Multi-dimensional success. – 2-deck production plus cold runner system lowers costs

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New S3 machines optimally suited for 2-deck production with central cold runner system. To lower production costs through 2-deck article production.

A 2-deck production is feasible on both horizontal and vertical machines by way of the central arrangement of the cold runner system. Especially as for mass-produced articles that are very often manufactured by using 2-platen moulds, the 2-deck production can be realized very efficiently. Machine-wise there are only a few additions required to realize the 2-deck production. If the 2-deck production is fitted with a central cold runner system, productivity will be enhanced and in addition runner waste will be at the same time reduced to a minimum. 
With the same machine size, productivity can be enhanced by an average of 70%. The extra investments for a second mould and the 2-deck cold runner system as well as additions on the injection moulding machine are causing extra costs to the average value of 30% only.

It is particularly easy to automate the 2-deck production on horizontal machines. Apart from output increased by 70 %, the specific space requirement due to saving another machine is also a strong argument. On the other hand, this means that a machine with lower clamping force can be used to achieve the same output.
Since all DESMA injection moulding machines are equipped with HighPressure (HP) injection units having up to 3,500 bar injection pressure, sufficient pressure reserves for high-viscosity compounds are available even if using multi-nozzle central cold runners.

ECONOMIC EFFICIENCY
If and how such a production is profitable is shown by the following calculation taking an O-ring production as an example:

As a supplier of turnkey systems, DESMA relies on the integration of cold runner systems within the control system of the injection moulding machine. The newly developed machine generation S3 hosts special features which are providing big advantages particularly for the 2-deck production:

FEATURES OF NEW S3 SERIES
The new driving concept ServoGear for dynamic and precise machine movements with lowest noise emission. For the production of precision seals e. g., a precise closed-loop control of the injection movement is required especially for extremely different injection profiles. This is ensured by the ServoGear  hydraulics at best precision possible. This energy-saving hydraulic concept is fitted with a two-pump system. Thus, a kind of 3-speed gear is available. Slow movements = small pump, medium-fast movements = big pump, very fast movements = both pumps together. Thanks to the ServoGear  hydraulics, the total energy consumption is reduced by 10-13%. The savings of the kinetic energy amount to an average of 45% with a 4-minute cycle as against a standard closed-loop controlled hydraulics.

• With the new swiveling FIFOAdvanced, material changing can be realized very simply.
• The new DRC 2020 HT with haptic touch display offers breakthrough user prompting and the optionally integrated SetupAssist which explains the entire setting-up procedure to the machine operator and hence makes the well-known notes glued on the control cabinet superfluous.
• An actively driven feed roller "ActiveFeed" enables the feeding of even strongly fluctuating rubber strips or low-viscosity elastomers.
• The hydraulically driven non-return valve PlastControl  is a strong asset particularly for processing low-viscosity compounds. The non-return valve guarantees optimal plasticizing accuracy and, moreover, material changing is of unequalled ease. 

Further information at www.desma.biz

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