Two large, black injection-moulded parts are what Alexandre Ramos, director of Mueller/Tecnoplast, presents to us on the factory tour during our visit in São Paulo City. The larger of the two has just come off the clock out band from a MacroPower 650 injection moulding machine. They form a glove compartment with its lid, which the Mueller division is producing for the Toyota plant in Sorocaba, just 100 kilometres away. These two parts are typical examples of the company’s product range. Mueller/Tecnoplast produces parts almost exclusively destined for the automobile industry. These include many large components, such as glove compartments or, for example, fender liners and mudguards. Here, the MacroPower from WITTMANN is the preferred machine model.

In a release, Jim Moran, business development manager at Engel North America, laid out the logistical challenges of transporting the machines from Austria to Kentucky. Actually, since each press was fully assembled and tested prior to shipping and then disassembled to be delivered to the U.S., the company was technically shipping components with 29 truckloads of parts eventually arriving in Kentucky from Austria, including the platens which were transported to and from St. Valentin via barge on the Danube River.

The high reproducibility of the surfaces is so very important, because these are visible components required to match precisely the look of the dashboards, which are produced elsewhere.

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

The enormous size of these machines required new manufacturing facilities to house them. Infiltrator completed a 59,000-ft2 building expansion over the same time as the parts were delivered. Over 2 months, the machine was assembled while the building and all the necessary auxiliary equipment and utilities were installed, including a 150-ton overhead crane intended to move molds in and out of the machine but used to help assemble the new press in the interim.

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.

A total of 54 injection moulding machines are standing on the production floor of Mueller and Tecnoplast in São Paulo. Most of these have come from WITTMANN, or WITTMANN BATTENFELD, as the WITTMANN Group’s injection moulding machine division was called until recently. As an overall system supplier, at Mueller/Tecnoplast, WITTMANN is responsible for the entire equipment, including injection moulding machines as well as automation and auxiliaries, ranging from granulate feeding devices right up to granulators for in-line grinding and recycling of sprue.

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.

“For us, WITTMANN is an important contributor to our high competitiveness,” Alexandre Ramos emphasised. And this concerns not only quality standards but also efficiency, which is due to several different factors. One of these is the high area productivity provided by the MacroPower machines. Compared to large machines of other brands, the two-platen machines from WITTMANN with their generously dimensioned mould platens take up only modest amounts of space.

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.

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

“We can always get help very quickly." This is a great incentive for us to choose WITTMANN again and again for any new projects. ”The companies Mueller, Tecnoplast and WITTMANN are linked by a long-standing, very close partnership – and one that goes beyond the borders of Brazil, according to Ramos.

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

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.

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.

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.

With its extremely accurate servo-hydraulic movements and highly consistent injection processes, the MacroPower 650 makes the most of its strengths in producing these parts. Especially combined with Flowcon plus, the intelligent water flow regulator from WITTMANN. This device controls all cooling circuits and detects any disruptive factors such as blocked cooling channels or flow quantity fluctuations. Via proportional valves, the system then automatically compensates these irregularities during ongoing production, accurately down to the tenth. In this way, the temperature remains evenly distributed inside the mould. The result is a very high consistency in quality.

Improvements in nozzle design in recent years overcome some of the limitations of previous filter, mixing, and shut-off nozzles.

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

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

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.

ADS, which places a high level of corporate emphasis on sustainability, said it has made significant investments in new equipment in recent years to help it more efficiently create its products, which are used to move water and now include high levels of recycled plastic. For Engel, which was recently been granted an EcoVadis gold rating, sustainability is also a top priority.

Determining the source of streaking or contamination in your molded parts is a critical step in perfecting your purging procedures ultimately saving you time and money.

Headlights, rear lights, reflectors, lenses and light guides are less and less often imported, but increasingly produced locally. Tecnoplast has established another mainstay for the group of companies with these product lines. Both polycarbonate and PMMA are being processed. “For this purpose, we need the best injection moulding technology."

Engel notes that dozens of individuals worked thousands of hours with a perfect safety record to complete the project. Engel received the purchase order in November 2020, with the handover of the first machine completed in February 2022. In Februray 2023, the second machine, a replica of the first, was delivered.

