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1
Mold-Masters Europe
by Robert Kirkby
MasterCARE-Team, EMEA (2012-05-11)
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Master-Series I The Flagship
12 standard gate options
6 standard nozzle sizes
Precise temperature control with
brazed heater technology and integrated T/C
3
Master-Series I Nozzle range
Hecto Femto Lite Deci Centi Pico Femto
3.5mm 5mm
6mm
5mm
7mm
6mm
8mm
8mm
11mm
12mm – 16mm
16mm – 18mm n/a
Valved
Non-Valved
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Valved vs. Non-Valved
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Tapered Pin
Cylindrical Pin
Types of Valve Pins
Premium valve gate solutions I Options
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Pin must close within
‘thermal window‘
defined by gate size
and hold time.
Advantages, Tapered
Advantages, Cylindrical
Disadvantages, Tapered
Excellent gate appearance
Small gate size possible
Accurate machining of
the gate is required.
Easy to machine
Self Centering
Large gates possible
Good gate appearance
A closer look at Valve Gating
Disadvantages, Cylindrical
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Accu-Valve I Premium valve gate solutions
Pristine cylindrical valve gating of
commodity and engineering resins
Continuous pin guiding
2 million cycle guarantee
<150 shot color changes
CX MEX EX
ACCU-VALVE CX - for Standard Resins
ACCU-VALVE MEX - for Standard Resins
ACCU-VALVE EX - for Standard Resins
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Accu-Valve I Leak-proof protection
Additional leak-proof protection at the manifold
V-Guide System
Innovative Valve Disk design prevents leakage between the valve pin
and valve disk at the manifold area by creating a thermal barrier within
the valve disk itself
New V-Guide Valve Disk Design Previous Valve Disk Design
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Accu-Valve I V-Guide
New V-Guide Valve Disk Design
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Accu-Valve CX
Gate quality that always meets your expectations
Ideal for high cavitation applications, fast cycle times & fast color changes
Bi-metallic design does not rely on gate steel for pin alignment
Pin alignment through constant engagement in liner
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Accu-Valve CX
The benefits of Accu-Valve CX over other valve gate designs:
Seal liner flow channels allow for fast color changes and no dead spots
Continual pin alignment and optimal gate temperature creates the perfect thermal condition at the gate
Resulting in minimal pin resistance and optimal gate longevity
0.0003” maximum clearance between the pin and cavity ensures that no crown flash even with very flash sensitive materials
Pin is stronger and has a simpler design
Any tolerance errors are completely eliminated as final gate/liner machining is done after assembly
Accu-Valve CX Seal/Liner
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Accu-Valve EX
Tailored for engineering grade resins (PC, POM, etc.)
Gate quality that always meets your expectations
Ideal for high cavitation applications
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Accu-Valve EX
The benefits of Accu-Valve EX over other valve gate designs:
Never any resistance to valve pin closure because gate temperature is always
above HDT point based on detailed FEA analysis
Results in even longer pin longevity as the pin is not exposed to additional
stress to seal/close
Double guiding mechanisms always ensure proper alignment through gate area
Gate seals and liners can be made from different materials based on the cooling
quality of the gate area in the cavity
Resulting in even more flexibility for all applications
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Hot-Tip I Premium open gate solution
Visco-Seal™: Additional leak-proof protection
achieved with a thin plastic membrane that solidifies
at edge of seal
Seals and liners can be easily replaced in the press
Liners are made from various materials depending on
resin properties and requirements
» Thermal cycling
» Wear resistance
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Actuation Methods (2012-08)
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Actuator Options I Today’s Actuation Methods
Individual Actuation
Hydraulic
Pneumatic
Electric (E-VG)*
Cluster Actuator
Hydraulic
Pneumatic
Synchro-Plate
Hydraulic
Pneumatic
Electric (E-Drive)*
*For detailed information about the E-Drive or the E-VG please
refer to the corresponding product presentations and Mold-
Masters Resource Guide (MMRG).
