Product novelty 12. September 2023

ALLROUNDER 720 A: Efficient injection compression moulding of IML thin-walled cups

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ALLROUNDER 720 A: thin-walled IML cups using injection compression moulding.
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Recyclable: IML round cups made of PP with only 0.37 mm wall thickness.
An electric ALLROUNDER 720 A "Ultimate" will be demonstrating that high-quality injection moulding technology can be an alternative to thermoforming. The exhibit will use injection compression moulding to produce thin-walled IML cups that can be easily recycled after use. The directly driven high-performance machine with a clamping force of 2,900 kN is specifically optimised for high performance and achieves injection speeds of up to 400 m/s.

The exhibit uses a 4-cavity mould from Brink to produce thin-walled IML round cups from polypropylene (PP) using the injection compression moulding process. The flowpath/wall thickness ratio is 380:1. For process monitoring, the mould is equipped with six high-resolution inductive position measuring and embossing sensors. Four moulded parts with a wall thickness of only 0.37 mm are produced in a cycle time of 3.95 s. The plastic has a biomass footprint and ISCC-certified. Also integrated into the production cell is a side-entry robot from Brink that inserts the labels, removes the finished cups and stacks them on a conveyor belt.

Special emphasis was placed on energy efficiency and on a part design that saves materials. Thanks to the all-electric packaging machine in combination with injection compression moulding, the energy footprint is improved by 20% with a significant reduction in part weight from 13 to 10.8 g. Meanwhile, the flowpath/wall thickness ratio is 380:1. Normally, this would require a very high level of injection pressure – at the expense of energy requirements and mould wear. This is why injection compression moulding is used for this application. The special "Next Cycle IML" label can be completely separated from the PP of the cup during recycling, so that the product can be recycled by type after use.