Netstal sets a new standard for thin-wall packaging with the ELIOS 7500 at K 2016

will present the ELIOS 7500, a new injection molding machine with newly developed, lightning quick electrical clamping unit at K 2016 in Düsseldorf (October 19–26, 2016, Hall 15, Booth B27/C24/C27/D24). In combination with proven technologies on the injection side, users get an extremely high-performance, robust and highly precise machine that is optimally tailored to meet the high demands of the competitive thin-wall packaging market. The ELIOS 7500 will be in continuous operation during the eight trade fair days: With a cycle time of 4 seconds, more than 43,000 round lids with a part weight of 2.8 grams are produced per hour in a 24+24 stack mold.

High performance injection molding, newly driven

At K 2016 in Düsseldorf, Netstal will present the ELIOS, a new high performance injection molding machine with a clamping force of 7500 kN. “Through its Elion series, Netstal is renowned for high-precision and extremely fast injection molding machines with an electrical clamping unit up to a size of 420 tons,” stressed Dr. Hans Ulrich Golz, CEO of Netstal and president of the Injection Molding Machinery segment of the KraussMaffei Group. “With the ELIOS, our engineers have succeeded in transferring the high speed and typical Netstal precision to a 750 ton clamping unit with electrical movement,” added Golz. With the currently fastest (measured according to Euromap) dry cycle in its size class, the ELIOS 7500 is a true high performer. The secret lies in the newly developed and especially energy-efficient electrical clamping unit. The centrally aligned 5-point dual toggle lever ensures optimum introduction of force into the center of the mold installation space, and hence uniform distribution of the clamping force. The extremely robust design effectively prevents any deformation of the mold plates. The very large pillar distance and the extremely ample opening stroke facilitates the installation of stack molds or simple molds with large cavities.

Live at K 2016: Production of 43,000 domed lids per hour

The new machine can be admired live in action during K 2016 in Düsseldorf. To demonstrate its enormous performance capacity, more than 43,000 round lids with a part weight of 2.8 grams will be produced per hour in a 24+24 stack mold. This corresponds to an impressive cycle time of 4 seconds. 

Modular design for maximum flexibility

The ELIOS 7500 represents the beginning of a new machine series that will be supplemented shortly by further variants with lower clamping forces. In combination with a selection of proven high-performance injection units and the latest adaptive drive technologies, an extremely productive and high-precision overall system has been developed that can be optimally adapted to the planned application. The ELIOS 7500 can be equipped with hybrid injection units in the 2900, 4200 or 6000 sizes. Two screw diameters can be selected.

The hydraulic injection axis is driven by means of two highly dynamic servo valves that guarantee very high acceleration values, high injection capacities and precision control characteristics during the injection and hold pressure process. The two-valve technology enables a flow rate of up to 2 x 550 l/min with a maximum reaction time of 11 ms. The ELIOS delivers impressive specification values with injection speeds of up to 2,200 mm/s and acceleration values of up to 20 G. The renowned Swiss precision is nevertheless not lost with these dynamics: The finely tuned digital controller ensures very high positioning accuracy and outstanding shot weight consistency. The plasticizing unit is equipped with a special clamping system. Thanks to excellent accessibility from above, the plasticizing unit can be easily replaced.

Less energy, more efficiency: The hybrid main drive of the ELIOS series has an adaptive drive controller and a series of interconnected power converters.  As a result, enormous energy savings can be achieved in comparison to conventional hydraulic machines. To fully exploit the superb performance potential, the high-performance and highly flexible aXos machine controller is used in the new ELIOS series. It has been equipped with some new further developments for which Netstal will provide detailed information at K 2016.

Optimum fulfillment of the high demands of the unit cost-sensitive thin-wall packaging market

As result of its characteristics, the ELIOS is a highly efficient and very fast solution that has been optimally matched to the needs of users in the competitive market of thin-wall packaging. “Meeting the performance requirements of our customers is fundamentally at the center of new developments. With the ELIOS 7500, a high-precision injection molding machine is now available especially to the producers of packaging products, which enables them to successfully manufacture high-quality thin-wall packages over the long term and with minimum unit costs,” said Markus Dal Pian, Vice President Sales & Marketing at Netstal. Added to this is an application-optimized equipment box that leaves nothing to be desired. Due to the high flexibility of the media, the ELIOS can be adapted for an extremely broad range of application areas with a large number of options. For example, the connections for hydraulic mold auxiliary controllers can mounted on the operating or the non-operating side. Depending on the mold, corrosion-protected cooling water distributors are available for all mold plates. Socket outlet boxes with integrated circuit breakers can be placed at various positions on the machine for the connection of peripheral devices.

Netstal at K 2016, Hall 15, Booth B27/C24/C27/D24

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