Latest Thermoforming Technology Presented by NPE2006

At the 2006 NPE show, several new thermoforming processing technologies were exhibited, both of which increased the processing capabilities of in-mold labeling (IML) and beautifying plastic products. One of the new vacuum forming technologies uses extruded TPO sheet to process paintless automotive parts with a paint film; another innovative technique is to use a pre-printed PP sheet to process dairy lids, which increases productivity. Times; The "intelligent packaging" created by the in-mold labeling technology using radio frequency tags has also taken a big step forward.

At the same time, in the thermoforming technology of pre-cut sheet materials, new rotary processing equipment was demonstrated, which is said to significantly increase the productivity of HIPS and ABS refrigerator door and cabinet liners.

1 to the direction of paint-free development

Geiss Thermoforming has demonstrated its latest technological achievements, the hot plate forming technology (TSF), which consists of laminating a decorative film or decorative material on a slab (3 to 6 mm) and then thermoforming directly into the final product. . The 2006 Mustang car engine cover introduced by Ford Motor Co., Ltd. uses a 4 mm thick TPO sheet to laminate a layer of lacquer film. The lacquer film is supplied by Soliant and the TPO sheet is extruded by Southtech Plastics. Pressure processed. TSF is a proven technology; its novelty is Geiss's new simplified processing technology. The company's representative John Pirkl said that they use vacuum forming and a special heating system, thus reducing the complexity of the process And costs.

Previously, this "Class A surface" component had to be machined on a more costly pressure forming machine with a complex cooling system. In order to avoid damage to the surface quality, the heating of these parts is less than 300!. However, using Geiss's T-Series pre-cut material vacuum forming machine, it is said that because the device has a fast halogen heating system, the TPO board can be heated to 360". The halogen is a short wave of 1 micron long, so it can penetrate the core, forming “Inside and outside” are both heated, in contrast to ceramic or quartz heaters, which have long wavelengths and absorb heat on the surface, thus making the surface of the part dull and dull.

Geiss stated that this type A component can be manufactured with less effort and more easily, in particular with less mechanical costs. The company is negotiating similar projects with other car manufacturers.

Marbach, a thermoforming specialist in Germany, has made great progress in processing pre-printed PP lids. This frame technology was developed by the German packagers Huhtamaki/Rube and RPC Bebo Plastik, together with the Marbach company and the machine manufacturer Gabler, and it is said that the above recorded information can be well preserved in the PP molding process. However, the application of this technology is very limited, mainly on some minicomputers in Europe. Marbach and Gabler have now increased their productivity by more than twice the molding area. Gabler's Varius SR coil feed thermoforming machine is equipped with Marbach's 4P (pre-printed PP) processing technology and now processes plates up to 840 mm x 800 mm. With up to 36 cavities, this machine can process approximately 50,400 500g margarine lids per hour. Usually the lid thickness is about 0.4 mm.

Huber t Kittelmann, president of Marbach Tooling and Equipment, said that the company's mold design has the smallest net shrinkage, which is achieved by controlling the water cooling and improved mold movement to avoid the sheet stretching and deformation at the forming edge. . In addition, the thermoforming machine is controlled by the offset printing press, which allows precise alignment of the plate positions. The split plate transfer system also eliminates wrinkles in the hot plate. In Europe, this new technology will be used this year to process a square margarine lid.

2 In-Mold Labeling + RF Tag

At NPE, German robotics supplier Hekuma (here represented by Electronic Media International) demonstrated its newly developed new system - multi-cavity in-mold labeling technology for processing PP yogurt boxes on Kiefel molding machines. . Although the system has been in use for at least two years, Hekuma added new technologies to it, namely its integrated in-mould labeling and radio frequency tag technology, so that the packaging can hold supplies for shipping, inventory, and shelf life tracking Chain data. The company said that they have validated this technology with a manual operating system and are developing an automated process for in-mold labeling and radio frequency technology on the cup.

The RF tag consists of a copper printed circuit attached to a PET film. This 0.5 mm thick label is 35x18 mm. Hekuma admits that this type of radio frequency tag is too expensive for commercial applications. Each tag costs between 15 and 20 euro cents. In this exhibition, a four-cavity in-mold labeling and radio frequency system for processing yogurt cups has a speed of 15 rpm.

