Focus on speed, precision and energy efficiency
Netstal Hall C6 – Booth 361
Netstal presents the next generation PET-Line at drinktec
Netstal will be presenting its latest generation PET-Line 4000. The injection moulding system includes updated solutions and functions designed to improve efficiency and offer intuitive user experience.
Photo top: Netstal PET-Line 4000 of the latest generation (symbolic image of complete system)
A PET-Line 4000 will be highlighted at the booth of the Swiss mechanical engineering company, producing 6.9 g preforms with a 25/22 thread. PET resin with a share of 30% rPET will be processed. In the interests of sustainability, the preforms produced are then fed back into the PET recycling loop.
High cavity moulds
Part of the injection moulding solution is a newly developed mould from Krones Group sister company MHT with 144 cavities and an integrated self-cleaning function. The PET-Line 4000 operates the mould with a fast cycle time of 4.8 s. With around 108,000 preforms per hour, it is one of the most productive systems with a clamping force of 400 t, says Netstal. For higher output with the same clamping force, MHT also offers a suitable mould with 160 cavities. If a maximum output is required, customers opt for the larger PET-Line 5000, which can be equipped with up to 192 cavities.
Energy efficiency
A key element in increasing overall efficiency in the production of preforms is the continuous optimisation of energy efficiency. With the integrated recuperation of kinetic braking energy from the clamping unit and post-mould cooling station, the PET-Line is the most energy-efficient system on the market, Netstal claims. The optional System Pressure Reduction is said to further improve efficiency. When this function is activated, the pressure in the hydraulic system is continuously maintained at the optimum point, which is often below the maximum pressure. This reduces energy consumption in the overall system and lowers the ecological footprint of production. According to Netstal a PET-Line can save annual energy costs in the five-digit euro range compared to similar systems on the market.
Integrated quality monitoring and quality shot
The highest output is useless if the quality of the preforms produced is not kept constant. Netstal places a strong focus on precision, repeat accuracy and long-term stability in the injection moulding process. Nevertheless, quality must be checked and documented in real time in a modern system. In cooperation with its partner IMDvista, Netstal has integrated a modern quality monitoring system into the PET-Line. The camera-based inspection system has been designed to enable real-time detection of defects that may appear. The inline inspection can be used flexibly for new preform designs and has an intelligent self-learning function for all cameras and inspection steps. With integrated quality control, users can identify potential weak points in the injection moulding process at an early stage and make optimisations. In addition, the quality of the delivered batches can be comprehensively documented for the customer.
Furthermore, the new and fully integrated Quality Shot offers the option of taking random samples and subjecting the preforms to in-depth laboratory testing on request. For this purpose, the system transfers the preforms of a complete shot to an additional conveyor belt and places them in a separate box.
Intuitive and secure operation
The Swiss company also focuses on flexible and intuitive operability so that users can get the most out of their system. The integrated 4-button Smart Operation control supports the operating personnel with clear instructions and colour-coding during production start-up to minimise waiting times and to eliminate operating errors. Netstal has added new tasks that extend the system’s functionality and offers smart support for more complex challenges in day-to-day production. Tasks are step-by-step instructions integrated into the Axos machine control system. The first of these is the Quick Mold Change task, which provides operators with an assistant for quick and efficient mould changes. With clear graphics and descriptions of the individual work steps, mould changes can be conducted by less experienced personnel in the shortest possible time. The new Quick Mold Change task addresses a challenge frequently mentioned by customers. Further tasks will follow in the coming months and years.
The digital partner bfa solutions will present the integration of the entire production system into its MES solution. The connection is made via the existing standard interfaces based on OPC-UA and Euromap for injection moulding machines and peripheral devices.
Trade fair exhibit with established system partners
In addition to the companies already mentioned, the following system partners will be participating in the drinktec trade fair exhibit. Neopet is supplying the food grade PET Cycle 80-R30. The material conveyor, material dryer and mould dehumidifier are supplied by Eisbär. EF Cooling supplies the chiller.