Chen Hsong is offering several new lines of machines, not all of which were at the show. The Jetmaster MK6 line of servohydraulic toggle presses comes in 88 to 668 m.t. The clamp, base, and injection unit have all been redesigned and beefed up. Also redesigned is the Jetmaster Large SVP/2 series from 650 to 3000 m.t. New Evolution MK6e servohydraulic toggles (90 to 650 m.t.) are a lower-cost version said to be suitable for 80% of the market. The powerpack has been downsized somewhat, so these machines are not optimal for high-volume or high-torque production. There’s also a smaller new low-cost line, Focus SVP/2 from 20 to 60 m.t. At the higher-performance end is the new Speed series of servohydraulic toggles (128 to 468 m.t.) with a “top-of-the-line,” high-response servomotor for ultra-high-speed injection. The related new Speed-Pack series (260 to 470 m.t.) has longer screws, up to 26:1 L/D. Finally, a new all-electric series is the Spark line from 100 to 230 m.t., boasting a more compact and more open design.

Right after the Lehman shock, the economy struggled, and our industry crashed pretty badly. I am proud to say that while we were very negative for a long time, but we were able to manage and keep going. We tried to keep the cash flowing. Despite being negative, we were able to keep our business and our promise to our grandfather. He always says that all our employees are our family. Our company's philosophy states that everybody eats the same meal, and we eat the same rice from the same rice cooker. We want to keep that philosophy as our tradition. In fact, we have employed people who cook for all of us in our cafeteria every day, and we used to serve dinner too. Back when my grandfather started the business, he asked my grandmother to cook daily for everybody. She was actually running the lathe too. She had my father on her back while working, running the lathe and working in the kitchen. That was how our family started our business 74 (forty) years ago.

Sumitomo (SHI) Demag added models and sizes to several lines of machines. Its IntElect S high-speed, all-electric series for thin-wall and precision parts in cycles of 3 to 6 sec will gain a new larger size—500 m.t.—this year (complementing the new 500-m.t. IntElect model for general-purpose technical molding in cycles under 10 sec). Also, the IntElect Multi line of two-component machines for automotive and consumer parts will extend its size range from 100 to 180 m.t. upward to 500 m.t. this year.

NPE2024: Sumitomo SHI Demag’s show focus is on the application of all-electric injection molding machine technology for a variety of markets and components.

Join this webinar to explore the transformative benefits of retrofitting your existing injection molding machines (IMMs). Engel will guide you through upgrading your equipment to enhance monitoring, control and adaptability — all while integrating digital technologies. You'll learn about the latest trends in IMM retrofitting (including Euromap interfaces and plasticizing retrofits) and discover how to future-proof your machines for a competitive edge. With insights from industry experts, it'll walk you through the decision-making process, ensuring you make informed choices that drive your business forward. Agenda: Maximize the value of your current IMMs through strategic retrofitting Learn how to integrate digital technologies to enhance monitoring and control Explore the benefits of Euromap interfaces and plasticizing retrofits Understand how retrofitting can help meet new product demands and improve adaptability Discover how Engel can support your retrofitting needs, from free consultations to execution

At the show, Wittmann molded a thick-walled cosmetic jar and cap with the heavy feel of glass, molded in two colors in 4 + 4 cavities, with a paper in-mold label (uncoated for biodegradability) and automatic assembly of jar and lid in a screwing station outside the press. (Wittmann Battenfeld will present this innovation in the Green Molding session at the Molding 2020 Conference.)

Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.

Mixed in among thought leaders from leading suppliers to injection molders and mold makers at the 2023 Molding and MoldMaking conferences will be molders and toolmakers themselves.

Another unusual demonstration at K was the debut of a machine and material for molding a new kind of eco-friendly products. Zeroplast is a patented material from a Polish company of the same name (zeroplast.com) that is composed entirely of mineral and nonfood plant-derived waxes, fibers and fillers (including rice hulls and calcium carbonate). This “plastic-free” material is compostable and biodegradable in natural environments. It is also recyclable without any loss of properties, the company says. The material is said to be heat stable to greater than 200 C (392 F) in processing and to 70-75 C (158-167 F).

Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.

KM’s new socialProduction app for machine-to-human communication provides realtime production monitoring for all KM injection machines anywhere and anytime—and soon for non-KM equipment. Using AI, the app is designed to provide early identification of potential machine anomalies and then alert plant personnel. The app allows all relevant personnel to communicate easily to solve problems.

In addition, several new features have been introduced to Milacron’s LPIM line, including the Mosaic+ control, which has VNC capability to mirror control screens from third-party auxiliaries like robots and hot-runner controls (for the latter, Milacron has standardized on Mold-Masters’ TempMaster system). This allows both monitoring and setup of the auxiliaries from the injection controller. Also new for LPIM machines is a hybrid option with a Fanuc servomotor and drive package for the screw, cutting energy consumption by 20-25%. Other new features available for LPIM machines in the last year are a 7-in.-diam. extruder capable of plasticating 3200 lb/hr, 4500-in.3 accumulator, and 10,000-psi injection-pressure capability, vs. the standard 6000 psi.

The following report presents news not covered in our September show preview and elsewhere for a more complete picture of injection molding news at the show. See also Keeping Up and Starting Up sections of this issue for additional K-related news. A report on robots will come next month.

