Automotive manufacturer SPAL needed to upgrade its production line to meet changing market demands — including faster cycle times and reduced energy consumption. This meant upgrading from hydraulic to electric injection moulding machines, which presented several challenges. SPAL turned to EPF, the distributor of Shibaura Machine injection moulding equipment in Italy, for a solution. The results? Significant gains in productivity, efficiency and energy savings with the new, all-electric machines.

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“EPF was able to supply Shibaura Machine — formerly Toshiba Machine — injection moulding machines with a tonnage range of 50 to 1,800 tones, which refers to the range of force or pressure these presses can exert during the moulding process,” added Carvani. With this range, SPAL can perform a variety of moulding tasks, from smaller components requiring less force to larger parts needing higher tonnage.”

To overcome these hurdles, SPAL turned to its strategic partnership with EPF, exclusive distributor and service partner of Shibaura Machine. The collaboration began when SPAL decided to focus on full-electric injection moulding machines. Shibaura Machine, already had the capabilities to supply injection moulding machines of a high tonnage range.

With Shibaura Machine's injection moulding machines at the core of its production processes, SPAL achieved significant gains in productivity, efficiency and energy savings. By addressing challenges such as technology adaptation, production capacity enhancement, efficiency improvement and quality assurance, the collaboration enabled SPAL to position itself as a leader in the industry.

The machines offer faster injection speeds and improved cycle times, contributing to enhanced productivity and cost-effectiveness. Furthermore, their user-friendly interface and integration with the Internet of Things (IoT) simplify operations and support preventive maintenance strategies, ensuring optimal performance and longevity.

To learn more about how Shibaura Machine's all-electric injection moulding machines support sustainable manufacturing, visit TM Robotics’ website.

Furthermore, the integration with the Internet of Things (IoT) allowed for remote monitoring and diagnostics, empowering SPAL to proactively identify and address potential issues, thereby reducing the risk of unplanned downtime and ensuring continuous production.

However, despite these challenges, transitioning to electric presses offers long-term benefits, such as reduced operating costs and improved sustainability. Overcoming these obstacles demands strategic planning, collaboration with suppliers, and diligent implementation to realise the advantages of electric press technology in automotive manufacturing.

Performance tests conducted by Shibaura Machine ensure the energy efficiency of all-electric injection moulding machines. For example, the Shibaura Machine EC650SX-61B IMM, boasting a clamping force of 650 tons, showcased a notable 51 percent reduction in energy consumption compared to hydraulic servo alternatives. Similarly, the EC1800SX-155B model demonstrated superior cycle time and an impressive 30 percent overall energy efficiency gain compared to rival machines.

"Embracing all-electric injection moulding machines brings more than just efficiency gains, it opens the door to more diverse manufacturing,” said Nigel Smith, CEO at TM Robotics, distribution partner of Shibaura Machine. “By providing flexible production capabilities, reduced energy consumption and enhanced performance, Shibaura Machine's machines empower manufacturers to explore new markets, and cater to varied product demands.”

These performance tests reaffirmed the value proposition of Shibaura Machine's injection moulding machines, providing SPAL with confidence in their ability to deliver both operational excellence and energy efficiency.

Established as Forum Molding in 1992, the company has a rich history of providing plastic injection molding and manufacturing solutions, predominantly for global medical clients. As demand for more robust molding and thermoplastics solutions increased, Forum remained dedicated to pursuing new offerings to cater to client needs. Evolving into a role as a contract manufacturer for its clients, Forum Plastics expanded its services beyond injection molding to additionally include rapid prototyping, modular molding, automation, cleanroom assembly, and CT part scanning. While Forum has historically specialized in medical molding, clients with general industrial molding, such as electronics, automotive, and consumer products, now turn to the contract manufacturer for everything from precision injection molding to fabrication.

Transitioning to fully electric presses presents significant challenges for automotive manufacturers. Firstly, the initial investment costs can be substantial, encompassing the purchase and installation of more expensive electric presses along with necessary upgrades to the facility's electrical infrastructure. Moreover, specialised training and expertise are essential for operating and maintaining these presses, requiring investment in staff development or recruitment.

Founded in 1959, SPAL Automotive has grown from being a manufacturer of plastic components to a pivotal player in the automotive sector, producing axial and centrifugal electric fans for various vehicles. However, the company realised that it needed to adapt its production processes to evolving market demands.

Based in Waterbury, CT, Forum Plastics LLC is a global contract manufacturer and partner of OEMs with a foundation in engineering and expertise in complex geometries and technically challenging injection molding, insert molding, and overmolding. For over 30 years, Forum has supported the manufacturing needs of clients across industries, most notably for medical devices where precision, accuracy, and quality are of the foremost concern. Forum provides molding services as well as mold design and fabrication, prototyping, multi-component assembly, and pad printing services, among others. Visit www.forumcm.com for more information.

