Our high-performance hybrid machines and turnkey solutions produce high-quality packaging items. Let us show you, for example, how you can produce thin-walled tubs and screw caps quickly and efficiently, manufacture two-component closures with cube moulds, or use the IML process for containers with labels.
Saving material and improving mechanical properties at the same time
The production of sustainable reusable cups from foamed PP is demonstrated by a hydraulic ALLROUNDER 470 S. The injection moulding machine is equipped with a MuCell® package, which includes a cylinder module with a special screw, hydraulic needle-type shut-off nozzle and SCF dosing system. The application was developed and optimised to series production readiness by British packaging specialist Bockatech.
The material is enriched with gas both chemically with blowing agent and physically with the MuCell process and foams directly in the opened mould after injection. This saves on material and cycle time. The latter is around 5.5 seconds for a 430-millilitre cup. The microcellular structures ensure a weight reduction of up to 50 per cent with this application compared to the unfoamed component and also have an insulating effect. The foam-moulded walls have a thickness of two millimetres, making them almost four times larger than those of a compact cup.
Mono-material packaging with digital product passport
The HolyGrail technology is demonstrated using the example of the production of thin-walled IML containers made of PP mono-material. The light grey 5-litre buckets with original closure as well as the associated IML labels are made of colour-sorted and mechanically recycled PCR material. The flowpath/wall thickness ratio is 430:1. An ingenious "rib structure" of the side walls also allows up to 18 per cent of material to be saved.
A hybrid ALLROUNDER 820 H in packaging design produces the 98-gram buckets in a cycle time of only around five seconds. The sequentially operating robotic system with linear guided horizontal axis engages the mould from the rear side of the machine. It populates the label, removes the finished IML buckets and places them on a conveyor belt.
Monomaterial Packaging With Digital Product Passport
Within a cycle time of around five seconds, a Packaging-version ALLROUNDER 1020 H is able to produce four thin-walled IML tubs including lids, which are then automatically placed and stacked on a conveyor belt. The part weight is 19.3 g. The tubs themselves plus their labels and lids are made from chemically recycled PP monomaterial. After use, the IML tubs can be recycled using economical, high-quality methods.
The digital watermark provides a stamp-sized code that is stored directly on the label and is invisible to the end user. The individual tile patterns form a “digital passport”, a fragment of which is sufficient to retrieve information about the manufacturer, the materials used for disposal and whether it is “food-safe or not”, for example, using the appropriate app. The information can be read out in sorting plants with a high-resolution camera.
New ALLROUNDER CUBE 1800
In the "personal care" area of application, the new ALLROUNDER CUBE 1800 uses two injection units in sizes 400 and 170 to produce four two-colour caps per cycle, with a cycle time of only 8.7 seconds. The machine is equipped with a 4-cavity “Compact Cube” pilot mould from Foboha and processes chemically recycled PP produced by Borealis.
At station one of the cube mould, four frames (0.85 g) are injection-moulded. After a 90 degree rotation, the pre-moulded parts cool down on the passive side of the cube (station two). After another rotation, the second component (2.10 g) is injected at station three. Finally, at station four, a six-axis robot that is fully integrated into the machine controller removes the finished parts – also without affecting the cycle time.
Upcycling: Packaging turns into durable folding box
This video by our partner and materials manufacturer Borealis illustrates how materials that are similar in type can be processed and used to manufacture durable everyday products.
A folding box was injection-moulded with high process reliability on a hybrid ALLROUNDER 902 H. The starting material was 100% recycled PP that our partner Erema had produced with its plastic recycling machine at K 2019. To achieve this, PP cups injection-moulded by ARBURG were processed into recyclate together with PP film from dog food packaging.
Digital watermark for intelligent sorting
“Intelligent” sorting of industrial and domestic waste is essential if plastics are to be recycled effectively. An application example featuring an IML container shows how plastics can be separated into homogeneous types with the aid of digitalisation.
“HolyGrail2.0” creates a “digital password” by writing product information directly to the corresponding IML label in the form of an invisible digital watermark. There is also an app which can be used to query all types of supplementary information and augmented reality content relating to the product, its use and its disposal. The IML containers are made from monomaterial on a packing version of the hybrid ALLROUNDER 820 H injection moulding machine.
Example of a closed circular economy
The hybrid high-performance machine ALLROUNDER 1020 H for the packaging sector with a 8+8-cavity stack mould shows its capabilities. New PP material is processed in combination with 30 percent added single-type PP recyclate to produce thin-walled round cups while maintaining the same high quality.
16 round cups are produced in a cycle time of around 4.3 seconds. Due to the two parting lines positioned one behind the other, the clamping force compared to a 16-cavity mould can be halved and a small machine size can be used. The finished parts are subsequently stacked and packaged in tubular film. ARBURG is collaborating with EREMA who supply the recyclate in order to achieve exemplary production of thin-walled packaging products with recyclate-proportion while maintaining the same high quality. This application proves: When it is possible to collect plastics safely and efficiently, they can be returned to the value-added chain.