In the meantime, Sumitomo Demag is exploring use of AI to predict part quality based on process data. For these trials, Sumitomo Demag has interfaced STASA QC software with its NC5 machine controls. STASA QC, developed by Steinbeis Angewandte Systemanalyse GmbH (Steinbeis Applied System Analysis) in Germany, is supplied by Kistler Group in its newly commercial ComoNeo Predict software. STASA QC uses machine learning to predict quality data such as part dimensions based on the cavity-pressure curve derived from in-mold sensors. The result is automated QC without time-consuming metrology tests. STASA QC software is “trained” by means of DOE configured by the software and executed automatically on an injection machine. (More details in Keeping Up section.)

Mold maintenance is critical, and with this collection of content we’ve bundled some of the very best advice we’ve published on repairing, maintaining, evaluating and even hanging molds on injection molding machines.

Using AI to permit autonomous machine learning is the goal of a research project previewed at K that involves Sumitomo (SHI) Demag and the German Institute for Plastics Processing (IKV) in Aachen. This project is aimed at automated process optimization and fully automated quality control of part weight, geometry and temperature. Initial work of Sumitomo Demag and the IKV will be the basis of a publicly funded AI development project this year involving trials at a commercial molding plant.

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

Victor Taichung of Taiwan (represented by Fortune International) brought out its third-generation all-electric series, the Va III. The first machine in the line is the biggest model, 230 tons, which was displayed at K. The line will start at 50 tons. Features include an upgraded controller and linear bearings on the injection carriage. The 230-tonner has tiebar spacing of 610 × 560 mm, shot capacity of 536 g (PS), clamp stroke of 520 mm, and injection speed to 160 mm/sec.

Can you elaborate on your relationship with your overseas partners? What do they gain from you, and what do you gain from them?

As noted above, Nissei previewed its NEX-V Series of all-electric injection machines for the global market. The model at the show was a 280-m.t. unit, but it will be available—starting this spring—in 30 to 360 m.t. It’s said to have one of the widest platens and longest daylights in the industry while maintaining the industry’s smallest footprint. The main new feature is the TACT5 controller, designed to be Industry 4.0-ready with OPC-UA communication protocol standard and Euromap 77 and 82 capabilities available, respectively, for integration with MES systems and with mold-temperature-control systems and hot runners. The controller has a 15-in. screen with top and bottom dual windows. Nissei says this is also is one of the first machines to conform to the upcoming ISO20430 Universal Injection Molding Machine Safety Standard.

What is your manufacturing philosophy or take on monozukuri? In your opinion, what sets your company and Japan apart from its regional manufacturing competitors?

Wittmann Battenfeld introduced a high-performance plasticating unit with modified barrier screw and improved throughput rate for molding PET blood tubes in 48 cavities on an all-electric EcoPower Xpress 160-m.t. medical machine. Also new are nonreturn valves with improved wear protection and flow engineering.

After successfully introducing a combined conference for moldmakers and injection molders in 2022, Plastics Technology and MoldMaking Technology are once again joining forces for a tooling/molding two-for-one.

In view of the tooling business being a complicated and old-type style business that keeps lots of traditions and standards, we want to be more easygoing, fashionable and creative.. That is why having younger people in management is advantageous because they have more ideas. The older ones usually keep things ordinary, fixed and old school. I asked all the former management people to step down. To do that, I needed a trigger. I do not think some of the old-school things have changed, but we have project management, which is unusual for tooling companies in Japan. Project management is common in the US and Europe. On the contrary, it is more army-style in Japan.

Another “green” thrust in molding exhibits involved processing of biobased materials. One impressive demonstration in this vein was Nissei’s production of champagne flutes from PLA bioresin. Nissei says PLA has poor flow characteristics, but was able to mold this deep-draw drinkware with what it claims is the thinnest wall ever molded in PLA—as thin as 0.65 mm over a flow length of 125 mm. To accomplish this, Nissei came up with a new way to inject supercritical CO2 into the melt to improve the fluidity of the material. Remarkably, the glassware is crystal clear, owing to the use of only 0.5% CO2 and the microscopic size of the gas bubbles.

Arburg also initiated the spread of features launched with the new hybrid Allrounder “H” series at K 2016 to other Allrounder lines. At this show, the all-electric 570 A (200 m.t.) and 630 A (250 m.t.) appeared for the first time with the new “H” series clamp design, exterior styling, and Gestica controller with gesture-based commands.

Say “manufacturing automation” and thoughts immediately go to the shop floor and specialized production equipment, robotics and material handling systems. But there is another realm of possible automation — the front office.

And JSW has enhanced its Net 100 plantwide machine-monitoring system with newly upgraded J-Wise remote troubleshooting capability.

Blazing speed plus shrinking energy consumption supported the “green” theme at the big show. Smarter controls and growing connectivity were another key focus.

Meanwhile, Wittmann Battenfeld introduced a data reporting and analysis concept that does not require access to company IT systems or external (cloud) data storage. The new TEMIone “one-machine MES” package comes from Italian software firm ICE-flex (partly owned by Wittmann). This involves installing a server inside the machine control cabinet that is integrated with Wittmann Battenfeld’s B8 machine controller and Wittmann 4.0 Com-X router. This allows TEMIone to access and store production data from the press and cell peripherals to provide completed data traceability for up to five years of production. It can display customized KPIs (key process indicators) in a dashboard and an hourly OEE trend for the machine and workcell. It also merges error messages from individual devices into one clear error list. Data can be stored externally via USB or network connection.