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Actuator Options I Valve Actuator Section Chart*
*For detailed information please refer to the MMRG
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Actuator Unit Minimum Pitch Type Fluid Piston Force
Competitive Design 25 mm Individual Pneumatic
Please refer to
catalogue pages MM Syncro-Plate 20 mm Multi-Pin Act. Pneumatic
MM Syncro-Plate t.b.d. Multi-Pin Act. Hydraulic
MM PN2300 44.3 mm Individual Pneumatic 596 N (@90psi)
MM HY550X 25 mm Individual Hydraulic 865 N (@ 400psi)
E-Drive* (reg. valve pin holders) 17.3 mm Multi-Pin Act. Electric STD Power Rate:
33000 N (Peak)
15000 N (Continuous)
High Power Rate:
50000 N (Peak)
24000 N (Continuous)
E-Drive* (mag. valve pin holders)
29.5 mm
Multi-Pin Act.
Electric
E-VG (55mm Solenoid) 58 mm Individual Electric
Please refer to
catalogue pages E-VG (75mm Solenoid) 78 mm Individual Electric
Small Synchro-Plate* 15 mm Multi-Pin Act. Hydr. / Pneu.
Actuator Options I Comparison Chart
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Design Options
The HY8400/HY8500 resolves issues with applications where high injection
pressures are required by increasing the closing force of the actuator
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Features
Similar to HY7100 / HY6500 design
Uses air or oil
HY8500 for cylindrical valve gating
HY8400 for non-cylindrical valve gating
Cylinder top
Centers air/oil flow to provide even downward pressure on the larger
piston diameter
Piston
Increases closing force without increasing supplied pressure
Wiper Seal
Reduces contamination entering actuator unit
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Advantages
The HY8400/HY8500 has advantages over standard HY65/7100 units:
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Components
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E-Drive I Powerful. Precise. Clean.
Syncro plate valve pin actuation with servo motor control
Fully enclosed valve gating system with electro-mechanical actuation
Applicable for 2 up to 128 cavities
Oil-free actuation, all electrical (no oil/air power)
Suitable for clean room applications
High performance system for absolute stable production processes
Sustainable production/part quality
Cost-effective solution based on TCO
60% less energy consumption compared to hydraulic valve gate systems
>50 % reduced maintenance costs due to extended maintenance cycles
Magnetic Pin Option
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E-Drive I System Features
Fully enclosed and all electrical (no oil/air power)
suitable for clean room applications
60% Energy savings compared to hydraulic valve gates
Applicable for 16 to 32 cavities
Higher cavitations possible with dual servos (future)
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E-Drive I Components View
Servo and gear box
Idlers (2)
Tensioning idler
Ball Screws (2)
Valve pin
(synchro) plate
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E-Drive I Section View
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E-Drive I Servo Drive and Ball Screw Solution
Belt and ball screw mechanism is over 90% mechanically efficient
All movements are based on rolling
No sliding (friction) losses
Servo drive actuation
High accuracy and repeatability
Variable speed and Acceleration
High Torque
Precision Control
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E-Drive I Features: Solid support
Synchro plate design allows pillar support from HR intermediate plate to mold
backing plate, resulting in stronger mold
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E-Drive I Features: Freedom in Cavity Layout
Outboard location of E-drive mechanism allows substantial freedom for cavity
positioning
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E-Drive I Ease of Use and Maintenance
Easy valve pin position and stroke set-up
automated in the controller
Modular design
Ease of access
Entire E-drive can be removed by removing top plate bolts and easing
belt tension
No o-rings
Top plate
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E-VG I Electric valve gate solution
High energy savings
High closing force
Fast cycle times
Sequential Valve Gate Control
Simple, Easy to Use Controller
Great flexibility
75 mm
55 mm
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E-VG I Advantages
Cleanroom Friendly
EVG is suitable for cleanroom applications
as it produces almost no particulate
pollution
Reliability
EVG is covered by a 2 year warranty and it
saves on maintenance costs as it has no
wear components
Reusability
Actuators can easily be removed and used
on future molds
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E-VG I Advantages
Sequential Valve Gate Control
Allows for sequential opening of valve
gates in base functionality
Pin motion sensor option for sensing
whether the pin has not been able to
close
Flexibility
Individual cavities can be remotely
turned off without temperature changes
in the nozzles
Simple and easy to use controller with
touch screen interface
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E-VG I Mold-Masters unique Solenoid Detail
Solenoid comprises of a permanent magnet holding the anchor in either one of the two
end positions.
To switch position, two electro-magnets are used; one to weaken the permanent
magnet’s magnetic field and the other to pull the anchor.
