Production efficiency

Greater efficiency - lower costs

Here, you can find out how to boost efficiency in your plastic parts production, plan production sequences with specific aims in mind and develop entirely new ideas for your business. The examples in the videos include comparisons of machine and robotic system performance, the set-up assistant for the machine controller, how to customise mass-production parts, and much more besides.

Individualised rocker-type light switch

ARBURG process chain at the Hannover Messe 2015
At the special Additive Manufacturing Plaza exhibition at the Hannover Messe 2015, ARBURG demonstrated a fully networked process chain involving injection moulding and additive manufacturing, including host computer technology. Here, rocker-type light switches produced in high volumes were individualised.

How can several machines and the production process be efficiently controlled, documented and tracked in the context of Industry 4.0? How can high-volume parts be individualised by means of industrial additive manufacturing using the freeformer? As an exclusive partner at the Additive Manufacturing Plaza, ARBURG demonstrated precisely how it’s done based on the example of rocker-type light switches. Trade visitors were able to go through and experience the complete process chain live – from order entry, injection moulding and industrial additive manufacturing through to automated packaging of the individualised products and display of the process parameters on a part-specific web page.

Robotic technology compared

Shorter cycle time with dynamic mould-entry axis
High-speed, mass production demonstrates how the MULTILIFT V robotic system with dynamic mould-entry axis reduces the mould-entry time by 38% compared with a standard mould-entry axis. This way, the cycle time for producing two cups can be shortened by 12%, to just 3.56 s.

The mould-entry axis has a speed of up to 4,000 mm/s and an acceleration of max. 20 m/s2. The mould-entry time is cut from 1.32 to 0.82 s. Over a year, this results in a production increase of more than 1.2 million moulded parts. Furthermore, automation enhances process reliability and minimises downtimes.

Industry 4.0

Integrated, personalised production
Parts-based online data acquisition and archiving ensure transparent production and 100% traceability. This entails the data integration of machines, order information and process data. The production of a toy buggy provides an example of how Industry 4.0 can work in practice.
The production process consists of five steps:

  • Enter your ID: Personalise a chipcard, have it read by the SELOGICA control system.
  • Produce the buggy: moulding individual parts, laser engraving (individual QR code), assembly.
  • Check assembly: correctly installed and fitted, dimensions of roof, chassis and axles.
  • Measure the speed: buggy "test circuit".
  • Call up the buggy data: scan QR code, archived part-specific production and quality data.

The ARBURG host computer system (ALS) is of central importance here, integrating the autonomous stations in one network as well as recording and archiving all parameters. Thanks to the QR code, the process parameters of each individual buggy can be uniquely assigned and all process steps seamlessly documented.


Customer magazine today 55, p. 8-9 “Data-integrated production” (PDF - 5,1 MB)

Personalised office scissors

Individualisation of moulded parts
Based on the example of a pair of office scissors, the flexible customisation of plastic products will be demonstrated by the combination of injection moulding using an ALLROUNDER and ARBURG Plastic Freeforming (APF) using the freeformer. The application also illustrates the topic of Industry 4.0.

At the injection moulding station, visitors will first be able to choose between different scissor versions. In order to enable flexible and fast product changes, human and robotic system work hand-in-hand. The handle of the scissors is moulded on by an electric ALLROUNDER and a DMC code is then applied by laser. The freeformer then adds individual lettering to the scissors. The data from the injection moulding process and additive manufacturing is recorded via the ARBURG host computer system (ALS) and transmitted to a web server. The relevant Internet page can then be called up by means of a DMC code using a mobile device.
to the moulded part

Performance comparison of machines

Hydraulic versus electric ALLROUNDER
A comparison of the performance of a hydraulic and an electric injection moulding machine, both size 370 and with identical process parameters, reveals that the electric ALLROUNDER operates more productively and with greater energy efficiency.

In this comparison, a hydraulic ALLROUNDER 370 S with dual-circuit pump technology and an electric ALLROUNDER 370 A each produced technical components for droplet irrigation with a 16-cavity mould. The electric machine scored highly through its precise movements, approx. 20% faster cycle times and reduced specific energy requirement. This higher productivity also resulted in lower unit costs and a faster return on investment.

Pickers compared

INTEGALPICKER V increases productivity
For a performance comparison, an electric INTEGRALPICKER V is used in the production of chip holders, and is also operated as a pneumatic system as a reference. The result: with a cycle time of 15.55 s, the electric picker operates approx. 9% faster than in pneumatic mode, which corresponds to an annual productivity increase of 93,782 parts.

The short intervention times of the INTEGRALPICKER V are achieved through the rapid 20 m/s2 acceleration of the entry axis (pneumatic 8 m/s2) and simultaneous movements. The picker enters the mould with three servo-electric axes. Moreover, it is integrated in the central SELOGICA control system, meaning that only one data record is required for the complete production unit.
Customer magazine today 55, pp. 18-19 "Faster and more precise" (PDF - 5,1 MB)

Optimising robotic systems

Integrated in SELOGICA – efficiency enhanced
Process control has a significant influence on production efficiency, This is impressively demonstrated by the production of stacking boxes. Here, the MULTILIFT robotic system is fully integrated in the central SELOGICA machine control system in one instance and connected via a EUROMAP 67 interface in another.

The comparison clearly shows: when all the options that can be implemented via programming of SELOGICA are utilised in the fully integrated MULTILIFT, cycle time reductions of over 2 seconds can be achieved on 20.98 seconds. Productivity is thus higher and unit costs are reduced. 

Set-up Assistant

Menu-guided set-up
Menu-guided setup – with the Set-up Assistant module, from mould change and automatic initial calculation of the parameters, right up to the completed production sequence. Convenient, simple and reliable, in only a few logical steps that require no special programming knowledge.

This human-machine interface can also be used to teach in complex production processes, i.e. guided set-up. This allows you to program your ALLROUNDER much more efficiently with a minimum of effort. Numerous functions running automatically in the background help you here.

Flow-enhanced plastics

Increased productivity – lower energy requirement
It is clear that efficiency and cost-effectiveness in injection moulding production start with product design and the selection of the right plastic – as demonstrated by a comparison of two materials, one of which has enhanced flow characteristics.

As an application example, an electric ALLROUNDER 370 E produces test parts alternately from standard PA 6 GF30 plastic and from flow-enhanced Ultramid B3WG6 High Speed from BASF. The comparison shows how the plastic with optimised flow characteristics can reduce unit costs: in this specific example, the result is 15% lower processing temperatures, 14% lower energy requirement and 9% shorter cycle times.