Broanmain Plastics is installing its first fully automated injection moulding machine cell which includes a 320-ton Haitian injection moulding machine and a Hilectro cartesian robot.
For mass-produced plastic components in particular, Broanmain is resolutely focused on addressing the scale of the sustainability challenge by reducing waste and being more resource efficient overall. This includes ensuring productivity from each unit of raw material and component manufactured at the Dorking facility is maximised.
The Generation 5 Mars machine is a servo hydraulic machine equipped with an electric screw motor as standard. This has a massive impact on energy efficiency as the use of a traditional hydraulic screw drive is the most energy hungry phase of the injection moulding process.
It is also incredibly quiet and delivers exceptional precision and reliability that mass manufacturers depend upon, said head of the Haitian UK sales team Veronica Edmunds. “Compared to fixed pump hydraulic machines, these energy-efficient servo-hydraulic moulding machines can save processors like Broanmain over 70% in energy consumption.”
Broanmain’s Operations Manager Thomas Catinat added: “We intentionally selected this particular 320-ton machine to provide extra manufacturing capacity and to mould larger components for a number of new projects we have won. Having the automation option was essential for the handling of 1kg parts.”
He added: “The energy savings were clearly impressive. Additionally, this new machine can accommodate tools that fit into both 250 ton and 500-ton machines, which allows us to bridge the production gap in the most efficient way.”
Weight and aesthetics considerations mean that each part must be carefully removed from the tool and placed on a conveyor to prevent structural and cosmetic damage. The Hilectro cartesian robot can perform this demoulding task at a consistent pace and rate. Having a choice of end of arm tooling means that the whole cell will be very adaptable to Broanmain’s future production needs, including lights out manufacturing.
As well as creating cost advantages per unit, the transition to efficient, cleaner production is another way to spur economies of scale. For example, deployment of more energy efficient injection moulding machines can also lead to fewer product defects and consequently less material waste. Thomas concluded: “This can induce additional cost reductions, which incentivises more deployment of cleaner technology. Creating another cyclical innovation ecosystem.
“The focus for us is unlikely to be full lights out production, but more lights out processes. This then enables is to increase productivity and our manufacturing capacity so we can better flex to customers’ needs. Having a cartesian robot that can take components from the mould, rather than having a full-time operative stationed at the machine that would slide open the door and stop production each time a component is taken from the tool, delivers a much faster cycle time, with no interruptions. It is also far safer for the workforce too.”
broanmainplastics.co.uk