An all-electric injection-molding cell produces twice the work with half the machines and less manpower and offers RFID tagging of consumer parts.

Cincinnati Milacron all-electric Powerline NT550 injection machine shows how to save machines, energy and labor at NPE with an unmanned molding cell producing an assembled flowerpot - complete with RFID label. The same product had previously required two molding machines and downstream labor. The Powerline NT also introduces a new high-capacity, direct-drive, reciprocating-screw injection unit with single roller-screw actuator that reduces noise and inertia.

'This cell highlights a range of all-electric molding advantages - process consolidation, floor-space reduction and a conservative 70+% energy savings over the two hydraulic machines previously used for this application,' said Powerline Product manager Andy Stirn.

'We started by marrying two molds in one machine with a sequential valve-gate hot runner from D-M-E.

The demonstration highlights how our new Mosaic control's standard injection setup permits sequential injection.

'The robot saves labor with part removal and press-side assembly, which had previously been done downstream, while the RFID labeling demonstrates how easy it is to add traceability to parts such as baby seats, medical devices, automotive parts and others that need an on-board manufacturing history.' The Powerline NT550 is the mid-size machine in a range of seven rated 2200 - 11250kN (220-1125 tonf).

It comes standard with Milacron's new Mosaic control.

'The control's 10-segment injection profiles, in combination with sequential valve gates, allow parts in the NPE demonstration to be filled and packed sequentially,' Stirn explained.

'This lessens the tonnage requirement to that of a single cavity.

'Each injection segment can be configured by the operator to be a fill stage or a pack-and-hold stage.' The NPE machine introduces a new high-capacity 54oz injection unit equipped with nozzle shut-off valve and 80mm, 24:1 BARR feedscrew from ServTek.

A single roller-screw actuator reduces mechanical complexity and components, while eliminating the need to perfectly synchronize two actuators.

The roller screw is capable of five times the speed of a ballscrew.

The all-direct drive injection unit is available with A, B, C screws, and can deliver up to 20,600 lb/in2 (at 41in3/s.).

The low-inertia direct drive eliminates all belt issues, providing faster response and more precise control, with cleaner operation, lower noise and less maintenance compared to other designs.

The Powerline's direct-connected, rack-and-pinion clamp drive powers a toggle clamp that has been mechanically balanced and refined over five generations of design.

The direct-connected system eliminates inertia and maintenance issues related to belts and pulleys, along with premature motor bearing failure caused by shaft side loading.

The clamp and drive are exceptionally quiet and responsive, with a maximum stroke length of 34.64in (880mm) - repeatable to +/-0.002in (0.05mm).

Euromap dry cycle time is a crisp <3.0s.

The clamp builds full tonnage in 0.4s.

but allows injection to begin before full tonnage is reached to cut cycle times and improve throughput.

'The rack-and-pinion clamp drive gives the Powerline NT a speed advantage over competitive electric and even allows it to compete with many accumulator-driven machines,' Stirn added.

All Powerline NT models have independent drives for each machine axis, making it easy to reduce cycle times with overlapped functions.

Cycle times are also improved by allowing pre-decompression, relaxing the toggle during part cooling to eliminate the wait on tonnage release before opening the clamp.

Tie bar spacing on the Powerline NT 550 is 36.2in x 36.2in (920mm x 920mm) with a base design that permits tri-directional part removal.

The base also houses an integrated 8.5 GPM hydraulic pump to power core or valve-gate actions.

The machine at NPE features extended daylight of 79.72in (2024mm)'.

Standard daylight is 67.72in (1720mm), with max/min mold height of 33.07in/9.84in (840/250mm).

The Powerline's advanced Moldguard and Ejectguard provide the most sensitive full stroke mold protection in the industry, according to Milacron.

'Powerline machines have historically been popular with captive molders running complex, expensive molds,' said Bob Strickley, Milacron's director of marketing.

'Moldguard and Ejectguard are technology innovations that result in significantly less repair and maintenance for molds over the life of a project or product.

'It is like free mold insurance built into the machine.' The Powerline comes standard with Milacron's new Mosaic control.

The new control's operator panel is all-sealed, with an embedded operating system that requires no hard-disc drive or back-up power source.

It has extensive capabilities for connectivity and security, with Ethernet LAN and Powerlink, dual USB ports, optional ID card reader, and web-based or network access to process data and machine status.

The 15in touchscreen display includes standard multilingual and inch/metric support, setup wizards and a single-page overview of all critical set points.

The latest toggle injection moulder combines a compact footprint with a fast lock-over clamp, easy-service hydraulics and injection unit for economical production in a fast changeover environment.

