Energy-saving e-cap production cell
Engel Hall C6 – Booth 140
ENGEL will showcase an automated production system for closure caps. At the heart of the cell is the all-electric e-cap 380 injection moulding machine with a clamping force of 3,800 kN. The application is designed to provide energy-efficient operation and consistent processing in closure cap manufacturing.
Photo top: The ENGEL e-cap
The closures produced for United Caps comply with a widely used standard in the beverage industry. The notch of the tamper-evident band is formed in the mould and then folded inwards on the underside in a subsequent step. When opened for the first time, the ring separates from the cap body, providing a clear indication of whether the product has already been opened.
Production takes place in a 48-cavity mould with a cycle time of 4 s. In the fully automated production cell, which is integrated into the ENGEL CC300 control unit, the 38 mm caps are conveyed via a cooling conveyor with waterfall sorting to the folding station, where the lower edge of the band is bent inwards, ensuring a secure fit on the bottle neck.
All-electric and efficient
The e-cap machine series was specially designed for the production of beverage caps. It offers short cycle times, high reproducibility, and low energy consumption, says ENGEL. The all-electric drive technology enables dynamic and precise motion sequences, while the rigid toggle lever is claimed to ensure reliable force transmission. With various clamping force sizes and a compact design, e-cap machines are flexibly deployable and designed for continuous operation under high demands.
As standard, the e-cap is equipped with the ENGEL Packaging package to increase performance. This includes a HIGH clamping unit optimised for very short cycle times, a reinforced, elevated moving platen, high-performance machine feet for stable and smooth operation, and high-performance injection units. The iQ motion control digital assistance system reduces cycle times by automatically optimising mould movements.
Robust plasticising
The exhibit already features the new 2465 injection unit in its premium version, which was designed for demanding high-performance applications in thin-wall injection moulding. It offers an almost 67% increase in injection speed. A dosing drive with a screw circumferential speed of up to 1 m/s is used. Special emphasis was also placed on ease of maintenance: Easily accessible service modules and maintenance points minimise downtime in the event of servicing and increase overall equipment effectiveness (OEE).
In combination with the new rotary slide shut-off nozzle, the injection unit is claimed to demonstrate high performance for applications requiring precise control of highly viscous materials at high injection pressure and with short cycle times.
Process consistency & consistent cooling
The iQ weight control digital assistance system analyses the injection process in real time and automatically adjusts the switchover point and holding pressure within a few hundredths of a second. This compensates for fluctuations in shot weight without manual intervention. The result is consistent part quality and reduced scrap, even when working with tight tolerance specifications, says the company. Additional process reliability is provided by a dry air hood over the mould and clamping unit. It prevents the formation of condensation by continuously supplying dry air.
In this production cell, ENGEL is presenting the new e-flomo one cooling water distribution system for the first time, developed specifically for applications with high cooling water demand. The new control system regulates flow rate and temperature difference directly at the main connection of the mould cooling and is fully integrated into the machine control unit. This allows cooling processes to be not only precisely adjusted but also continuously monitored. The system enables targeted optimisation of the cooling water volume, automatically compensates for seasonal temperature fluctuations and thus reduces water consumption.