Engel’s latest initiatives in digitization include integrating processing and simulation (see Starting Up) and a program in horizontal networking via its participation in the German ADAMOS (Adaptive Manufacturing Open Solutions) consortium for Industry 4.0 and IOT solutions (adamos.com). Besides Engel, the alliance includes at least 13 other companies, such as DMG Mori, Mahr, Durr, Oerlikon, Illig, Zeiss, Software AG and ASM Solutions.

For PET preforms, SIPA of Italy introduced an enhanced version of its hybrid XForm system, dubbed Gen4 XP. It reportedly provides a new operator experience with a 21.5-in. touchscreen with high-definition graphics, swipe functions like a smartphone, and a multifunction control knob for one-handed operation. The control features automated setup routines and an in-depth part-quality troubleshooting tutorial. The servohydraulic toggle boasts a record fast dry cycle and braking kinetic-energy recovery system. Other upgrades are increased injection rate and energy efficiency—the latter is said to be typically 0.195 kWh/kg (0.886 kWh/lb). Cycle time for a 7.5 g preform is said to be 7.5 sec. Maintenance is reportedly made easier by mounting the accumulators on a pull-out rack inside the machine frame and redesigning the oil tank so that it doesn’t have to be emptied for maintenance. What’s more, SIPA introduced a smaller size in the XForm range—250 m.t., suited to 96 cavities; existing models are 350 m.t. for 128 cavities and 500 m.t. for up to 180 cavities.

While the melting process does not provide perfect mixing, this study shows that mixing is indeed initiated during melting.

In the last few years, we had a difficult time, just like everybody else globally. We most likely open our demands to our customers so that they could support us. At the end of the day, we are always supporting customers however they need us. We tell our customers exactly what is going on, even about the transfer of tools or parts. We try to be honest, and we are only trying to profit from what we make. That philosophy, which stays in our partnerships, counts in order to gain their trust.

The Coronavirus pandemic has been incredibly disruptive, especially in terms of supply chain management and supply chain partnerships for your builders and supporters. How did you react to those disruptions?

Elmet showed its new servo-driven TOP5000E LSR dosing system with web connectivity and remote monitoring/control via mobile devices.

Incidentally, Elmet noted that the emergence of LSR 3D printing has opened up a new market. A single TOP 5000 system could feed 10 to 20 3D printers.

How do you envision your international development, and what kind of tools or partnerships are you looking to create to become globalized?

Meanwhile, Sumitomo Demag’s El-Exis SP high-speed packaging hybrid series gained a new 1000-m.t. model at the upper end of its size range, aimed particularly at pail production. Accumulators provide 1000 mm/sec injection speed. At the show, it molded two 17 L PP pails (675 g each) from 50% PCR, with IML, in 12.9 sec.

A key product of the alliance is the ADAMOS Hub, a software solution for manufacturer-independent access to applications of different providers. This one unique platform reportedly can interconnect all the machinery in a plant, eliminating “data silos” and permitting an integrated view of the operating status, settings, and performance parameters of all those machines. The Hub does not collect data from the machine, but shares access to the various controllers. The result, says Engel, can be one dashboard for a whole plant or department, rather than many dashboards for individual equipment. The result could be OEE (Overall Equipment Efficiency) calculation across all machinery, something that has not been possible before now. Another example could be monitoring energy consumption for a whole plant, with the ability to drill down to individual equipment. Another benefit would be the ability to purchase and manage apps from all providers centrally, as well as access to various providers’ customer portals. (See here for other K news from Engel.)

Smart machines, smart production, and smart services—the three-part mantra of Industry 4.0 drove a lot of the news at K 2019. Arburg, for example, promoted all three as part of its “arburgXworld” (pronounced “Arburg’s world”) concept. Available in Germany since last March, it is now active globally in 18 languages. In future, all Allrounder macines will be equipped with Basis Connectivity, an IIOT (industrial internet of things) gateway to networking with higher-level software tools and the web portal.

Mike Sepe has authored more than 25 ANTEC papers and more than 250 articles illustrating the importance of this interdisciplanary approach. In this collection, we present some of his best work during the years he has been contributing for Plastics Technology Magazine.

Nissei solved the problem of molding thin-wall, deep-draw parts like this two-piece champagne flute from PLA bioresin. Nissei injects supercritical CO2 into the melt to aid flow while maintaining microscopically small bubbles that don’t affect the crystal-clarity of the product. The flute was molded on Nissei’s new NEX280V-71E all-electric, Industry 4.0-ready press (below).

When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.

Exhibitors and presenters at the plastics show emphasized 3D printing as a complement and aid to more traditional production processes.

Plastics Technology covers technical and business Information for Plastics Processors in Injection Molding, Extrusion, Blow Molding, Plastic Additives, Compounding, Plastic Materials, and Resin Pricing. About Us

Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.

TMW is a specialist producer of plastic-injection molds for automobile parts such as instrument panels and bumpers. Founded in 1949, the Japanese company supplies a host of major vehicle manufacturers both at home and abroad.

This month’s resin pricing report includes PT’s quarterly check-in on select engineering resins, including nylon 6 and 66.

The glasses were molded in two parts, a base and cup in a cell utilizing two presses with Cartesian robots that deliver parts to an assembly station with a Kawasaki DuAro two-armed collaborative SCARA robot. The machine were Nissei’s brand-new, all-electric NEX 280V-71E (details below). One press molded the 185 g cups in eight cavities in 37 sec, and the other molded 108 g bases (o.74 mm thick) in four cavities in 72 sec. (Nissei will be speaking about this application in the Green Molding session at the Molding 2020 Conference, March 17-19 in Lombard, Ill.)