The new Cincinnati Milacron MTg Hydraulic Toggle injection molding machines are US designed and built to deliver the greatest versatility, productivity and value in their class. Innovative engineering from Milacron on the sixth-generation model of the Magna toggle machine combines a compact footprint with a fast lock-over clamp, new easy-service hydraulics and new injection unit for economical production in a fast changeover environment. Equipped with Milacron's new Mosaic control, the MTg shows off its adaptability in a two-component molding application at NPE, mated up with a low-cost, drop-in second injection unit from Ferromatik Milacron.

'The MTg machine's adaptability is just the beginning of the surprises visitors will get at our injection molding exhibit,' said Bob Strickley, Milacron marketing director.

The new ANSI-compliant MTg includes standard features such as a Meltstar screw, twin-cylinder injection with twin pull-in cylinders, and three clamp closing speeds with mold protection configurable with three setpoints.

State-of-the-art proportional hydraulics, positioning accuracy to +/-0.0014in (+/-0.035mm), closed-loop process control, and the new Mosaic control bring precision and flexibility to high-output production.

In addition, the MTg is strongly supported throughout North America with training, service and parts from Milacron's Ohio headquarters.

'The Magna is the only US toggle design that has thrived in the middle of the imported equipment onslaught, and this sixth generation design shows how Milacron listens to the voice of the customer who wants an economical workhorse to compete in a tough environment,' said Strickley.

'The MTg is designed for the molder who wants affordability, fast, easy setup, reliable operation, and excellent repeatability.

It is the 'smart weapon' they need to defend their home markets, whether it is custom molding, medical or precision work.' Glenn Anderson, vice president and general manager of Milacron's North American Injection Molding Machinery business stated: 'We invested in the development of the MTg, even as the dominance of all-electric toggle machines continues to grow.

We listened to our customers, who clearly require a high-performance hydraulic toggle that is US made and supported.' The new Cincinnati Milacron MTg is available in 170, 225, 310, and 450 US tonf (1520, 2000, 2770 and 4020kN) sizes, all designed for molding versatility and fast changeover with maximized daylight, generous platen area, ample clamp stroke, and very competitive distance between tie-bars.

The 10-pin clamp linkage - proven on countless Cincinnati Milacron toggle machines - folds on itself to shorten clamp length and reduce machine base size, while delivering faster lock-over to shorten cycle times.

Injection needs are easily matched to process requirements with multiple injection unit choices, nearly unlimited A-B-C barrel and screw combinations, injection pressures up to 36,100 lb/in2 on A barrels, and 20:1 L/D or greater screws.

Injection units feature twin pull-in cylinders and precision ways for superior alignment.

True closed-loop control is provided with 10-stage velocity and 10-stage pressure profiling.

Temperature control includes automatic PID tuning and stand-by heat capability.

'Set-up on the MTg hydraulic toggle is easy with configurable injection velocity switch points - by time, position, hydraulic pressure or volume,' said Brain Bish, product manager for the line.

MTg machines bring equal versatility to ejection, beginning with easy access to the knockout bar for fast setups, and tri-directional part removal for operating flexibility.

'Eject-on-the-fly', long ejector stroke, and eject-retract verification are available to enable fast cycle times with positive process control.

Pulsating eject (up to nine pulses) and three-stage air eject provide additional flexibility.

MTg machines are designed for high output and up time with particular attention to minimizing downtime for changeovers and machine service.

The injection unit swivels for quick screw or screw tip maintenance or replacement, while a hopper swivel enables rapid and convenient material or color change.

Automatic tonnage adjustment and bull-gear die height setting aid fast mold changes and accurate setup, with automatic heat start-up to maximize production up time.

Advanced variable volume hydraulics provide proportional control of all machine functions - clamp, injection, eject and extruder - while optimizing energy efficiency.

'Zero Leak' seals eliminate hydraulic oil leaks.

A pump-outside-the-tank system with variable-volume P/Q pump and closed-loop oil temperature control ensure easy service and stable operation.

The MTg comes standard with Milacron's new Mosaic control.

The new control's operator panel is all-sealed, with an embedded operating system that requires no hard-disc drive or back-up power source.

It has extensive capabilities for connectivity and security, with Ethernet LAN and Powerlink, dual USB ports, optional ID card reader, and web-based or network access to process data and machine status.

The 15in touchscreen display includes standard multilingual and inch/metric support, setup wizards and a single-page overview of all critical set points.

'This control fully supports the multilingual workforce and all cultures will find it easy to use,' Bish added.

All MTg machines are factory calibrated and fingerprinted with Milacron's exclusive Machine Validation Technology, allowing them to be 'cloned' for performance at the factory and validated/recalibrated to original specs as required in the future.