The tradename is designed to more accurately reflect the breadth of services offered by the manufacturing solutions provider.

WATERBURY, Conn., Feb. 6, 2024 /PRNewswire-PRWeb/ -- Forum Plastics LLC (Forum), a premier global contract manufacturer catering to OEMs, today announced that it will begin to operate under the DBA Forum Contract Manufacturing. The addition of the DBA name is designed to better represent the wide range of services and capabilities offered to manufacturers across all industries. The corporate name rebranding will also be accompanied by the launch of an updated website designed to reflect the company's modern approach to complex manufacturing solutions.

"Forum Contract Manufacturing may be one of the best kept secrets in the medical device, industrial, and military and defense industries. Forum has incredible on-time delivery and unparalleled quality and is on a constant quest to lower cost while reducing our carbon footprint."

Throughout its 30+ year history, Forum has dynamically grown in response to client demand, market trends, and technological developments, allowing it to remain at the forefront of not just molding but also value-added services such as printing and laser marking, cleanroom manufacturing, automated assembly, and prototyping. "Forum Contract Manufacturing may be one of the best kept secrets in the medical device, industrial, and military and defense industries," said Mark Polinsky, President of Forum. "Forum has incredible on-time delivery, unparalleled quality, and is on a constant quest to lower cost while reducing our carbon footprint."

Moreover, the machines boasted faster injection speeds, resulting in reduced cycle times, thereby increasing overall productivity and throughput for SPAL's manufacturing operations. The user-friendly interface simplified operation, enhancing ease of use for SPAL's production personnel and facilitating seamless integration into existing workflows to minimise downtime and maximise efficiency.

The shift from hydraulic to all-electric presses would mean not only updating production processes, but also revamping infrastructure to seamlessly accommodate the new technology. To support with these challenges, SPAL turned to its longstanding partner EPF, a partner for Shibaura Machine injection moulding equipment.

SPAL’s collaboration with EPF facilitated an expansion of its production department, equipped with 21 fully electric injection moulding machines ranging from 50 to 1800 tons, with a capability to reach 2500 tons. This expansion enabled SPAL to meet market demands effectively and cater to a broader range of products.

Joseph Stephens, Forum Plastics LLC, DBA Forum Contract Manufacturing, 1 203-754-0777, [email protected], www.forumcm.com

Forum promises to continue its legacy of partnering with clients to develop and manufacture complex products with a constant eye on quality. Notably, Forum continues to meet the requirements for ISO 13485:2016, a standard in quality for the design, production, installation, and servicing of medical devices. The company also holds ISO 14001:2015 certification for environmental management systems. In addition, Forum is ITAR compliant and registered with the FDA under Medical Devices, enabling clients to proceed with peace of mind that their products will be produced with the utmost precision, quality, and sensitivity.

Manufacturers must also ensure that the performance and efficiency of electric presses meet production requirements, which may involve testing and optimisation. Integrating electric presses into existing manufacturing systems poses complexities, including compatibility issues and software adjustments. Additionally, sourcing components and adhering to regulatory standards present further hurdles, while the transition period itself can disrupt operations.

Automotive manufacturer SPAL needed to upgrade its production line to meet changing market demands — including faster cycle times and reduced energy consumption.

Additionally, the inclusion of Digital Direct Screw Transfer (DST) Control enhanced production flexibility by enabling precise calibration of clamping force, optimising processes, and ensuring consistent product quality.

In particular, SPAL sought to evolve — and also expand — its production line in Correggio, Italy, to achieve faster cycle times, reduce energy consumption and streamline logistics. A crucial step towards this would be upgrading its hydraulic injection moulding systems to all-electric. This would invite several challenges, including the potential of significant capital investment retrofitting complexities and retraining of personnel.

“SPAL decided to focus firmly on electric presses, which was an ideal solution,” explains Moreno Carvani, managing director, EPF plastic. “The benefits include very low energy consumption, high yields in the moulding process, and high reliability.”

While the new DBA name more accurately reflects Forum's ability to partner with manufacturers with a variety of contract manufacturing needs, the brand remains focused on the tenets that have helped it achieve success over the decades. Forum prides itself on a customer-focused approach by providing project support throughout the entire development and manufacturing process. Clients experience quick response times, program management services, and assistance through every stage of the development process from concept to final parts approval. The result is a contract manufacturing partnership with Forum that empowers clients to achieve even the most challenging engineering requests with accuracy and excellence.

The adoption of electric presses not only enhanced production capacity but also streamlined logistics within SPAL's production department. Efficient material handling, improved workflow management, and reduced downtime contributed to overall productivity gains.