Companies that have been able to succeed and have that kind of status for so long have accumulated expertise passed down to the next generations. However, the transfer of that technical expertise to the younger generation has become an growing problem, especially for chushokigyos. What has your experience been in that respect? What has been the main challenge of Japan’s demographic decline for your company?

We are always moving, but not just because there is a business there. Besides looking at new tools, one of our targets is also to put forth an effort in following up on all the tools that we have sent in the last 20 years. Tools have a lifespan of 10 to 15 years, so we do everything we can to be responsible, and we get paid for that. There is a time limit for our voluntary services, then we move on. We do what we need to do to keep our name and remain where we are.

Also new is easyTrace, a central data hub for collecting all relevant production data for any age, type, and brand of machine, including extruders, injection presses, and auxiliaries (dryers, cameras, scanners, automation systems, quality test instruments, etc.). It’s described as a “lean” solution tailor made for plastics, which translates different signal-transmission protocols for communication with MES and other central plant IT systems. EasyTrace reportedly supports nearly all interfaces that exist in the market, including Euromap 63 and 77, Profinet, etc.

Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.

In this collection of content, we provide expert advice on welding from some of the leading authorities in the field, with tips on such matters as controls, as well as insights on how to solve common problems in welding.

Introduced by Zeiger and Spark Industries at the PTXPO, the nozzle is designed for maximum heat transfer and uniformity with a continuous taper for self cleaning.

We need the capacity of our subsidiaries in China and Korea as well as our many partners outside in order to keep our business like Yokozuna (sumo champion). There are only a few firms left that are considered Yokozuna tooling companies, which means being independent.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

The Worldfolio provides business, industrial and financial news about global economies, with a focus on understanding them from within.

Zeiger Industries has enhanced its LSR conversion kits with new quick-disconnect water-cooling jackets for the barrel to facilitate maintenance. These also come in a toolless version. Also new is a connection to allow easier uncoupling of the pump assembly from the barrel. This version eliminates threads, reducing the risk of damage to the barrel in case of LSR leakage into the coupling, which can lock the threads.

In the history of your company, perhaps the biggest transformation in the automotive industry is the switch to EV and FCV. What has the impact been for you? How are you adapting to the external changes in the automotive sector?

Sustainability continues to dominate new additives technology, but upping performance is also evident. Most of the new additives have been targeted to commodity resins and particularly polyolefins.

Everybody says that it is a threat, and that is true for someone in our shoes. Plastic injection tooling businesses significantly deal with automotive, but we also do other things. We feel that the automotive side of the market is an opportunity because we can try more different ways of approaching injection tooling. That is why I have a hot runner system business. I have key factor components that need to be in the tooling. We try to work on injection businesses at the same time so that we can gather more information and collaborate back into tooling.

New from Nissei is the N-Constellation system for networking all cell components—robots, dryers, feeders, TCUs, etc.—using Euromap communication protocols and EtherCAT, with the new TACT5 injection-machine controller as a hub. Using data collection in the cloud, this system allows centralized management of settings and performance of all connected devices. Coming soon are Nissei’s Support Cloud to provide visibility of the operating status of all connected machines, and Maintenance Assistance Cloud to analyze operating data and facilitate predictive maintenance. Nissei has also updated its PQ Manager with v3.16 of this quality and production-control system. It monitors and graphs process data and events, and sends email or text alerts.

Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.

Across all process types, sustainability was a big theme at NPE2024. But there was plenty to see in automation and artificial intelligence as well.

Wittmann Battenfeld will introduce the new EcoPower B8X injection molding machine line and show direct current as an energy source for a concept machine that will power its own robot.

After working for about five years in America, I came to Japan. My uncle, the former president of the company, asked me where I wanted to go and what I wanted to do. I told him that I wanted to work in the shop. I did not care, even if that meant a two to five year commitment. Most employees who are working, managing and serving as officers in the company (shop) now are those I worked with in the shop twenty years ago. They know who I am in and out, what I do and what I expect. I do not want to be Tatematsu. Here at our company, there are six Tatematsu-san (sons) working, including my father. I am the head of this company, but we have a holding company. My father has two brothers, and each of them has a son. One of my cousins just went back to the US. He is going to be 40 next year, so he is very young to be taking over the entire US operation. Despite that, I want him to take on that challenge. I also took over this company at 40. Before, you would have to be 50 or 55, maybe even close to 60, to become the president of the company. That happens in chushokigyos all the time, as there is always the difficulty of passing things down. At our company, we are trying to lower that age required to become an officer, so we now have several younger leaders and managers. Our officers are in their mid-30s to 70s, and we consider them experienced. Still, we welcome inexperienced employees who display an understanding of who we are, what we do and what our company is expecting. If they have the capability and willingness to put their time into our business, I am also willing to put them up with our upper management. A bad thing about Japanese culture is that once you go up to higher management, you never go down. That is where you get stuck. At the same time, many younger people cannot go up. Therefore, we ask them to step down, which is a mindset that I have set up in our company 10 years ago before I became president.

