Injection molding machinery suppliers from South Korea, China, Taiwan and Turkey booked booths at NPE with an eye toward raising their stake in the growing North American market.
Increasing demand for plastics products has given original equipment manufacturers, many based in Asian countries, an incentive to offer high-performance machines at a lower price, compared to their competitors.
"The U.S. market is looking for pricing that is cost-competitive without giving up quality. Our machines are well-accepted in Europe and that has drawn attention by U.S. molders. Therefore, we decided to enter the North American market," says Mehmet Sarac, GM of Sarac Plastics Technologies Industry ve Tic. Inc., Istanbul.
NPE marked the re-introduction of a former U.S.-based nameplate, HPM North America Corp. Although based in Marion, Ohio, HPM is owned by Guangdong Yizumi Precision Machinery Co. Ltd., Foshan, China. In addition, at least one Western European-based company, Stork IMM B.V., Hengelo, Netherlands, exhibited at the triennial show for the first time. North American units launched for three Chinese machinery manufacturers: Welltec North America, Pacific, Mo., a division of Welltec Machinery Ltd., Hong Kong; Tech Bole USA, Franklin, Ohio, a distributor for Ningbo Shuangma Machinery Industry Co. Ltd., Ningbo, China; and Maruka U.S.A., Pine Brook, N.J., a distributor for FCS Group (Fu Chun Shin Machinery Manufacture Co. Ltd.), Tainan, Taiwan. (NPE news from the international companies was detailed previously in PMM in May. A related story on Tech Bole can be found here.)
Additional suppliers displayed or discussed the capabilities of their machines. Much of the news focused on hybrid systems that mate the power of hydraulics with the energy-efficiency and precision of a servo motor. Reputable component brands available in the U.S. are incorporated into their machine designs, improving the long-term service outlook for their customers.
MADE IN KOREA
Woojin Plaimm Co. Ltd., Jangan-myeon, South Korea, exhibited at NPE for the second consecutive time as it continues to expand into the North American market.
Woojin Plaimm does business as Woojin Plaimm Inc. in the United States with sales offices in Norco, Calif.; Auburn, Ala.; and Chicago. It was founded in 1985 in South Korea as Woojin Selex Co. Ltd., changing its name in 2012, says Andrew Kim, GM of the Chicago office. The company has an annual manufacturing capacity of 4,000 to 6,000 horizontal and vertical injection presses of various types, with a majority of its machines sold and installed outside of Korea, says Kim.
The company's proprietary machine design makes use of high-quality components that are familiar to its customers. Kim says that combination results in a well-equipped injection unit that can compete with European and American brands at a 10-20 percent lower price.
Woojin Plaimm began developing its TH (D&B) series hybrid machine in 2012. With a servo motor-driven hydraulic system, the series is designed for production environments demanding long-term machine reliability supported by scheduled preventive maintenance.
The TH series comprises 10 clamp sizes of 55-500 tons and 13 screw sizes from 22mm to 80mm. It has a center-press toggle clamping design and screw options that improve color dispersion and the processing of abrasive or corrosive materials. The line features a nozzle-touch design that compensates for fine misalignments between the nozzle and mold, and is intended to minimize mold deflection.
The injection unit runs on a linear motion guide for alignment consistency. Its hoist-out barrel provides easier access to the screw. A direct-operated proportional control valve maintains consistent back-pressure by a closed-loop pressure feedback circuit.
The company also displayed a DL650S (720-ton) unit from its DL series of two-platen direct-locking horizontal presses. The line, in 10 sizes ranging from 500 to 3,300 tons, has been available since 2009 but has been updated. The dry cycle time has been trimmed from 5.12 seconds to 3.6 seconds due to design revisions in the clamping unit, including simultaneous locking of half-nuts, more robust and dynamic hydraulic control cylinders and compact hydraulic circuits. The clamp position is accurate to within 0.2 percent of set position. The DL is equipped with Woojin Plaimm's proprietary double-flight screw.
Woojin Plaimm also updated its TE series of all-electric toggle machines, which are designed to offer market-competitive precision with a more intuitive and automation-friendly controller. The TE series uses the same servos installed on the TH models; however, the machines' power delivery is through belt drives and high-load ball screws rather than hydraulic fluid, says Kim. The TE series is suited to clean-room operations and facilities that require high-precision machinery with low energy overhead.
Woojin Plaimm also showed its VH series of vertical injection, vertical clamping units with its 80-ton VH75RS model. The VH series, released in 2009 but new to North America, features an energy-efficient hybrid hydraulic system with a two-station rotary table driven by high-precision AC servo motor.
SUPPLIER FROM GUANGZHOU
Guangzhou, China-based injection molding machine maker Borch Machinery Co. Ltd., unveiled two models that are new to the North American market, according to U.S. representative Wally Salls.
Borch, created in China in 2003, established a North American branch office in 2012, which operates as Borche North America, Ontario, Calif. The company, which showed one machine at the 2012 NPE, introduced its BU series of two-platen hydraulic presses and showed its BH series of servo-hydraulic machines. Both lines underwent a design change in 2014 and are simpler to operate, more functional and higher performing, says Salls.
