High line flexibility through quick format changeover, ergonomic engineering solutions, high machine performances, energy saving and compact footprint : the new IPS Injection Preform System, a 48-cavity model with a clamping force of 220 tons achieves all these goals.
• Performance: cycle times and reduced consumption
• Ergonomics and user-friendliness: innovative user interface and integrated control of the entire plant
• Flexibility: fast mould and pick-up unit changeover.
Greatly reduced cycle times have been achieved thanks to optimised hydraulics, the use of digital servo-valves fitted close to the actuators and optimised machine design to make the opening and clamping stages even more efficient.
The toggle joint system and mobile platen making up the mould clamping unit are hydraulically controlled and were designed using FEM structural analysis to optimise mechanical inertia while guaranteeing excellent mechanical strength. This ensures extremely fast lock-to-lock times and so reduces the preform cycle time.
The injection unit consists of a motor-driven plasticizing screw and shooting pot controlled by a servo-valve, thus combining high performance with energy savings.
Other interesting new features include the preform extraction robot, fully integrated on the machine. Furthermore, a three-station pick-up unit collects the preforms and allows post-cooling prior to unloading; this ensures higher preform quality and prevents any damage that might stem from handling preforms before they have cooled completely. Another key feature is the linear motor that moves the pick-up unit; in addition to outstanding performance, it allows braking energy to be recovered during the deceleration stage, thus providing assured power savings, high precision, speed and unparalleled movement repeatability.
The preform extraction solution is based on a system controlled by two hydraulic cylinders, each able to optimise ejection force and so ensure considerable energy savings.
Ergonomics and user-friendliness
An extremely innovative, simplified user interface makes utilisation easy, minimising the time needed to train machine supervisors. All the operator needs to do, in fact, is enter the relative preform geometry data: dedicated software then determines the main process parameters which can, nevertheless, be adjusted depending on the specific item being manufactured.
All the elements making up the system - machine, robot, mould, PET drier, mould-drier, booster pumps etc. - are integrated into the system and managed from the control panel.
Equally cutting-edge is the cooling system; the pumps are installed directly at the rear of the machine and its control software ensures homogeneous water temperature throughout every stage of the process.
This is where the new IPS proves to be truly outstanding. The mould zone has been designed to make size changeovers ultra-fast; a special system ensures correct positioning of the mould, which automatically “hooks up” to the platens, connecting the air and water supplies needed for its correct operation.
A similar device has also been designed for the robot pick-up unit.
The machine can also be supplied in a configuration that allows competitors’ moulds to be fitted; however, in this case the rapid mould “hook up” system cannot be used and the advantages of fast size changeovers are lost.
Max clamping force = 2,200 kN
Space between tie-bars = 720 x 688 mm
Screw diameter of the extruder = 100 or 85 mm (depending on mould cavities)
L/D screw ratio = 25
Max. PET plasticizing capacity = 625 kg/h
Shooting pot diameter = 95 mm
Max. shot weight = 2,880 g
Max. mould cavities number (30 mm as NF)= 48
Max. mould cavities = 72
Max. preform weight & length = 60 g / 160 mm