We do have that problem, but what helps us is our style of being an cool tool maker, which we want to be our core style. We tried to commercialize and showcase that to make our employees feel that we are doing something cool. The TMW red logo that we have been using for over 65 years was designed by my grandfather. In 2018, I designed the black logo to separate our tooling business from our venture or start-up businesses. We also pursue start-up businesses internally by taking ideas from our employees. On every occasion, I am upfront in providing any support toward that endeavor, like considering agreements. Ideally, though, we try to make our business target and end up in the tooling business. All our departments are structured to connect back to our tooling business. Our core business is the mold tooling business, which we are good at and famous for because we have been doing that for more than 60 years.

For us, continuing as Yokozuna means we have to consolidate a big number of tools with the projects they are giving to toolmakers. Our capacity cannot be calculated by just our facility. We have to share our engineering method, know-how, timekeeping, and even our software with our supply chain partners for them to be able to build our tools to our standards. Keeping that supply chain is very difficult especially during years when business is slow. We tried to stay a Yokozuna by gathering a lot of business at our facility here to supply to our partners. The benefit for us is being able to stay a Yokozuna, and for them, they get more business.

We have numerous internal mechanisms to make that possible. Likewise, we have the know-how as we have already experienced building big tools that have a lot of space. We know that we have many ways to make different shapes inside the tool. Small tools that require small injection machines have very limited space, and we cannot really do so much. The durability of big-sized tools is very hard, so we have many things that we can do inside. The airbag tear cut was one of the ideas that came from that.

Our September show preview highlighted several exhibits of machines from Arburg, Engel, KraussMaffei and Wilmington Machinery tailored to handle large amounts of regrind or PCR, in some cases through foaming and/or sandwich molding.

KraussMaffei also launched a range of new apps for digital manufacturing. New smartAssist provides immediate remote technical service at the press of a button, with audio, video and augmented-reality capabilities. New forensicExpert is a consulting service providing data-driven decision support. Via the web app, KM technicians can analyze high-resolution process data (>500 different signals every 5 millisec) for customized process optimization with no downtime during data analysis.

When I was in junior high, I moved to the US, and I did not speak a single word of English. I started from scratch. Although I was like a baby learning English, I managed to be able to speak in English. Though I am not perfect, I successfully attended school, made a lot of friends, worked and enjoyed my stay in the US. When my family decided for me to join a company in the US and not come back to Japan, I started my career there. Back then, we only had around 20 people working in the mold division of our company in the US. As I walked into the shop, I had to do literally everything, even cleaning. Nevertheless, that was a great experience for me because, in a short period, everyone was quickly teaching me everything. I was able to give support to our company's tool shop, and I was able to run machines and make data on my own as it had a smaller capacity. The younger people who come into our company here in Japan are usually assigned to a specific area and gain expertise in machining, finishing or designing. They will not get generalized training, which we consider a big problem. Given how I grew up and my experience, I know the shop, what the tools are and what the future is supposed to be. I strive to share that with our people all the time.

Negri Bossi (which is 75% owned by Nissei since November) showed the first model of Nova iP servohydraulic hybrid two-platen presses in a 1000-m.t. version. This is an extension of the Nova i hybrid toggle line introduced in 2018.

Also on display was one of the new Nova e 130T all-electric presses converted to an injection-blow molding system by means of a mold from Molmasa of Spain. The tool has eight preform injection and eight blowing cavities in alternating positions. A mold plate shuttles up and down to move preforms to blowing cavities. It’s suited for small to medium production. (Other tooling-related conversions of injection presses to injection-blow were shown at K 2016 by Boy, Engel and Wittmann Battenfeld.)

I do not send Christmas cards, but I call to say, "We apologize that we have not had a business deal in a year. This is how Japan's economy is now." We let them know, and they usually understand. They understand the good and bad times.

“Green” was the theme of K 2019, and Wittmann Battenfeld showed an all-electric machine specially modified to process the new Zeroplast 100% biobased, non-plastic material that is biodegradable/compostable (below) and potentially recyclable.

In this collection of articles, two of the industry’s foremost authorities on screw design — Jim Frankand and Mark Spalding — offer their sage advice on screw design...what works, what doesn’t, and what to look for when things start going wrong.

Other examples at the show included Boy Machines processing wood-plastic compound (Fibrolon from FKuR) on a Boy 125 E. Husky highlighted the ability of its newest HyPET HPP5e system to mold PET bottle preforms from 100% PCR with no sacrifice of cycle time or product quality (e.g., color). What’s more, the Husky machine can take molten PET reclaim directly via melt pipe from Erema, NGR, or other recycling systems, thereby eliminating pelletizing, crystallizing and drying steps and saving large amounts of energy. Husky says customers prefer this approach to feeding reground flake. This “RMTP” capability is expected to be commercial mid-to-late this year.Machine capabilities to process large amounts of recycle or bioplastics supported the “green” theme of K 2019.

Join Wittmann for an engaging webinar on the transformative impact of manufacturing execution systems (MES) in the plastic injection molding industry. Discover how MES enhances production efficiency, quality control and real-time monitoring while also reducing downtime. It will explore the integration of MES with existing systems, emphasizing compliance and traceability for automotive and medical sectors. Learn about the latest advancements in IoT and AI technologies and how they drive innovation and continuous improvement in MES. Agenda: Overview of MES benefits What is MES? Definition, role and brief history Historical perspective and evolution Longevity and analytics Connectivity: importance, standards and integration Advantages of MES: efficiency, real-time data, traceability and cost savings Emerging technologies: IoT and AI in MES

Boy Machines introduced a couple of new features not previously reported: an electric slide table for the Boy 35 E VH with vertical clamp, and integration of a Regloplas TCU with the Procan Alpha controller on a Boy XS (10 m.t.), enabling mold temperatures to be displayed and adjusted on the press control screen (via Euromap 82.1 protocol).

Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.

While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.

Imagine we come back in two years for your 75th anniversary and have this interview all over again. What would you like to tell us? What are your dreams for this company, and what goals would you like to have accomplished by then?

New “digital assistants” include the “filling assistant” for the Gestica controller, which provides a 3D graphic animation of the fill level of the part in relation to the screw position; and the “plasticizing assistant,” which utilizes a memory chip integrated into the barrel to record data on the working history of the screw and barrel to facilitate predictive maintenance.

Fanuc has a new standard execution for medical Roboshot machines, including such features as stainless-steel construction, special screws, HEPA filter, and new “bush-less” tiebars.

A bad thing about chushokigyos is that we sometimes time to preserve that legend too much. In other words, Japanese people cannot be too dry. In the business field, that is referred to as ninjo, a human connection deep within one’s heart. The upper management will try to save even the worst employee. They never fire someone, and that happens in our company. My grandfather hated to lay off employees. Throughout our 75 years of history, we have not done any layoffs in TMW, even though our business was doing badly after Lehman or 10 years before that. However, we did it in the subsidiary I managed in Malaysia. The first thing I had to do was to lay off around 20 members, which was a very tough decision for me, but it was an important learning experience. My mindset changed when I came back. Today, I am asking all my employees to input whatever they can to be in this company; otherwise, I will have to make that difficult decision. Everybody, including the banks and consultants, tells me to downsize the company due to high wage costs. However, I respond, “So what? That only means we have to make more.”  Keeping our employees means allowing them to continue making a living. Whenever we are in a bad situation, I go up in front of everybody and say, “Hey, I need to cut your wage down. Help me for a year or six months.” They always agree each time I do that because they know that the company has their interests at heart.

Artificial intelligence (AI) is increasingly a feature of Industry 4.0 digitization of molding operations. An example is KraussMaffei’s new app to provide early warning of production anomalies. KM plans to extend real-time production monitoring to non-KM equipment.

Among the new apps available via the customer portal are the Configuration app for the new Allrounder 270 S (see above) and the MachineFinder, which enables the user to enter certain parameters—such as the material to be processed and size of the tool—and the app will recommend the Allrounder machine for the job. The MachineDashboard delivers status information and key performance indicators (KPIs) for the user’s machines. VirtualControl simulates the machine controller; while SelfService provides guided error analysis and troubleshooting. And Shop allows customers to place orders 24/7 with direct access to prices, availability and order history.

In a time where sustainability is no longer just a buzzword, the food and beverage packaging industry is required to be at the forefront of this innovation. By adopting circular packaging processes and solutions, producers can meet regulatory requirements while also satisfying consumer demand and enhancing brand reputation. Join Husky to learn more about the broader implications of the circular economy — as well as how leading brands are leveraging this opportunity to reduce costs, increase design flexibility and boost product differentiation. Agenda: The cost and operational benefits of embracing circularity Key materials in circular packaging — including rPET and emerging bioplastics How to design a circular food and beverage package Strategies for selecting sustainable closures to future-proof packaging solutions Optimization and streamlining of production processes for enhanced efficiency How Husky Technologies can enable your sustainable success

No other toolmakers do some of the things we do because of our history. The only thing I ask those who want to join our company is whether they have the passion to work with us or not. Of course, they say they do on the interview. I never say, "I am going to make you into this kind of person, or I am going to groom you into being this person in our company." I always encourage them to try it. If you do not work out, then you walk out. I try to be honest with them.

Zeiger Industries’ latest LSR conversion packaging includes quick-disconnect water jackets and a pump connection without threads that can lock up if exposed to resin leaks.

Our core business will not change so much. Whether it is EV, FCV or gasoline engines, there is always interior and exterior. It is not a motorcycle, so it needs a body. Also, it does not really matter if it is simplified or electrical. Except, the design of the many things we build here will have to change because buttons will be changed to touch panels. The air conditioning, radio or other components do not have to be separated, which makes things simpler. However, the design and shape are going to be more complicated than they used to be.

Milacron is tripling its workforce for digital solutions and is enhancing its M-Powered suite of Industry 4.0 services and predictive functions through partnership with ei3, a 10-year-old firm based in New York with offices in Montreal, Copenhagen and Zurich), which specializes in remote collection and analysis of industrial machine data. Ei3 believes such data “becomes more valuable when securely liberated from the plant floor.” Its latest innovation is AI developed through ei3’s Data Science center in Zurich. Milacron says this AI paves the way for new applications to support preemptive spare-parts stocking and expanded lifetime tracking for tooling and auxiliary components. Building on these capabilities, Milacron’s M-Powered is now able to interpret the data to determine impending failures, maintenance needs, or incorrect machine settings. Any Milacron machine can be enhanced with ei3 AI capabilities in less than two weeks, the company says.

In order to change that, we have to physically change the way we run the tooling and processes. It took me about a year to continually discuss with the management how we can transform our styles and daily processes at our workplace. A year ago, we came up with new project management, and we also brought in a new management that runs daily. The older management keeps watch over the new management, but they are usually under it, as they are ordered to work and do whatever they need to do to provide support. We did that for a year and a half before totally switching over. Meanwhile, the wages remained the same.

