E N T E R T H E A L L - E L E C T R I CW O R L D O F M I L A C R O N

The Current And Future State-Of-The-Art OfAll-Electric Injection Molding Technology

FEW COMPANIES CAN CLAIM LEADERSHIP INFEW COMPANIES CAN CLAIM LEADERSHIP INALL-ELECTRIC INJECTION MOLDING TECHNOLOGY.ALL-ELECTRIC INJECTION MOLDING TECHNOLOGY.

FEW CAN EVEN CLAIM LENGTHY EXPERIENCE INFEW CAN EVEN CLAIM LENGTHY EXPERIENCE INALL-ELECTRIC MOLDING TECHNOLOGYALL-ELECTRIC MOLDING TECHNOLOGY

VERY FEW, IN FACT, CAN CLAIM PIONEERINGVERY FEW, IN FACT, CAN CLAIM PIONEERINGALL-ELECTRIC TECHNOLOGY AND PRODUCT ALL-ELECTRIC TECHNOLOGY AND PRODUCT DEVELOPMENTDEVELOPMENT

MILACRON CAN EASILY OFFER CREDENTIALSIN ALL THREE. THIS IS THE EXPERIENCE WEPRESENT, AND PLACE AT YOUR DISPOSAL, IN THIS PRESENTATION.

ENTER THE ALL-ELECTRIC AGE

A New Age of All-Electric Technology, Power and Processing Capability

Why Electric Molding Technology

Comparison Charts: All-Electric Injection Molding vs. Existing ProcessingCapability• Economic of Good Parts• Shot Control Variation• Shot Weight Variation• Energy Usage vs. Throughput• Electric Usage vs. Regeneration• Overall Power Consumption• Overall Power Regeneration: Power Storage and Reuse• Noise Evaluation

The History of All-Electric Injection Molding

Drafting Your Own Technology and Productivity Plans for the Future

A NEW AGE OF ALL-ELECTRIC

TECHNOLOGY, POWER AND

PROCESSING CAPABILITY

A NEW AGE OF ALL-ELECTRIC

TECHNOLOGY, POWER AND

PROCESSING CAPABILITY

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The Technology, the Power, the World has turned the corner

It happened to industrial robots.

It happened to machine tools.

Precise, consistent all-electric machines replacedoily, maintenance-prone hydraulic equipmenton the factory floor.

Milacron slugged it out in both these markets, and began applying those electric-technology lessons to plastics machinery as early as the mid ‘80s.

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The turning point is in our rear view mirror

Today Milacron leads the revolution in all-electric injection moldingmachinery, while dozens of other companies are waking up to therevolution. We sold more than 400 electric IMMs in 1998, an increase of 50 percent over ‘97.

Our new designs, new technology - developed and improved throughyears of experience - bring you market-leading electric machines today, while the rest of the industry introduces first-generation equipment…or none at all.

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In addition to co-pioneering the development of a precisionIn addition to co-pioneering the development of a precisionall-electric machine with Japan’s Fanuc in 1985, Milacron:all-electric machine with Japan’s Fanuc in 1985, Milacron:

• Developed its own proprietary high-tonnage, large shot capacity all-electric IMMs by 1995.

•Mainstreamed the ultra-high-speed, all-electric machine technology developed by Ferromatik Milacron in Germany.• Broke all known shot-size limitations for electric IMMs in 1998 with a patented two-stage electric injection unit needed for large-part molding on electric machines

• Is uniquely positioned as a global company to synthesize and mass-market electric molding technologies from Europe, Asia, and the U.S.

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In an industry at a technology turning point, In an industry at a technology turning point, we have already lapped the field.we have already lapped the field.

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WHY ELECTRIC MOLDING TECHNOLOGY?WHY ELECTRIC MOLDING TECHNOLOGY?

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From the day the machine starts up, your cost per part is lower,part quality is higher. All-electric machines use less energy thanhydraulic machines, they are more reliable, cycle times arefaster because of independent clamp/injection functions, and part quality is higher because of unbeatable repeatability.

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Here’s why molders buy all-electric machines for low-tech productsHere’s why molders buy all-electric machines for low-tech productssuch as pet food dishes and beverage crates - not just for cleanroomsuch as pet food dishes and beverage crates - not just for cleanroomwork or precision parts.work or precision parts.

1. Electric IMMs are in a class by themselves Electric machines consistently hold tolerances one-half those of a Hunkar Class 1 hydraulic machine. They stand out in a class of their own.

2. They start that way, they stay that way Accuracy, repeatability and consistency are inherent to all-electric machines. They are digitally controlled, mechanically driven, just like precision machine tools and coordinate measuring machines. They do not vary over time, because there’s no hydraulic fluid to heat up or compress, no hoses that expand, no valves that stick.

Molders say these machines make good parts by the third or fourth shot, and then run without attention until it’s time for a mold change.

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3. Precision shot control saves material, reduces mold-in stress You can’t afford to give a customer more resin, colorant, or additive than the part needs. Electric machines let you mold closer to the threshold of just-the-right-amount of material, without falling below that threshold. Screw position for fill and pack is controlled with digital precision, eliminating overpacking and greatly reducing molded-in stress - ideal for top quality headlight lense, optics, etc.