Inserting 18 labels and removing 6 parts at the same time
Thin wall IML containers for the packaging sector are becoming more and more complex. As a result, the requirements for high-speed turnkey solutions are also increasing. The detailed coordination of machine, mould, and automation technology is crucial for ensuring economic production.
At the centre of the production cell stands a “Packaging” version of the hybrid, high-performance machine from the HIDRIVE series with a clamping force of 4,600 kN and designed especially for the high demands of the packaging industry. The central process control system forms the basis for flexible process setting with optimised cycle time. In this way, six containers, each with three labels are reliably produced in 5.8 seconds.
Two interlinked ALLROUNDER machines
ARBURG has developed a flexible turnkey system for several product variants in the extremely fast and precise production of disktop closures for cosmetics bottles. Two ALLROUNDER machines are linked via two robotic systems.
The concept with two injection moulding machines and in-line assembly is worth the investment with a correspondingly higher output compared to a two-component solution with assembly injection moulding. An ALLROUNDER 570 H is used to produce the base of the closure, while an ALLROUNDER 470 H produces the lid at the same time. The MULTILIFT robotic systems remove the moulded parts and set them down on the two-station rotary table of the assembly system. The transfer unit then picks up 24 lids and presses them onto the bases. The assembled closures are set down on a conveyor belt and packaged in cartons in the appropriate numbers.
Cube-mould machine for high-speed applications
The ALLROUNDER CUBE is specially designed for high-speed cube-mould applications. With a clamping force of 2,900 kN and two size 800 and 400 injection units, it will produce two-colour flip-top PP closures for Pril washing-up liquid bottles from Henkel in a cycle time of 8.5 seconds.
With four usable sides and two parting lines positioned one behind the other, the 32+32-cavity cube mould offers key benefits: manufacturing of the pre-moulded part and the final product, as well as cooling and removal, are performed simultaneously. The first component produced is the 0.8 gram drop-shaped top section, which then cools on the second cube side, while the 2.4 gram second component is moulded on in the third position. On the fourth side of the mould, the flip-top closures are removed without influencing the cycle time, set down on a separate station and capped. Finally, an optical quality inspection is carried out on the finished parts.
Four packaging items in only 1.65 seconds
Extremely short injection and cycle times: The production of thin-walled containers for the packaging sector places the highest demands on the performance of injection moulding machines. For this purpose, ARBURG offers ALLROUNDER machines in the special "Packaging" version (P).
The production cell is built around a hybrid high-performance machine from the HIDRIVE series with a clamping force of 1,800 kN. Thanks to hydraulic accumulator technology and the position-regulated screw with adapted non-return valve, four tubs weighing 3.55 g each can be injection moulded in just 1.65 s with maximum reproducibility. In conjunction with mould technology and automation designed for fast cycles, an extremely production-efficient turnkey solution is created.
2-component closure: simultaneous filling, cooling and removal
An innovative cube mould is used for the production of two-component water bottle closures. ARBURG fully integrates mould functions such as servo-electric turning into the multi-component ALLROUNDER 920 S injection moulding machine.
A 32-cavity cube mould from Foboha is used to produce closure caps for five-gallon water bottles. The cycle time is around 10 seconds, while the material throughput is over 120 kilograms per hour. Thanks to the four mould sides that can be used during production, the mould filling, cooling phase and part demoulding can be carried out simultaneously. Compared to conventional moulds, the system enables many more cavities to be implemented on the same mould mounting surface. This ensures a correspondingly higher production performance and significantly shorter cycle times.
72 closures in less than 3 seconds
Multi-cavity moulds that produce large unit volumes in a matter of seconds are the dominant technology when it comes to the production of screw caps. For maximum productivity, system solutions precisely configured to your requirements are needed – e.g. high-performance hybrid machines.
The hybrid HIDRIVE-series ALLROUNDER 720 H combines a servo-electric clamping unit with a high-performance hydraulic injection unit, energy-optimised hydraulic accumulator technology and servo-electric dosage. Thanks to its high production capability and short cycle times, it is ideally suited for the production of packaging items.
to the moulded part
Efficient automation for medium unit volumes
A special automation system is not always required for the production of packaging items in medium to large unit volumes. A standard MULTILIFT V robotic system with dynamic mould-entry axis demonstrates how much removal and cycle times can be shortened.
Mould-entry times are nearly 40% faster than on a robotic system with conventional mould-entry axis. An electric ALLROUNDER 570 A injection moulding machine produces two beakers made from PP weighing 6.4 g in just 3.56 s. This example shows just how important equipment can be when it comes to saving valuable seconds during production.
ARBURG offers complete turnkey solutions for the manufacture of thin-walled containers with inserts. Using the IML process, two 1-l buckets with labels and handles can be produced in a cycle time of only 4.85 s, for example. Material throughput is approximately 50 kg/h.
The containers are produced on an energy-efficient ALLROUNDER 720 H with a clamping force of 360 tons. The hybrid injection moulding machine features special packaging equipment: an extended 70-mm screw ensures a high degree of plasticizing and short cycle times. In addition, a reinforced movable platen, plus the appropriate interface for running an IML system are used.