The BU line of two-platen machines comes in 14 models ranging from 550 to about 7,500 tons and is designed for deep core or complicated molding applications, including household appliances, automotive or electrical parts. Features include a toggle-structure hydraulic clamping unit that the company says guarantees precision adjustment and high repeatability of clamping lock. The fully hydraulic clamping unit has four high-pressure, direct-clamping cylinders on the moving platen for uniform pressure build and a long platen support system that ensures precise platen movement and long life even when loading heavy molds. Meanwhile, four short-stroke cylinders provide fast mold movement, clamp-up and unclamp.
The injection unit features a double-carriage cylinder and double-injection cylinder. The cylinders move along a linear guide rail and provide shot sizes from 3 to 221 pounds, and injection pressures from 30,747 pounds per square inch (psi) to 21,755 psi, depending on screw diameter and screw length-to-diameter ratio. A Keba 2580 controller manages all machine functions, says Salls. The BU series features an optional tie bar auto-removal device. A BU 600 was on display at the show.
Borche also introduced its servo-hydraulic toggle presses for high-speed molding of food packages, caps and medical parts. Known as the BH line, it has six models with clamping forces from 165 to 550 tons are offered. The patented toggle structure hydraulic clamping system works by extending to close the mold at high speed, leaving a small gap inside the mold. Four direct hydraulic cylinders pull the tie bars to generate clamping force. Servo-valve control of mold movement ensures positioning repeatability accurate to within 0.05mm. (This series is covered in more detail in Product Innovations on Page 43.)
Other features include a Keba 2580 controller, rigid mold platen design, linear guide rails for the clamping unit and a double hydraulic system (governing overall machine hydraulics) that allows for parallel movements that can minimize cycle time. Oil-free lubrication in the mold and product drop area provides a clean work environment. The company says nano-infrared heater bands deliver precise heating while bringing energy-savings of around 40 percent, compared to conventional heater bands.
TURKISH SENSIBILITY
Press-maker Sarac Plastics Technologies was established 50 years ago as a seller of used European brand plastics machinery and a provider of reconditioning services for older machines, says GM Mehmet Sarac. The company expanded its expertise by selling used machines for injection molding, PET-preform making, blow molding, rubber molding, thermoforming and sheet, film, pipe and profile extrusion. Sarac Plastics is setting up support service in the U.S. and says its connection to scientific molding experts ensures the manufacturing of a high-quality machine that meets or exceeds required performance.
The company developed its servo-hydraulic toggle press series, the SRC ServoTech, in 2008. That series now spans 16 models with clamping forces from about 67 to 2,100 tons. The series is distinguished by the company's focus on installing components from well-known suppliers, such as Keba, KEB and Eckerle.
Sarac says the company is able to incorporate the components into a unit priced at least 40 percent lower than competing brands from Western Europe and Japan while achieving high-performance and reliability. An SRC 160 / 550 S with 470-mm tiebar distance was on display at NPE. The unit can be supplied with servo pump drive or a variable pump which can trim energy consumption 30 to 80 percent.
Features include a servo drive system with a 0.005-second response time to reach maximum power output that can shorten cycle time. The five-point double toggle clamp is offered with a four-stage mold open-close pressure and speed control. During NPE, Sarac got its first agreement to install its equipment in the U.S. Dixien LLC Co., which operates a plastics division in Warner Robins, Ga., purchased a unit with 90 tons of clamping force.
TAIWAN SAVINGS TIME
Enaiviv Machinery Industrial Co. Ltd., Tainan, Taiwan, achieves energy savings with its EN series of servo hydraulic injection molding machines, which are equipped with an enhanced inverter, gear pump and servo motor, says manager Jimmy Fang.
The company offers the EN line outfitted with a number of known brand components, including Tokimec and Daikin hydraulic valves and Intermot hydraulic motors. The line has SACM645 alloy steel barrel units and toggle-clamp-use tie bars made from Japan-made NH48MV alloy steel that provide a 30 percent increase in tension.
The SN3 is Enaiviv's third generation of machine control. SN1 is the standard machine control, featuring an inverter and providing up to 56 percent energy savings compared to a fully hydraulic unit of similar size. SN2 uses a servo motor for energy savings of up to 50 percent. The new SN3 concept incorporates an inverter, rotary encoder, high-efficiency gear pump and a servo motor, delivering energy savings of up to 78 percent, says Fang. SN3 can quicken or enhance primary operations, including mold closing, injection, holding pressure, cooling and charging.
In a test, Enaiviv molded 3,100 coat hangers on an SN3-160, trimming energy consumption by 70.2 percent versus a standard EN-160 injection machine. In both cases, cycle time, total shot size, product weight and working time were the same. In addition to energy, Fang says the SN3 can be used to save product weight through faster and more precise molding, which can increase production. The EN series is offered in a standard line or in configurations for PET preform molding or processing bulk molding compounds.
Mikell Knights, senior correspondent
Contact:
Borche North America, 909-498-4691, www.borchenorthamerica.com
Enaiviv Machinery Industrial Co. Ltd., 886-6-254-4328, www.enaiviv.com.tw
Sarac Plastics Technologies, 90-216-419-47-32, www.sarac.com
Woojin Plaimm Inc., 951-734-7890, www.woojinplaimm.com/global/en
