHINE FOR DRY ICE PRODUCTION AND DRY ICE BLASTING

COMBI 75




The Right Solution for Plastic Mold Cleaning & Maintenance

Cold Jet offers environmentally responsible dry ice blast cleaning and production solutions that reduce operating costs, improve part quality, increase productivity and comply with the plastic industry require-ments.

LEAN:Reduction of Waste & Costs

GREEN: Environmentally Responsible

CLEAN:Improved Finished Goods

Benefits of Cold Jet Dry Ice MicroParticle Cleaning

FASTER THAN TRADITIONAL METHODS• Clean online, in place, while hot• Less down-time + more run-time = increased production

PRODUCES A CLEANER CLEAN• Cleans in tight spaces with precision• Does not leave residue• No equipment damage• Environmentally Responsible

DRY CLEANING PROCESS• Non-abrasive• Non-conductive

ENVIRONMENTALLY RESPONSIBLE & SAFE• No secondary waste• Dry ice CO2 is recycled• Increased safety• Less air and ice used = Less noise than traditional methods

www.coldjet.comAmericas. EMEA. Asia-Pacific.

Global HeadquartersCold Jet LLC

Loveland, OH USA+1 513.831.3211

European HeadquartersCold Jet Europe bvba

Zellik, Belgium+32 (0) 13 53 95 47

Cold Jet Deutschland GmbHWeinsheim, Germany

+49 6551 9606-0

Cold Jet/IceTech PolandOborniki, Poland+48 664 312 127

Cold Jet/IceTech DenmarkBramming, Denmark

+45 7656 1500

Cold Jet S.L.Madrid, Spain

+34 628 384 366

Representative France+33 (0) 6 09 01 28 75

Representative UK+44 7949561508

Asia HeadquartersCold Jet Technologies

Tokyo, Japan +81 3 6869 2665

Cold Jet locations worldwide:www.coldjet.com/offices

www.coldjet.comAmericas. EMEA. Asia-Pacific.

www.coldjet.com

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PLASTICS - coldjet.com · Monterrey, Mexico Europe ... cern for plastic part manufacturers in maintaining ... INJECTION MOLD CASE STUDY THE SOLUTION