•ELECTROMAGNET
•PERMANENT MAGNET
•ELECTROMAGNET
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E-VG I Mold-Masters Unique Force/Stroke Curve
3 times higher stroke forces available than competitive systems
60% more closing force compared to a pneumatic system
A 3 mm pin can close against a hold pressure of up to 23,000psi
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E-VG I Mold-Masters Unique Force/Stroke Curve
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Backup-Slides
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Mold-Masters I Product & Service Portfolio
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Patented 2-piece brazed manifold technology
Unique in the industry
Runners are carefully milled and polished,
with no sharp corners or dead spots,
promoting fast and precise color change
Endless configurations of runner routes
that drilling doesn’t allow for
Master-Series I The Manifold Technology
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Cast-in heaters improve temperature uniformity versus pressed in heaters
Multiple melt channels for different materials can be designed in the same
manifold reducing the overall stack height by up to 22%
Master-Series I The Manifold Technology
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NEW I IRIS I Co-Injection Technology
Unique barrier molding solution for i.e. food and
beverage containers
Barriers to protect the product and ensure
a long shelf life
Such barriers are typically created using glass, metal or
plastic, with liners or multiple layers
IRIS co-injection technology is a revolutionary
alternative to these traditional packaging methods
IRIS co-injection is achieved via the combination and
integration of Mold-Masters’ key technology elements
Single source supply of the melt distribution and
control system with global service and support
Lower capital investment with the ability to use
existing tooling and machinery
Production flexibility as the IRIS system can easily be
moved to other machines and locations
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MasterCARE I Service offerings
System installation
System trails
System refurbishment
Retrofitting and repairs
Onsite repairs to systems
System cleaning
Trouble shooting
Dedicated Contact
Complete support management
Technical consulting for new systems
Seminars (on-site/off-site)
Technical trainings
Service and maintenance contracts
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MasterCARE I Benefits
First customer contact for any service issue
Global field service
Dedicated team of specialists
24/7 spare parts hotline
Global spare parts services
Part centers on all continents
Immediate support
Resolution of issues in the shortest time possible
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MasterSOLUTION I Offerings
Custom engineered solutions
Technical training and consulting
Mentoring program (co-development program)
Large program management incl. risk assessments
Trouble shooting
SAMP > Solution Assessment Management Program
CAMP > Cause Assessment Management Program
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MasterSOLUTION I Benefits
Quick turnaround and solution finding process
Direct contact, from beginning to end
Cost effective solutions, tailored to your needs
Integrated Risk Management through project due diligence
Global pool of industry experts
Extended development capacities
Ongoing knowledge management and transfer
Worldwide Project Management
Individual, cost effective and time-to-market product solutions
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Success in the Field - CX Customer: Major Caps and Closures Company
•Push pin mark for symmetry
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Success in the Field - CX
Customer: Major Medical Company
System Description:
Master-Series Femto, 2 Pilot Drop Systems, 2 Production Molds 48
Drop Systems
Material: PP
Processing Temp: 232˚C; Mold Temp: 38 ˚C
Plastic Part Size: 2g
Plastic Part: Medical Parts
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Success in the Field - CX
Customer: Major Personal Care Company
System Description:
Master-Series Pico 96 Drop System with Syncro Plate – Quantity 2
Material: PP
Processing Temp: 255˚C; Mold Temp: 35˚C
Plastic Part Size: 2.0g
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Success in the Field - EX
Customer: Major Medical Company
System Description:
Master-Series Femto
Material: PC/ABS Blend
Processing Temp: 282˚C; Mold Temp: 99˚C
Plastic Part Size: 0.14g
Plastic Part: Medical Part
In production December, 2006
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Success in the Field - EX
Customer: Major Medical Company
System Description:
Master-Series Femto 4 Drop
Material: PC/ABS Blend
Processing Temp: 282˚C; Mold Temp: 99˚C
Plastic Part Size: 0.14g
Successful EX implementation – could not close the gate of the Husky system
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Success in the Field - EX
Customer: Major Medical Company
System Description:
Master-Series Centi, 12 Drop
Material: PS + K-Resin + Zinc Styrate
Processing Temp: 230˚C; Mold Temp: 30˚C
Plastic Part Size: 19.28g, 17X17X264mm