Efficiency at the Core of Diagnostics Production

At K 2025, ENGEL is presenting an integrated, fully automated production solution for the diagnostics market. The system achieves an increase in overall efficiency of approximately 25 % compared to conventional production methods. In a single cell, well plates and lids are produced and packaged in a validated manner. At the heart of the solution is an all-electric ENGEL e-motion 280 WP combi MW injection moulding machine with 2800 kN clamping force.

Two machines in one – in just 11 seconds

ENGEL’s compact system concept combines with the innovative high-performance Variotwinstack mould technology from HACK Formenbau GmbH to implement the principle of two machines in one. The mould is designed for the simultaneous production of up to four polystyrene well plates with 24 wells and their matching lids. For optimal media connection, the e-motion features a movable centre platen. The two injection units operate in parallel – not sequentially – reducing the cycle time to just 11 seconds. The shot weight for the well plates is 42.6 grams, and 13.2 grams for the lids.

The angled arrangement of the moving injection unit brings the nozzle closer to the hot runner, reducing its volume and thus increasing process reliability. Valve gate hot runner injection without a sprue optimises material usage while completely eliminating weld lines and flow marks. A multi-stage demoulding process with intelligent cooling and optimal part orientation further provides a particularly wide process window. In addition, integrated HACK moldlife sense sensor technology continuously monitors the mould mechanics, increases system availability and detects faults at an early stage. This system also supplies data to support digitally assisted process validation.

Premiere for shortened validation times

ENGEL is premiering its new validation assistant in this cell – a system for digitally assisted qualification and validation of injection moulding processes. Developed in collaboration with HACK Formenbau and Professor Thomas Seul, the solution combines ENGEL’s iQ assistance systems, moldlife sense technology and structured software modules. It supports all validation phases from DQ to PQ, accommodates future release methods such as parametric release, and simplifies the transfer of validated processes to additional machines or sites. As a result, both time and staffing requirements for validation are significantly reduced, leading to a much shorter time to market.

Compact, precise and cleanroom-ready – with cost savings

One of the key advantages of this production solution lies in its reduced system height, made possible by the newly designed layout. The overall footprint of the production cell is reduced by 40 percent – a significant cost-saving factor in cleanroom environments, where floor space comes at a premium.

ENGEL’s e-motion series has been specifically developed to meet the most demanding requirements in injection moulding for medical technology and sets new standards in precision, efficiency and long-term cleanroom performance.

Automated post-processing and quality assurance

After demoulding, a side-entry robot from Ilsemann removes the moulded parts. Two arms simultaneously grip the parts from both sides of the mould and transfer them either to a sampling station or to a laser marking station where a QR code is applied. The parts are then automatically assembled, stacked and sealed in sterile packaging.

https://www.engelglobal.com/

#engelglobal#Modernplasticsindia #Pasticsnews #ModernPlasticsIndiaMagazine
#PrintPublication #PrintMagazine #modernplasticsbangladesh

Redefining Plastics Recycling with Smart Innovations

Herbold Meckesheim, a brand of Coperion, will showcase its latest advancements in plastics recycling technology at K 2025, taking place from October 8 to 15 in Dusseldorf, Germany. Building on its long-standing expertise in modular system solutions for size reduction, washing, separation, drying, and agglomeration of plastics waste, Herbold Meckesheim offers tailored, highly automated plants for numerous industrial recycling applications. The company will present a range of integrated systems and solutions designed for mechanical processing, including the new high-capacity Mechanical Dryer T150-300 and the latest SMS granulator model. Visitors can explore these innovations firsthand at Hall 9, Booth 9B34. In addition, a Hydrocyclone Separation Stage will be showcased in the Coperion and Herbold Meckesheim Recycling Pavilion in the Open Area FG/CE07, where the companies will demonstrate their comprehensive interlocking recycling solutions. This participation highlights Herbold Meckesheim’s and Coperion’s ongoing commitment to delivering cutting-edge machinery and process solutions that drive the shift toward a more circular plastics economy.

New Dryer: A Step Forward in Drying Technology

Herbold’s latest innovation, the Mechanical Dryer T 150-300, debuts in a new size at K 2025 in Booth 9B34 in Hall 9. This high-capacity model sets new standards in large-scale drying applications, reaching throughputs of up to 2.5 tons of film per hour or >10t/h of PET or rigid flakes. The dryer features a fully redesigned construction, including a rotating sieve basket with integrated water spray nozzles for full-coverage cleaning and a centrifugal drying chamber for rapid moisture removal.

Designed for maintenance simplicity, it is equipped with hydraulically hinged housing for quick access and advanced monitoring systems supporting predictive maintenance. This innovative dryer is perfectly suited for demanding industrial workflows, particularly for film processing, ensuring consistent surface cleanliness and superior drying efficiency.

Granulator: High-Performance Efficiency

The next size of Herbold’s SMS Granulators, renowned for its durability and precision, will also be showcased at Hall 9. The SMS 80-200 Granulator is built for demanding applications. It integrates energy-efficient double cross-cutting action and pre-adjustable rotor and bed knives to produce a high-quality regrind with minimal fines and consistent particle size distribution. Its design emphasizes ease of maintenance, featuring a hinged housing and quick knife change system, ultimately reducing downtime and operational costs.

As the largest model in the series, the SMS 80-200 Granulator’s robust construction and forced feeding system—via three horizontally mounted screws—enables a high throughput of PET and rigid plastics, making it ideal for large-scale recycling operations.

The SMS series is optimized for a wide range of materials and ideal for the size reduction of standard applications in the recycling industry, as well as special processing needs—for example, heavy lumps, tough fibers, thin films, or substantial amounts of material.

At the Recycling Pavilion: Hydrocyclone Stage – Integrating Precision Separation

At Coperion and Herbold’s Recycling Pavilion in the Open Area (FG/CE07) a Herbold Hydrocyclone Separation Stage, a key component designed to deliver precise material separation through centrifugal forces, can be seen together with a Coperion ZSK FilCo filtration compounder. Herbold’s hydrocyclone stage enhances the purification of plastics during recycling, extending equipment lifespan and improving product quality.

The Hydrocyclone system, featuring a robust density separation, accommodates various application needs, providing additional washing and efficient impurity removal. The system includes capabilities for separating residual contaminants such as sand, glass, or metals using heavy medium cyclone technology and high-turbulence washing. The system includes also a friction washer which is capable to remove paper and other fiber contaminants.

System Solution for PET Recycling: Seamless Integration

Together, the Hydrocyclone Stage and the ZSK FilCo filtration compounder are exemplary exhibits that demonstrate how integrated Herbold and Coperion process modules produce high-quality recyclates. The ZSK FilCo recycling extruder system allows filtration and compounding in a single production step, and works in tandem with the Hydrocyclone Stage to deliver a complete, streamlined system for post-consumer recyclate (PCR) or any highly contaminated polymer reprocessing. This combination ensures the highest levels of purity and efficiency, meeting the stringent end product quality standards.

www.hillenbrand.com

www.coperion.com

#hillenbrand#coperion#Modernplasticsindia #Pasticsnews #ModernPlasticsIndiaMagazine
#PrintPublication #PrintMagazine#modernplasticsbangladesh