AkvisIO IME from Kistler aims to bridge this gap and enables customers to manage and analyse data across devices and processes. The data analysis software for recording, storing and analysing high-frequency sensor and machine signals during injection moulding is intended for use by both process engineers and data scientists. It replaces the previous ComoDataCenter (CDC) data management solution from Kistler and provides a comprehensive analysis function including automatic data synchronisation with all connected systems.

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The family-owned company runs three shifts at its plant on the new MX 4000, producing approximately 20 different products with weights of up to 50 kilograms, including pallets, boxes and Paloxes. The material is usually a polyolefin such as PP or HDPE, but ABS or technical plastics are also sometimes used.

This latest purchasing decision is based on a long-standing relationship based on mutual trust. The group already operates a total of 50 injection moulding machines from Krauss Maffei, 22 of which are running in Switzerland at clamping forces starting at 800 kN.

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According to Andreas Schlegel, Head of Operations/ Managing Director at Georg Utz, the important factor is that this new investment opens up a wider gateway for material purchasing. In the case of regrind, for example, it is also possible to buy different quality grades or polyolefin blends that are more readily available. APC plus has been used on the smaller machines for two years, and in this time, scrap has decreased significantly.

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Utz is currently using another of Krauss Maffei's digital products to develop a predictive quality solution in collaboration with the Institute for Materials Technology and Plastics Processing (IWK) of the Eastern Switzerland University of Applied Sciences. The DataXplorer can save up to 500 signals per second from the machine and other sensors and display them as curves. The goal now is to determine how many of these are needed in order to predict good components reliably.

Containers for today's logistics have to be stackable, feature IML barcodes, integrated RFIDs and, of course, the logo of the company that owns them. Switzerland's Georg Utz company has specialised in this application, and for this reason it has commissioned the country's largest injection moulding machine, a Krauss Maffei MX 4000-75000.

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As a modular, scalable software solution, AkvisIO already comes equipped with a number of analysis features that are being continually expanded. These are the well-known monitoring functions of ComoScout and ComoNeo (known as evaluation objects or EOs) as well as working with reference curves. Other features include cross-cycle trend analysis and statistic statistical process control (SPC) with output of characteristic values for process capability and stability such as cp, cpk, mean value and standard deviation. All of the analysis data obtained can be visualised and integrated into various reports.

At eight locations on three continents, Utz produces solutions for in-house and external logistics. Recently, the company from Switzerland commissioned the largest injection moulding machine in the country to date. The new machine with a clamping force of 40,000 kN will allow the manufacturer to use stack and multi-cavity moulds and thus increase production volume. As a global player, Utz has over 1,350 employees and state-of-the-art production locations in Germany, England, France, Poland, China, the USA and Mexico. With an export share of around 40 percent, Utz Switzerland delivers its products primarily to Italy, Austria, Eastern Europe, the Scandinavian countries and Oceania.

The AkvisIO IME data analysis software is available for the process monitoring system ComoScout since September. This entry-level solution from Kistler analyses all available machine signals and is ideal as a retrofit for the digital connection of injection moulding machines that are not yet equipped with mould sensors or which have sensors that are used for the analysis of temperature signals at voltage inputs. Starting in January 2024, the data analysis software will also be available for use with the process monitoring system ComoNeo, which monitors the injection moulding process with the help of cavity pressure and temperature sensors.

All of the data from machines and process monitoring systems like ComoNeo and ComoScout can now be visualised and analysed synchronously and across processes.

Customers can individually determine the scope of AkvisIO IME based on their requirements. Additional modules such as trend monitoring with artificial intelligence will be released over time. Users of the previous database solution CDC can simply upgrade to AkvisIO, which will be the standard software for ComoNeo and ComoScout as of 2024. Thanks to integrated user management and rights management via lightweight directory access protocol (LDAP), AkvisIO also leaves nothing to be desired in terms of auditing, data security and traceability.

In the trend visualisation, recorded characteristic values of the machine and sensors can be compared across cycles with regard to their intervention limits, similar to statistical process control (SPC).

The heavyweight machinery traveled on a total of 22 trucks from Munich to Bremgarten (about 15 kilometers west of Zurich): one for the machine bed, each platen, one per two tiebars and one each for many other components. After twelve weeks of set-up, the MX 4000 went online on the requested target date and replaced an older machine with a clamping force of 27,000 kN that was energy-inefficient, offered limited technical options, had only a simple linear robot and had insufficient energy efficiency.

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AkvisIO IME simplifies the setting up and configuration of the connected injection moulding machines and process monitoring systems from Kistler such as ComoNeo and ComoScout. Thanks to seamless synchronisation, digital assets like tool configuration, reference curves and monitoring objects can be easily transferred and consistently managed – both on the master computer (AkvisIO) and directly on the machine. All data is saved on a cyclical basis and can be compared and analysed across cycles, giving customers a single source of truth for all their plastics processing product data. Furthermore, the cross-machine and cross-device monitoring of all injection moulding processes simplifies the creation of customised reports for quality assurance.

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The percentage of recycled material is currently 35 percent and Utz operates its own recycling sites for this purpose, for example a mill in Switzerland with a throughput of 1.2 tons per hour. Plans call for the percentage of recycled material to increase to 80 percent as part of the Utz Group's global climate strategy. This is where one function of Krauss Maffei machines plays a special role: APC plus. Based on the melt viscosity, APC plus controls the changeover point and the holding pressure level and thus ensures parts with extremely consistent weight. This balances out batch fluctuations that result from different raw materials and percentages of recycled material.

The new model features a sophisticated two-story automation system that implements the subsequent process steps such as the application of RFIDs, IML barcodes and logos plus post-processing and quality assurance within the cycle time. The two Krauss Maffei LRX robots right at the machine have twelve-meter-long Z-axes and thus a particularly large working radius.

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In addition to suitable machines and tools, transparent injection moulding processes often require more in-depth optimisation with sensors and continuous production monitoring. Moreover, when it comes to designing processes that are optimal over the long term, data management and data analysis play a decisive role: they are the missing, often underutilised, link in the value chain of modern plastics processing.

With the AkvisIO IME (Injection Moulding Edition) data analysis software, Kistler is aiming to help its customers take a further step towards the digitalisation of injection moulding.