Sumitomo (SHI) Demag: Leading position in the race for productivity, PAC-E

Innovative PAC-E Injection Moulding Machines

David Svoboda, Managing Director of Sumitomo (SHI) Demag Plastics Machinery Česko spol. s r.o., takes a closer look at how innovative manufacturing solutions address current and future sustainability challenges. Manufacturing any product, but especially packaging, has always been about balancing processing speed and costs. Manufacturers across all industries are now also tasked with reducing their environmental impact. As many customers among leading manufacturers are pushing for a transition to all-electric production, Sumitomo (SHI) Demag has invested considerable time and energy in creating a range of machines that combine all-electric drive technology, processing speed and energy-efficiency-enhancing features.

PAC-E is one of the latest examples. Originally designed for the caps and closures market, the PAC-E model not only leads the competition but also draws on the company's extensive experience with all-electric drives to help injection moulding machines save energy and win the productivity race.

Energy-Efficient PAC-E Injection Moulding Machines

Approximately 90 % of the machines installed annually by Sumitomo (SHI) Demag are now all-electric. The company estimates that a third of these are currently used by packaging processors to manufacture caps, closures and containers used in the consumer, medical and food sectors.

“In recent years, we have certainly seen a shift in machinery investments. Energy efficiency, repeatability and precision have been key drivers of these investments. Moreover, most industries, including packaging, automotive and consumer goods, are rapidly moving towards lightweight and environmentally friendly alternatives that deliver high performance while also reducing the consumption of virgin polymer materials,” notes Svoboda.

Evidence of how quickly technologies are evolving is the fact that, over the past decade, the El-Exis SP machine has set the benchmark for processing and energy efficiency for machines operating with fast cycles in the packaging industry. The PAC-E range not only matches this speed and dynamic performance but also reduces energy consumption by almost half compared with the El-Exis SP machine.

“Fluctuating energy costs create uncertainty. Especially for packaging manufacturers, where energy is one of the highest and most unpredictable costs. Against this backdrop, fast, repeatable processing and waste reduction combined with lower energy costs are now even more essential,” confirms Arnaud Nomblot, Director of Business Development for Packaging.

The PAC-E machine, available in four clamping force variants, including the latest 420-tonne model, paves the way for even greater production efficiency. Nomblot explains: “In addition to reducing component wear, minimising waste and addressing machine maintenance and downtime, PAC-E directly tackles the biggest cost in every production cycle - energy consumption.”

In addition to being exceptionally energy-efficient, PAC-E is also cleaner. The toggle mechanism's lubrication system addresses cleanliness issues. The fully enclosed circuit design is leak-free. Instead, the oil is extracted, filtered and recycled. This eliminates the need for regular cleaning.

For high-volume manufacturers, however, it is the reliability of the PAC-E machine and its fast cycle times that increase production capacity and support large-scale growth, adds Nomblot. “This is where the PAC-E machine truly excels. It delivers a stable production speed and adapts to changes in dynamics to maintain optimum performance.”

Flexible All-Electric IntElect S Injection Moulding Machines

The latest IntElect S machine also fills a critical gap, bringing the associated benefits of the all-electric market to even more product applications. Positioned precisely between the conventional all-electric IntElect range and the new high-speed PAC-E machine, the IntElect S machine is aimed specifically at plastics processors manufacturing in series within tight tolerances while operating at the highest speeds.

Svoboda particularly highlights responsive, high-performance drives, a shorter screw pitch on the clamping side and a longer service life. This is topped off by a more pronounced increase in injection speed, achieving an average cycle time saving of one second compared with the standard IntElect model.

These all-electric technologies benefit even the most productive and highest-performing manufacturers. For example, some of the latest machines are now equipped with new, extremely powerful injection units. These include PAC-E as well as one of the latest IntElect medical machines in the 130-180 t clamping force range, which can be powered by a 910 injection unit. Rapid energy savings are among the key benefits of being able to choose a smaller medical machine capable of handling larger shot weights.

“This highly efficient yet compact production cell for medical cleanrooms is characterised by repeatability and cleanliness. Engineered for high speed and precision, it is designed to meet the extremely tight tolerances of high-volume medical applications in the most efficient way, while giving processors the flexibility to injection mould everything from small medical parts to larger components,” elaborates Andreas Montag, Director of Business Development for Medical Applications.

“The speed characteristics and injection performance of these new injection units, combined with the electric direct drive, ensure that no high-speed application now needs to compromise on any aspect of processing speed, productivity, reliability or energy savings,” assures Svoboda.

All PAC-E and IntElect machines are compatible with Sumitomo (SHI) Demag's cross-platform open communication software. These real-time digital tools can also lead to more productive planning and a significant reduction in unplanned machine downtime.

Fully Integrated Plastics Injection Moulding Automation

Thanks to a standardised approach to manufacturing solutions, linear robots work in complete synchronisation, further enhancing the benefits of our injection moulding machines. SAM-C robots, used, for example, in IntElect production cells with clamping forces from 50 t to 500 t for applications with cycle times longer than 9 seconds, are valued for their dynamic performance, precision, efficiency and, of course, full integration into the machine control system.

These automation solutions, which increase productivity through proprietary servomotors and precision gearboxes, cover a wide range of applications, from standardised solutions to complex projects. “Thanks to our interdisciplinary teams with industry experience, forming a network of more than 500 dedicated automation experts, we cover the entire spectrum of plastics injection moulding automation, from machine technology, robotics and conveyor technology to networked control and information technology,” explains Svoboda.

The article was published in Svět plastů.