A new level of performance in fitting production

With the new electric, tie-bar-less victory electric 220, ENGEL is presenting an injection moulding machine at K 2025 that is a genuine world first in terms of its design. It combines the benefits of ENGEL’s tie-bar-less technology with maximum energy efficiency, high precision, short cycle times and a reduced footprint – addressing increased customer demands and making it ideal for use in fitting production. The new machine will be unveiled to the public for the first time at the centre of a fully automated production cell in Düsseldorf.

The new victory electric combines the advantages of two worlds: ENGEL’s tie-bar-less technology and the benefits of electric injection moulding machines. The entire ENGEL victory series features compact machine dimensions thanks to the tie-bar-less design, offering a large platen area and a spacious, unobstructed mould area. This not only simplifies the handling of large moulds, but also significantly expands the possibilities for automation. This is a key advantage in the production of fittings, where core pulls require substantial space within the mould area. Here, the tie-bar-less concept comes into its own: the spacious mould area often makes it possible to use smaller machine sizes. In addition, the high accessibility helps reduce setup times considerably. Electric injection moulding machines stand out for their high energy efficiency, precise reproducibility and short cycle times, while also requiring minimal maintenance.

The ENGEL production cell is designed for maximum productivity. Fully automated, it covers the entire manufacturing process for fittings – including assembly and quality assurance.

At the trade fair, the machine at the heart of this solution is equipped with a family mould from toolmaker ifw, producing four fittings in a single shot: two with a 90-degree elbow and two with a 45-degree elbow. A polypropylene from Borealis is processed with a shot weight of 4 x 80 grams.

The production cell is equipped with several digital assistance systems from ENGEL that enhance ease of operation, reduce scrap, and improve efficiency. One of the key highlights is the iQ hold control digital assistance system, which automatically optimises the holding pressure time. This can increase the number of parts produced by more than ten percent in many applications – a clear competitive advantage for injection moulders. The new iQ weight control plus system also significantly reduces scrap by automatically compensating for viscosity fluctuations in every shot. This is done either via speed- or pressure-based control, using only two parameters, and can reduce scrap by up to 50 percent.

These systems are complemented by iQ process observer. It analyses up to 1,000 process parameters with every shot, detects deviations, and provides AI-based recommendations for optimising the process. The result is a stable, reproducible process with consistently high part quality.

Another element for increasing overall equipment effectiveness is ENGEL’s digital set-up assistant. It guides the operator step by step through the mould change, reduces setup time by up to 80 percent, and enables even less experienced personnel to perform fast and safe changeovers. This represents a significant gain in efficiency, especially for production cells with frequent product changes.

The entire automation of the production cell is fully integrated. After demoulding, the parts drop directly onto a built-in Z-conveyor belt. This eliminates the need for a removal gripper and saves two seconds per cycle – an advantage for product variants with changing ellbow angles or diameters. The parts are then detected by a camera system, picked from the belt by an ENGEL easix articulated robot, and handed over to a second easix robot, which feeds them to an automated ring insertion unit by Lüers. There, the seals are precisely inserted, checked for tightness, and the fully assembled fittings are discharged from the cell.

With this innovative production cell, ENGEL demonstrates its expertise in perfectly aligning machine concepts, digitalisation, and automation. The new victory electric 220 combines energy efficiency with maximum flexibility, creating a cost-effective solution for highly automated manufacturing. Customers benefit from significantly increased overall equipment effectiveness, a reduced footprint, and reliable process stability – even with changing requirements and high product variety.

https://www.engelglobal.com/

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Hot runner innovations chart new courses to efficiency across industries

At K 2025, taking place in Düsseldorf/Germany from 8 to 15 October, Oerlikon HRSflow will showcase at Hall 1/Stand C72 its groundbreaking STARgate HRS hot runner technology, which enables precise control of melt injection into the mold cavity through a revolutionary Valve Gate concept. Another new development is the Glow HRS solution, which allows for the direct injection of aesthetic parts in amorphous materials. Systems from the global hot runner specialist will also run live at partner companies, including an injection molding tool for automotive parts that delivers a flawless surface and minimizes secondary operations. Beyond, visitors can expect to see interesting developments in application-specific solutions for multi-cavity systems. These include the Up Nozzle series, which is specifically engineered for compact, tight-space applications with low shot weights, and new solutions designed for luxury and eco-friendly parts in the beauty and personal care industry.
The upcoming K 2025 is organized in close cooperation with Oerlikon HRSflow’s sister brand, Oerlikon Balzers, highlighting the group’s integrated approach to innovation and excellence.

