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 molds, or use the IML process for containers with labels.
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.
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-molded 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-molded 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 digitalization.
“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 molding 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 mold 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 mold 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, mold, and automation technology is crucial for ensuring economic production.
At the center 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 optimized 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 molding machines and in-line assembly is worth the investment with a correspondingly higher output compared to a two-component solution with assembly injection molding. 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 molded 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-mold machine for high-speed applications
The ALLROUNDER CUBE is specially designed for high-speed cube-mold applications. With a clamping force of 330 tons and two size 15.3 oz. and 8.2 oz. injection units, it will produce two-color flip-top PP closures for Pril dish-washing 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 mold offers key benefits: manufacturing of the pre-molded 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 molded on in the third position. On the fourth side of the mold, 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 molding 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 200 tons. 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 molded in just 1.65 s with maximum reproducibility. In conjunction with mold 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 mold is used for the production of two-component water bottle closures. ARBURG fully integrates mold functions such as servo-electric rotation into the multi-component ALLROUNDER 920 S injection molding machine.
A 32-cavity cube mold from Foboha is used to produce closure caps for five-gallon water bottles. The cycle time is around 10 seconds and the material throughput is over 120 kilograms per hour. Thanks to the four mold sides that can be used during production, mold filling, cooling phase and part demolding can be carried out simultaneously. Compared to conventional molds, the system enables significantly more cavities to be implemented on the same mold mounting surface. This ensures a correspondingly higher production performance and significantly shorter cycle times.
72 closures in less than 3 seconds
Multi-cavity molds 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-optimized 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 molded 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 mold-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 mold-entry axis. An electric ALLROUNDER 570 A injection molding 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.
In-mold labeling (IML)
ARBURG offers complete turnkey solutions for the manufacture of thin-walled containers with inserts. Using the IML process, two 1-l containers 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 molding 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.