This in-mold labeling system was demonstrated at the 2004 K show and was jointly developed by Hekuma, Kiefel and Mould & Matic, Austria's mold specialist. At this NPE show, Hekuma revealed that the commercial application of the first in-mold labeling system is expected to be implemented in the spring of 2007. It will be used on a 10-cavity and processed at a speed of 15 to 20 rpm. Food container.

3 Machinery Development Cooperation

At the NPE show, we also saw some of the industry's leading machinery suppliers announce new partnerships. The first is Sencorp's cooperation with Asano Laboratories, Japan's largest supplier of thermoforming machines. According to Br ian Urban, president of Sencorp, the company hopes to expand its position in the North American food packaging market by using Asano's wide bed thermoforming machine, metal die cutting thermoforming machine, and rapid reaction heater. Sencorp will sell Asano's FLC coil feed thermoforming machine and PLS presses in the United States. In addition, it will use Asano's heaters on its Sencorp 2200 and 2500, Armac and Gen II coil feed thermoforming machines. Asano's "Hot brand" heater Hekuma has already combined the thermoformed IML system with RFID technology to create a "smart packaging."

The pre-printed PP lid can now be machined at higher yields with the Gabler Varius SR roll feed thermoforming machine and Marbach's 4P technology.

It has been reported to have a very high watt density characteristic and can be increased from ambient to 500°C in about 10 seconds and then back to 200°C. According to Sencorp, the "instantaneous" features of this heater greatly increase the efficiency of the molding machine. In addition, the oven's fast switching characteristics save 20% of energy compared to common quartz heaters.

Asano's technology also includes a special clamping substrate transfer system that saves 1 inch of material compared to conventional needle-chain transport sheet systems and eliminates the sliver left by punching. . Other features include the use of robotics, automatic tracking and counting systems for board transfer.

At the same time, OMV USA is in the process of signing a cooperation agreement with Irwin R&D, which will manufacture OMV online molding machines in the United States. Irwin will install OMV's large-scale F57 system at its Washington office. This large-capacity molding machine is now used in Italy. It features a combination of extrusion, forming, rotary take-up, tracking and counting functions. If a 70-cavity mold is used, this F57 system can process 32-ounce PP containers at 60000/hour. Extrusion capacity up to 6000 lbs/hr. Irwin will provide its fast-moving toggle technology and experience on a large platform molding machine. This machine will be sold by OMV USA.

Four years ago, the F57 system was introduced. Currently, four systems are sold in Europe and two in the United States. Kent Johansson, president of OMV USA, hopes that this U.S.-made machine will have more users in the United States without transportation costs and import taxes.

Another new development in in-line extrusion and molding is a new type of roller screw designed by Brown Machinery, which uses an independent three-platform auxiliary plug device to drive. This pending approval of the patented technology claims that the molding machine can provide greater hardness, greater load capacity, and longer operating time due to the use of auxiliary plugs.

The plug platform system is driven by a single roller screw driven by a servo motor. The platform is pulled by eight linear axes and fast-changing ball locks are used on the plug platform. The roller screw also has a separate oil system.

According to Brown's data, the roller screws of this system can be operated at a higher speed than a ball screw, and its service life is equivalent to 15 times that of a ball screw.

4 fast rotation

In industrial thermoforming, the highlight of the show is Brown Machine's four-platform rotary pressure forming machine for rapid processing of refrigerator doors and cabinet liners. The company claims that this new model has achieved a new processing record of 80 to 90 liners/hour, and the previous speed was 70 to 75.

The new model based on the company's R-Serries model can use 35 psi air pressure and claims a special flange cooling system. Other features include: Rapid rotation, variable speed electric and sealing control of the rapid platform, is said to provide high and low platform repeatability within ±0. 005 inches. In addition to this main oven, there is a multi-zone, high-wattage preheating platform. According to Brown, a global office equipment manufacturer has assembled a serial slicing equipment with a new rotary thermoforming machine in a new factory.

Reprinted from: Foreign Plastics