A radical change in injection molding – patented solution

With its newly developed STARgate HRS hot runner technology, Oerlikon HRSflow will present its revolutionary concept for the injection molding industry to the public for the first time at K2025. This technology is a groundbreaking development in the injection molding of PP, PE, PS, and other amorphous thermoplastics. Compared to conventional designs, production, assembly, and maintenance of various components are unnecessary; cycle time is significantly reduced; color changes are easier; and power consumption and pressure loss are reduced. Additionally, the thickness of the back plates can be reduced. STARgate HRS hot runner technology also enables short filling and packing times. At K 2025, this technology will be on display at BMB, an Italian injection molding machine manufacturer (Hall 13/Stand A33), during the production of a bucket. This project was made possible by Oerlikon HRSflow, BMB, the Dutch plastics processors Dijkstra Plastics, Oerlikon Balzers, Piovan and R&D Plastics.

Avoiding halos and weld lines

Another innovation to be unveiled for the first time at K 2025 is the patent-pending GLOW HRS technology, which enables the production of high-quality parts by direct injection, avoiding halos and weld lines. With precise surface temperature control and a compact design, this cutting-edge solution easily adapts to a wide range of applications.

Paint-free, premium automotive parts

At the booth of injection molding manufacturer Haitian International Germany (Hall 15/A57), Oerlikon HRSflow will give a live demonstration of how the FLEXflow HRS servo-controlled needle valve technology can be used to get high-quality automotive parts directly from the mold. This will be illustrated by the manufacturing of a car wheel arch. Developed in collaboration with DNP Group (producer of automotive decoration film printing) and Inevo (mold maker), this joint project impressively demonstrates that the painting of large-format injection-molded parts can be eliminated, minimizing the need for expensive post-processing, even when using recycled materials. Other advantages of FLEXflow HRS technology include quick color changes and reduced material waste.

MULTIflow HRS: New nozzle series and PET thick wall solution now available

With its compact gate-to-gate pitch (down to 15 mm), the new Up Nozzle series from Oerlikon HRSflow (Picture. 1) is specifically engineered for tight spaces with low shot weights. With a 12-mm nozzle cutout, the series delivers exceptional performance in hard-to-reach gate areas. These features make the series ideal for industries such as beauty and personal care, packaging, beverages, and technical applications.

At their booth, Oerlikon HRSflow will present crystal-clear, eco-friendly parts produced with dedicated hot runner solutions for luxury cosmetic packaging (Picture 2). These components benefit from advantages of the technology, including crystal clarity, significant wall thicknesses of up to 12 mm, and high process repeatability.

Advanced injection moulding technology live

• At the Engel booth (Hall 15/B42-C58), a three-drop system from the Ga series of Oerlikon HRSflow’s Diamond Lux line of hot runner solutions will be demonstrated for producing a rear light concept application. In this process, a decorative foil is back-injected with PLEXIGLAS 8N from RÖHM and then overflooded with PUR. The foil enhances the visual design of the final product. This project is a collaboration between Zechmayer (toolmaker), LEONHARD KURZ (LED and surface design integration), Engel (injection molding machine producer), and RÖHM (material supplier).
• A cable clipper made of PA6.6-GF30 that weighs just 1.2 grams will be produced in a 16-cavity mold at Haitian’s booth in Hall 15/A57. The hot runner configuration consists of 16 Oerlikon HRSflow SA Series nozzles with an open gating system. These nozzles were specially developed for processing glass fiber-reinforced plastics, ensuring perfect cavity filling and outstanding process repeatability.
• BOY’s booth (Hall 13/A43) will feature the injection molding of a conical blood filter using a Jestar medical demonstration mold on a BOY 35E injection molding machine. This process utilizes Oerlikon HRSflow’s Multi Valve Plate (MVP) technology in conjunction with a 16-drop MULTIflow HRS system from the SP series. This technology offers synchronized valve actuation and reduced drop-to-drop spacing, enhancing precision in small weight applications.