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

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

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.

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.

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.

“When it comes to colour and gloss, we have zero tolerance,” said Ramos. It was six years ago when Mueller received its first order from Toyota to produce glove compartments. Meanwhile, the processor has become the sole supplier of this interior component for all Toyota models manufactured in Brazil. “We have never had any discussions about quality issues over all these years. The glove compartments are really a success story.” One of many – for the corporate history of Mueller/Tecnoplast is closely linked to the development of the automotive industry in Brazil.

Two mammoth 8000-ton presses built at its St. Valentin plant in Austria have been delivered to Infiltrator Water Technologies in Winchester, Ky.

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

To collect even more specific data in future and to be able to evaluate these more easily, the Group is currently installing software solutions from WITTMANN Digital, such as the TEMI+ MES. The automobile industry drives its suppliers at high speed towards CO2 neutrality. With Toyota, for example, Mueller has signed a joint commitment to that effect. The individual actions to be taken go beyond injection moulding production. For instance, transport packaging for both moulded parts and raw materials is being minimised more and more and re-used wherever possible. Milk run optimisation is also underway.

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.

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

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.

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.

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

Infiltrator Water Technologies will use the machine’s 270-lb combined shot weight to injection mold water management products. Photo Credit: Engel

Austrian injection molding machine and automation supplier Engel (Schwertberg) has delivered the two largest-ever injection molding it has built to the U.S., shipping a pair of 8000-ton duo combi machines to Advanced Drainage Systems‘ (ADS) subsidiary Infiltrator Water Technologies (IWT) in Winchester, Ky.

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

An Engel spokesperson told Plastics Technology that ADS and Infiltrator wanted to keep most of the key details around the machine close to the vest, but Engel says going forward it will be manufacturing even larger machines, including the possibility of presses with clamp forces exceeding 12,000 tons and shot weights of a few hundred kilograms. For these machines, maximum platen size would 13 by 10 ft, with the ability to run molds weighing up to 444,000 lb and offer material throughput of 4400 lb/hr.

Both MacroPower and SmartPower injection molding machines from WITTMANN are being used to produce headlights, rear lights, reflectors, lenses and light guides for the business segment of Automotive Lighting.

“Optimelt screws ensure a gentle plasticising process to preserve the material undamaged,” said Cássio Luis Saltori, managing director of WITTMANN BATTENFELD do Brasil. “Even in the event of brief production interruptions, ongoing production can be continued without any risk of start-up scrap.”

“Michael Wittmann welcomes me just as cordially whenever I am in Austria, as Marcos and Cássio do here in Brazil. We keep in close contact with the corporate headquarters concerning technical matters, too. Our projects and issues are known there, and I know that the management in Austria is solidly backing its team in Brazil. That gives me a very good, secure feeling.”

With this new business segment, the first SmartPower injection moulding machines, also from WITTMANN, were added to the machinery. But the MacroPower machines, long proven in the company, are in use here as well. Vehicle lighting has now become a design element. In some cases, very long light guides are needed – a trend which increases the size of moulds.

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

“Mueller and Tecnoplast are pioneers in plastics injection moulding in Brazil. During the early 1950s, these companies were the first to supply the rapidly developing automobile industry in this country with plastic parts,” reported Alexandre Ramos, who has had a hand himself in shaping the company’s history for the last 25 years - for a long time as sales and purchasing manager, before he was appointed director of today’s companies by the owners in 2018.

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

As Ramos explained, injection moulding of glove boxes and their lids places extremely high demands on precision and surface quality: “These two parts are joined together by vibration welding. To get a good weld seam, their geometries must be perfectly matched.” In this case, “good” does not just mean that the weld seam looks clean, but above all that it lasts for a long time, even when the vehicle achieves a long service life and is subjected to vibrations caused by rough roads.

Quite apart from this, sustainability is gaining more and more significance and can be improved by way of material and energy efficiency. In São Paulo, material and energy consumptions are recorded, analysed and optimised systematically. For this purpose, the machines already deliver a lot of valuable data today.

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.