4. Predictable performance facilitates “lights out” molding Consistent machine performance allows labor cost reductions with unmanned shifts at night, on weekends. Utilization of skilled labor is greatly enhanced.

5. Electric molding turns an art into a science Electric machines turn injection molding into a predictable, robotic operation. With a more consistent machine, process setups can be used repeatability without adjustment, without changes in part consistency or quality.

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6. Huge energy savings cut molding cost, plant construction and operating costs Whether small or large, all-electric machines dramatically reduce operating costs, using 50-90 percent less power than equivalent hydraulic machines. Connected power requirements for an electric machine are only 25% those of a hydraulic machine. Utility companies sometimes even help pay the cost for more efficient electric machines to reduce generating capacity needs for a market area.

7. Less electricity means lower cost for new plant construction Because electric machines use less energy and throw off less waste heat, new plant construction is reduced through:• Smaller electrical service connection software• Smaller busbars, etc. throughout the plant• Smaller air conditioning compressors for temperature-controlled plants• Cooling needed only for feedthroat• Elimination of oil storage and disposal facilities

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8. Cooling water costs are eliminated An electric IMM is air cooled, with no plumbing or hoses, no heat exchanger to clog, no cost for cooling water. A hydraulic 55-ton molding machine runs up an annual bill of $3800 for cooling water alone.

9. Electric machines use no oil Electric IMMs eliminate the costs and headaches of hydraulic oil: purchase, disposal, monitoring, leaks, burst hoses, clean-up, slips and falls sticking valves, fire hazard, etc.

10. Electric machines are cleanroom ready Electric machines are ideal for molding optical media, medical parts, and other dirt-sensitive parts.

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11. Low noise levels improve plant environment Molding machine noise is coming under closer scrutiny from workers compensation insurance agencies, but electric machines are so quiet, it’s hard to tell they are running. They typically operate at less than 70 dB. That’s about two-thirds the noise of a hydraulic machine, greatly reducing fatigue and stress for operators.

12. Electric machines allow more flexibility in plant layout, workflow Clean, quiet operation allows relocation of the injection molding process into areas such as assembly, shipping areas and warehouses.

13. Electric machines are more reliable, have fewer parts, need less maintenance Fanuc servomotors have failure rates below 0.2% for total parts produced. Milacron all-electric average warranty costs are less than $135 per machine per year. High voltage components are circuit board mounted with automated assembly techniques. In contrast, hydraulic machines use a complex network of pumps, hoses, filters, tubes and valves requiring extensive maintenance.

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A tighter window of process capability allows operations to be movedconfidently toward the lower specification limit where savings accrue in material, scrap, energy, etc.

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Typical plot of repeatability of electric injection machine shot weights

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A two-cavity, polycarbonate lens was running consistent cycles at .35%total variation of part weight. As a test, the shot size was arbitrarilyreduced by about 40% and the mold was allowed to continue runningin “short” condition for four consecutive cycles. After the fourth cyclethe shot size was reset to the previous value with the results shown.

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All-electric machines dramatically reduce operating costs, using 50-90 percent less power than equivalent hydraulic machines. Connected power requirements for an electric machine are only25% those of a hydraulic machine.

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All-Electric machines use a smart regenerative power circuit to produceelectricity during clamp deceleration and other functions. This poweris stored and re-used.

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Comparison of power consumption between all-electric and a hydraulicmachine for applications involving molding of food packages.

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Electric machines use a smart regenerative power circuit to produce electricity during clamp deceleration and other functions. The power is stored and re-used.

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All-electric machines typically operate at less than 70 dB. That’s abouttwo-thirds the noise level of a hydraulic machine, greatly reducing fatigue and stress for operators.

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WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

1952 - Numerical control (NC) of machine tools is established by MIT equipping a Milacron milling machine with a computer control. The MIT report becomes “the bible” for a research team at Fujitsu

1959 - Electro-hydraulic pulse motor (an NC-controlled hydraulic servomotor) is patented by Dr. Eng. Seiuemon Inaba of Fujitsu. MN controlled hydraulic servodrives are widely adopted for machine tools during the 1960s. In 1972, Fujitsu spins off it’s motor and NC control technology in a new company, Fanuc (Fuji Automatic Numerical Control), with Dr. Inaba as executive vice-president.

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WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

1973 - World oil crisis prompts Fanuc to develop a more energy efficient, all-electric servomotor, culminating in full development of NC servomotors by Fanuc. Electric servomotors sweep through the machine tool industry, obsoleting hydraulic drives. Milacron’s Machine Tool group becomes a major technology partner with Fanuc.

1983 - Recognizing the mutually beneficial potential for electric servodrives in traditionally all-hydraulic injection molding machinery, U.S. Market leader Milacron begins strategic partnership with Fanuc, licensing it’s toggle machine technology to Fanuc for development of a CNC-controlled all-electric injection molding machine. Long range objective for Milacron is to “leapfrog” competitors for inevitable shift to all-electric injection molding.