www.oerlikon.com/hrsflow

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Compact Foaming Innovation Paves Way for Smarter Resource Use at K 2025

At K 2025 ENGEL will be demonstrating how maximum sustainability, cost-efficient production and space-saving system concepts can be successfully combined. The focus is on a production solution for foamed technical parts made from 100 percent post-consumer recyclate. The heart of the exhibit is an all-electric e-mac 220 injection moulding machine which produces thick-walled and robust plastic parts for the construction industry on a minimal footprint. These components offer significant weight savings – in an energy-efficient, precisely foamed and fully automated process.

The manufacturing principle used in this ENGEL production cell is particularly well suited to robust components that are as lightweight as possible and easy to handle, for example for replacing concrete in shafts.

The all-electric e-mac injection moulding machine with a clamping force of 2,200 kN uses ENGEL’s foammelt technology to foam components using a blowing agent. In combination with a specially developed additive mix, this creates a homogeneous, finely celled foam core. The advantage: reduced weight with increased stability. In the application shown, the ENGEL injection moulding cell achieves a weight saving of around 30% with a shot weight of 538 grams, while at the same time increasing the impact resistance of the component by 10%.

A post-consumer recyclate (PCR) is processed, originating from the “Gelber Sack”, collected by PreZero and high-quality reprocessed by EREMA. For the foaming process, an additive and blowing agent mixture developed by Moxietec is used, combined with the Vistamaxx additive from ExxonMobil. The dosing is carried out via a gravimetric system from Movacolor. The Moxietec formulation ensures a particularly homogeneous distribution of the foam structure and is therefore especially suitable for thick-walled components, where conventional physical foaming processes reach their limits.

A standard mixing screw from ENGEL ensures a homogeneous melt. It is specially designed for this type of application and optimised for uniform mixing behaviour. In addition, decompression after dosing can be completely omitted, reliably preventing sink marks and air inclusions in the component. This is made possible by a ring non-return valve with a newly developed geometry. Crowned valve wings ensure even greater reproducibility and – in combination with the short-stroke version – significantly faster closing behaviour.

The plasticising unit of this system uses iQ melt control to deliver an optimally prepared melt for foamed recyclates. The digital assistance system iQ melt control analyses the plastification process during sampling and suggests ideal setting parameters for screw speed, back pressure and dosing stroke. In this way, iQ melt control supports consistently high part quality with maximum material efficiency.

A cold runner system additionally supports the desired foaming behaviour. The cycle time on the all-electric ENGEL e-mac using the 2-cavity mould from Moxietec is approximately 120 seconds.

Especially for thick-walled components such as in this application, mould temperature control plays a crucial role. The latest generation of e-temp units operates with just 90 °C water temperature, eliminating the need for separate hot-water piping – which further reduces costs. The digital assistance system iQ flow control actively monitors the temperature control behaviour and regulates it dynamically. In combination with ENGEL’s e-temp devices, this ensures that temperature deviations are detected immediately and automatically corrected. The result is uniform cooling of the entire component – warpage is minimised and dimensional accuracy improved. The system makes a significant contribution to process stability and reduces the energy consumption of temperature control thanks to optimal flow regulation.

The entire production cell is designed to be compact. A servo sprue picker removes the sprue, while an ENGEL viper 12 linear robot takes out the moulded part and places it on a conveyor belt – which is space-savingly integrated into the machine’s safety guard. The automation is fully integrated into the control system of the injection moulding machine and helps reduce cycle times, as iQ motion control independently optimises the movement sequences. At the same time, it also reduces energy consumption. Savings of up to 85% in temperature control are possible. With this application, ENGEL demonstrates how sustainable production, advanced foaming technology and an intelligent cell layout – supported by digital assistance systems such as iQ flow control – can be combined into an economically compelling overall solution. Injection moulding companies benefit from a stable process for demanding recycled material applications, which can be reliably integrated into existing production environments without requiring much floor space.

www.engelglobal.com

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