As a long-standing partner of Brazil's well-known major automobile manufacturers, Mueller/Tecnoplast faces the daily challenge to combine first-rate quality with maximum efficiency. The technological means to meet this challenge come from injection moulding solution partner WITTMANN.

Special transportation was required for many parts of this huge machine. Pictured is the arrival of the 257,941 lb stationary platen at the Infiltrator facility in Winchester, Ky. Photo Credit: Engel

Established in 1937 by Dr. Fritz Jacob, a German emigrant, the company first made a name for itself with household goods, manufactured primarily from metallic materials at the time. In the mid-twentieth century, the new polymeric materials provided new opportunities and extended the product portfolio, thus shifting the focus of the industry. Now they can look back on decades of cooperation with partners such as Ford, Volkswagen, Scania Latin America and Toyota.

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.

“This task could not be accomplished manually, since variations in temperature control conditions only rarely show an immediate effect,” explained Marcos Cardenal of WITTMANN BATTENFELD do Brasil. “But with this intelligent assistance system, Mueller/Tecnoplast can intervene before scrap is produced and thus save both raw material and energy.

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.

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.

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

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.

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

Detecting and making use of new opportunities – this virtue is firmly anchored in the DNA of Mueller/Tecnoplast. A business segment still in the making is automotive lighting, with good growth potential due to the increasing commitment of Japanese automobile manufacturers in South America. For several years now, Japanese companies have been creating a considerable stir in the market. New demands, but also more automotive suppliers are coming into the country. But even though competition is increasing, Alexandre Ramos sees this as a positive development: “I don’t intend to be the only one here, I’d rather be part of a strong production chain. After all, as the director I’m not only responsible for the company and its associates. It is very important for me to contribute to the further advancement of our country and our society as well.”

To combine first-class optical quality with processing efficiency, WITTMANN delivered the SmartPower and MacroPower machines destined for the lighting business segment with Optimelt low-compression screws specially developed for this field of application.

To make sure that his own production staff can fully exploit the potential of WITTMANN technologies, Alexandre Ramos sends them regularly to training courses. Of course, to the training center at the local WITTMANN subsidiary close by, but also to Kottingbrunn in Austria. “For our associates, it is very exciting to visit the machine manufacturing plant. They learn an enormous amount from the WITTMANN training sessions and thus always remain up to date. This is an important method to motivate our teams. So, the trip to Austria pays off.”

Modifications to the common core pin can be a simple solution, but don’t expect all resins to behave the same. Gas assist is also worth a try.

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.

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

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

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.

An improved line of large two-platen injection presses offers new sizes plus greater speed, educed maintenance, more operator-friendly design, and added flexibility for a range of molding requirements.

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

Today, more than ever, granulation is an important step in the total production process. Our expert explains a few of the many common traps to avoid when thinking about granulators

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.

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

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.

The Engel duo 130000/130000H/8200 combi machines each feature two 85,000 cm³ (approx. 2900 oz.) injection units capable of a combined total shot weight of 270 lbs (122 kg). In terms of footprint, the machines measure 96 feet (29.3 meters) long and 37 feet (6.4 meters) wide. Big no doubt, but in relation to their shot size and clamp force, Engel points out that these behemoths actually have a relatively small footprint made possible by the duo’s two-platen design.

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.

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 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.

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).

“The WITTMANN machines make work very easy for our technical staff,” continued Alexandre Ramos, meaning not only the robust design of the machines with clever features for easy maintenance and servicing. The manager is thinking primarily about the technical support the companies receive locally in São Paulo. WITTMANN BATTENFELD do Brasil is only an hour’s drive from the Mueller/Tecnoplast production plant.

“In this way, more machines fit into the hall,” Ramos concluded. “Here we are not in an industrial zone, but in the middle of a city, where industrial properties are very expensive. Compact machines and production cells mean that we can continue to grow for quite a while without having to extend our building.”

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From left to right: Cássio Luis Saltori from WITTMANN BATTENFELD do Brasil, directors Pablo Aparecido Rabachini, Alexandre Ramos and Valdir Luiz Benedicto from Mueller/Tecnoplast, and Marcos Cardenal, also from WITTMANN BATTENFELD do Brasil.