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WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

1985 - Milacron and Fanuc introduce the jointly-developed ACT (AC Technology) all-electric injection molding machine at the National Plastics Exposition. ACT machines are initially available in 50, 75, and 150 tons clamp force. The two companies later expand this to 250 and 330 ton sizes.

1985 - Fanuc grants Milacron exclusive distribution rights to market all-electric machines in N. America.

1985 - Fanuc becomes the world’s leading producer of all-electric injection molding machines.

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WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

1992 - Milacron commits to develop its own all-electric injection machine, aimed at the high tonnage end of the market, a market niche as yet unanswered by the industry.

1993 - Milacron purchases Ferromatik, a German injection molding machine maker, thus acquiring Ferromatik’s ultra-high-speed machine technology.

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WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

1994 - Milacron introduces its own all-electric injection molding machine line in tonnages to 300 at the National Plastics Exposition. At the same show, Milacron and Fanuc introduced the first all-digital, servo-controlled electric molding machine, called Roboshot. Roboshot represents a fourth generation of all electric design, and is now kinematically optimized by Fanuc, totally divorced from hydraulic concepts.

1995 - Milacron introduces the world’s largest all-electric machine (725 tons) at the K show in Dusseldorf.

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1996 - Milacron is the worldwide leader in all-electric injection molding machinery, positioned with U.S., Asian and European technology, to satisfy the needs of any customer

1997 - Thirty percent of the 150 machines sold by Milacron at the triennial National Plastics Exposition are all-electric.

1997 - Milacron forms Elektron Technologies business unit with separate facility and staff to concentrate on development and sales of next generation, global-design, all-electric IMMs.

WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

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1998 - Ferromatik Milacron introduces the DISCO all-electric IMM for replication of optical disc media and molding of smart cards. The all-electric design allows programmable coining, eliminating the need for mechanical stops and adjustments used on hydraulic IMMs.

1998 - Elektron Technologies introduces new Powerline series electric IMMs with significant advances in performance, size and simplicity for the highest appeal in any molding application. First model is 330 tons clamp force. The ultra-quiet machine utilizes a blend of new and existing design features developed in both the U.S. and in Germany at Ferromatik Milacron. Fanuc is a key technology partner, providing drives and low-inertia motors.

WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

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1998 - Elektron Technologies introduces new two-stage electric injection unit that breaks the limitation of large shot capacity that had been a de facto ceiling on the upper end of the size range for electric machines.

1998 - Sixty percent of Milacron’s exhibit at the K Show (four machines out of seven), consists of electric injection molding machines, more than any other manufacturer at the show.

1998 - Milacron announces sales of all-electric IMMs surpass 400 units for the year, a 50 percent increase over 1997.

WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

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1999 - Three new models added to Powerline machine range in 220, 440, and 550 tons clamp force with 1500 tons targeted within 48 months.

1999 - Fanuc - now the world’s largest producer of all-electric molding machines - continues its significant technology relationship with Milacron. More than 8,000 Roboshot machines have been sold worldwide, approximately one-third of them in the U.S. through Milacron.

WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

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1999 - Fanuc/Milacron introduces new Roboshot I series machines, the first which fully exploits new artificial intelligence technologies, the first with standard ethernet capability, and featuring all-electric processing advantages like pressure trace, low mold-pressure mold protect and metering (screw recovery). The new Roboshot line includes complete tonnage capacities from 17 through 330 tons.

1999 - Liquid Injection Molding (LIM) processing capability is offered by Milacron through both the Powerline all-electric line and Fanuc/Milacron Roboshot line.

WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

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2000 - Complete Powerline line is featured at NPE 2000, with new large tonnage models introduced at show: Powerline 750 and Powerline 935.

2000 - Comprehensive processing capability is offered by Milacron through it’s all-electric lines, now including: PET, multi-colored/multi-component, thermoset (BMC/bulk molding compound), ceramic and metal molding, mucell molding, gas-assist and complete integrated all-electric systems, like bucket and lid machines (5 gallon containers and up).

WE HELPED WRITE THE HISTORYOF SERVO-CONTROLLED MACHINE TOOLS

AND ELECTRIC MOLDING MACHINES

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Milacron would be pleased to help you draft your “White Paper” inall-electric processing technology - your plan for the future.

Milacron would be equally pleased to assist in adding the power ofall-electric technology to your competitive processing technology - creating your future now.

ENTER THE WORLD OF MILACRONALL-ELECTRIC TECHNOLOGY

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Write, fax, call or enter the World of Milacron All-Electric Technology online:

Milacron, Inc.Plastics Technologies GroupElektron Technologies Business4165 Halfacre RoadBatavia, Ohio 45103Tel 513-536-2000Toll Free 1-888-MILACRON (1-888-645-2276)Toll Free 1-888-368-7470 (Direct to Sales)Fax 513-536-2624www.milacron.com

ENTER THE WORLD OF MILACRONALL-ELECTRIC TECHNOLOGY