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

AI software “learns” via DOE the influence of process variables on part quality and applies that “learning” to make good/bad part determination in production.

Engel’s simlink will refine offline simulation with results from actual molding and use Engel’s machine data to constrain simulation within the actual machine’s capabilities.

Chen Hsong demonstrated three-layer sandwich molding with recycle in the core. It utilized a second injection unit and an adapter plate to divide the two streams. And Milacron showcased its M-Powered integration of iMFLUX low-pressure molding technology, which is said to adjust automatically for large variations in melt viscosity, a potential risk in processing PCR. Milacron’s multi-nozzle low-pressure injection molding (LPIM) technology for structural-foam and structural-web molding is already to handle up to 100% regrind, and testing is underway with iMFLUX on LPIM machines.

The aim of this presentation is to guide you through the factors and the numbers that will help you determine if a robot is a smart investment for your application. Agenda:  Why are you considering automation? What problems are you trying to solve? How and why automation can help Crunch the numbers and determine the ROI

Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.

Although it is a supply chain in which there is a business between us, we call them partners, never suppliers. We make tools every day, used for applications such as instrument panels and bumpers. Considering the capacity of our headquarters plant in Inazawa, we cannot make 20 big tools in this facility each month. We are limited to seven or eight tools a month.

Sumitomo (SHI) Demag also introduced a turnkey LSR package for its IntElect series with a special screw, nonreturn valve, vacuum system and other LSR-specific options. For the pumping/metering system, the company has partnered with Nexus Elastomer Systems of Austria.

Negri Bossi also displayed a Cambio St servohydraulic toggle press outfitted with the new Motus control system (from B&R in Austria) with 21.5-in. multitouch display. It has a finger-operated mini-joystick that can be used in setup mode to move the screw, clamp and ejector. This is the same controller used on the new Nova s servohydraulic toggle and Nova i series. Coming soon is a new injection unit for Cambio presses.

Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.

Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.

August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today.

Take a deep dive into all of the various aspects of part quoting to ensure you’ve got all the bases—as in costs—covered before preparing your customer’s quote for services.

Arburg introduced its first machine that can be configured with an app. The Allrounder 270 S compact (hydraulic, 35 m.t.), as the name suggests, has a space-saving design with reduced width and the control cabinet integrated into the machine base. It can be configured and ordered online with an app on Arburg’s customer portal in a few simple steps. The customer benefits from faster delivery and prices about 25% lower than standard hydraulic machines, Arburg says.

Another introduction from Arburg was the vertical, hydraulic Allrounder 1600 T (200 m.t.) with a larger (1600-mm) servo-electric rotary table for automated overmolding of metal inserts.

JSW introduced its patented SOFIT foam injection technology. It involves injecting nitrogen gas into the barrel in a decompression zone after the melting zone and before the metering/compression zone. A special screw and barrel are required, but a cost-saving feature is the ability to feed nitrogen directly from a storage tank via a pressure-reducing valve, with no need for a high-pressure metering pump.

MHS Mold Hotrunner Systems brought its latest M3 micromolder (shown at NPE2018) to K with one new feature—an integrated vision system that can check part dimensions or ensure that all parts are removed from the mold within 5 millisec.

A profusion of new and upgraded injection machinery at K highlighted twin themes of Circular Economy and Smart Manufacturing. While presses keep getting faster, they also grow ever more energy efficient in kWh/lb of plastic processed. The vast majority of injection machines at the show were all-electric, hybrid, and/or servohydraulic. This year’s exhibits featured machines equipped to process large amounts of post-consumer recycle (PCR) or biobased materials.

A new option on J-ADS all-electric machines from JSW is said to be advantageous for molding thick-wall parts from PLA and other resins. The optional JS servo drive is said to enable extended hold times together with fast injection and high responsiveness.

The Plastics Industry Association (PLASTICS) has released final figures for NPE2024: The Plastics Show (May 6-10; Orlando) that officially make it the largest ever NPE in several key metrics.

Elmet has shrunk its TOP 5000 P pumping system with 15% smaller footprint and 10% reduced height. Also, Elmet is developing an alternative to this pneumatically driven piston-pump system: the TOP 5000 E with servoelectric screw pump. Elmet says servo drive is more expensive and will offer the same precision as the existing version, but it is being offered to meet competition from other vendors.

In this three-part collection, veteran molder and moldmaker Jim Fattori brings to bear his 40+ years of on-the-job experience and provides molders his “from the trenches” perspective on on the why, where and how of venting injection molds. Take the trial-and-error out of the molding venting process.

We do everything we can to maximize our capacity. In that situation, the business forecast in Japan does not look very good. Even though I talk about good things and our history, no one knows what is going to happen next year. It is possible for us to go down. To prevent that, we need to keep growing. Having said that, I am not trying to grow our business. Rather, I am trying to stay in business. My idea is to keep this legendary company from my grandfather, who started it. I changed the name of the company in 2018 because I wanted to take Tatematsu out of the company's name. Tatematsu Mold Works not only has over 65 years of experience but is also trusted by our customers, and everyone knows us. It was on our 60th anniversary when I changed the name. I asked my employees, "How long is it going to take us to go over that 60 years with a new plan, a new logo and a new name?". I would like my CEOs and officers to be able to go up to be in management, and to eventually take over my position. I made the decision to have others step down. Now, they can make the decision of making me step down.

Reducing waste and downtime also contributes to more efficient and therefore more sustainable manufacturing. In that vein, K 2019 saw a continued push toward greater self-regulation in processing, greater connectivity between machines, and improved communication between humans and machines as milestones along the road to Smart Factories and Industry 4.0.

Milacron showed its new Q-Series of servohydraulic toggle presses and hinted that an all-electric version is on the way—perhaps to debut in October at this year’s Fakuma show in Germany.

Successfully starting or restarting an injection molding machine is less about ticking boxes on a rote checklist and more about individually assessing each processing scenario and its unique variables.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

Most of Japan’s economy is held by monozukuri- something built. Whether small or large and global or domestic, everything starts from manufacturing and goes into the service. We understand that we have competitors in China or Korea in our tooling business. I think each company’s philosophy depends on whether they consider them competitors or partners. For our part, we think of them as our partners, and we utilize and leverage their capacity.Many in our industry would always try to compete with China and Korea or ASEAN like Vietnam, Indonesia or Thailand. On the contrary, TMW looks at them as partners in order to stay in global business.

This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.

We have to keep our core business going. We always have a QCD problem or cost issues globally. However, my philosophy is that business will come as long as we keep our healthy relationships with our customers harmonious, and not be too selfish. I might be too Japanese in saying that. We have bad and good times, as well as times with busy and less workload.

Plastics Technology’s Tech Days is back! Every Tuesday in October, a series of five online presentations will be given by industry supplier around the following topics:  Injection Molding — New Technologies, Efficiencies Film Extrusion — New Technologies, Efficiencies Upstream/Downstream Operations Injection Molding — Sustainability Extrusion — Compounding Coming out of NPE2024, PT identified a variety of topics, technologies and trends that are driving and shaping the evolution of plastic products manufacturing — from recycling/recyclability and energy optimization to AI-based process control and automation implementation. PT Tech Days is designed to provide a robust, curated, accessible platform through which plastics professionals can explore these trends, have direct access to subject-matter experts and develop strategies for applying solutions in their operations.

Additive technology creates air pockets in film during orientation, cutting down on the amount of resin needed while boosting opacity, mechanical properties and recyclability.

technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.

Across the show, sustainability ruled in new materials technology, from polyolefins and engineering resins to biobased materials.

In 2018, we changed our name from Tatematsu Mold Works to TMW. Tatematsu Mold Works was one of the biggest brands in the tooling business in Japan, especially in automotive. Everybody knows us, but we do not know everybody. Thanks to the valuable efforts of my grandfather - the former president and the company's former employees, we were considered one of the top and largest tool-making companies in Japan. We have that background that allows us to go anywhere in the world and be viewed as a good company to collaborate with in Japan, especially being a chushokigyo (SME). Partnerships are maybe the most important value and the core of our business.

Join Engel in exploring the future of battery molding technology. Discover advancements in thermoplastic composites for battery housings, innovative automation solutions and the latest in large-tonnage equipment designed for e-mobility — all with a focus on cost-efficient solutions. Agenda: Learn about cutting-edge thermoplastic composites for durable, sustainable and cost-efficient battery housings Explore advanced automation concepts for efficient and scalable production See the latest large-tonnage equipment and technology innovations for e-mobility solutions

KraussMaffei showed the new Netstal Elios 4500 (450 m.t.) high-speed, hybrid toggle press. The series was launched at NPE2018 with a 750-tonner, which is now supplemented by models of 450, 550, and 650 m.t. Also new was a 21.5-in. multi-touch display on the KM CX 80 hydraulic machine with a PLC control based on the KM MC6.

Zeroplast worked with Wittmann Battenfeld on an exclusive basis to develop a molding process for this material. The result is a specially modified, all-electric EcoPower 240 press (240 metric tons) with a special injection unit, heating system, and processing software. According to Wittmann sources, this system was adapted to the Zeroplast material’s sharp transition from solid to liquid and the resulting narrow process window.

Meanwhile, Elmet introduced a web-enabled Premium Connectivity Package with email functionality and remote support for the whole TOP 5000 series. All TOP 5000 dosing systems already have a VNC and OPC-UA interface for data exchange with the molding machine. The new remote-access interface allows users to change settings and monitor system status via the new Elmet Connect online portal and an app, without requiring access to the customer’s own IT network.

Resin drying is a crucial, but often-misunderstood area. This collection includes details on why and what you need to dry, how to specify a dryer, and best practices.

Apart from news reported in our September K preview, Fanuc of Japan (represented here by Milacron) has developed new standard software for LSR processing on Roboshot all-electric machines of 50 to 100 tons, as well as its own screw and barrel design for this process.

Join KraussMaffei for an insightful webinar designed for industry professionals, engineers and anyone interested in the manufacturing processes of PVC pipes. This session will provide a comprehensive understanding of the technology behind the production of high-quality PVC pipes: from raw material preparation to final product testing. Agenda: Introduction to PVC extrusion: overview of the basic principles of PVC pipe extrusion — including the process of melting and shaping PVC resin into pipe forms Equipment and machinery: detailed explanation of the key equipment involved — such as extruders, dies and cooling systems — and their roles in the extrusion process Process parameters: insight into the critical process parameters like temperature, pressure and cooling rates that influence the quality and consistency of the final PVC pipes Energy efficiency: examination of ways to save material and energy use when extruding PVC pipe products

In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.