KraussMaffei's ultra-efficient plastics processing technology has done it again, bringing time and energy savings to a plastic transport packaging provider in South Africa.
KraussMaffei
Bobby Damalis (Operations Manager at MCG), Klaus Zeiler (Head of LOG/Pack BU at KraussMaffei), Stefan Scheuerer (Director Sales Africa at Schoeller-Allibert), Ian Victor (Managing Director at MCG), Benjamin Cockram (Director at P&CT), Jaco Geldenhuys (Regional Sales Manager at MCG) and Fabian Lewicki (Regional Sales Manager at KraussMaffei) (from the left)
MCG Industries invested in three large MX 1000-17200 machines from KraussMaffei, slashing its cycle times and energy consumption and creating a true competitive advantage for itself.
Sophisticated 2-cavity mould
Transport packaging manufacturers in South Africa are experiencing increasing cost pressure. The main reasons for this are primarily the continuously increasing raw material prices and fixed costs such as those for wages and energy. The requirements for the new injection moulding machine and mould technology at the Johannesburg location were correspondingly high.
MCG decided in favour of using a new, sophisticated 2-cavity mould and selected the suitable injection moulding machine. The partners in this project were mould makers Schoeller Allibert and KraussMaffei, who provided the suitable injection moulding technology. The goal: More output at lower cost without sacrificing quality, durability or user-friendliness.
KraussMaffei
Sophisticated combination: In terms of a two-cavity mould, the large MX 1000 - 17200 machine offers optimal utilisation of platen dimensions and clamping forces.
The first milestone
First, the focus was on the mould.
"We wanted the best and most productive mould there is for such applications," stipulated the guideline. This is where Schoeller Allibert came into play, known worldwide for the development of innovative reusable packaging products. The bid entailed a mould with two cavities – a similar mould was already being used to make transport crates for beer and brewery products. The market share of MCG in this segment is now to be expanded significantly with the first use by a manufacturer of milk crates.
This mould form combination was the first milestone for MCG. Due to the high requirements, a special injection moulding machine was needed that went beyond the usual specifications. KraussMaffei fit the bill perfectly with a large MX 1000-17200 machine. In terms of the two-cavity mould, this injection moulding machine offers optimal utilisation of platen dimensions and clamping forces with an excellent price/performance ratio. On-site service and a training concept for every employee involved, from the operator to the project manager, proved to be another important factor in the decision.
The target-oriented solution
Selected technical components supported MCG's requirements with regard to shorter cycle times and low energy consumption. This led to choices such as the HPS barrier screw being installed in the MX machine, providing exceptionally high throughput with excellent melt quality and allowing shorter cycle times, and a 20 per cent lower energy consumption as a result.
The insulating sleeve around the injection unit offers even more potential for saving energy. It reduces the heat-up time by 20 to 30 per cent. The total heat energy required drops by 20 to 40 per cent.
"Schoeller Allibert, KraussMaffei and its South African representative, P&CT, developed a solution perfectly tailored to our requirements. We were amazed at how effectively they worked together," said Ian Victor, Managing Director at MCG. "The combination of a precisely configured machine and a high-tech mould allows us to realise a wide variety of tasks simultaneously, such as short cooling times without warpage or sink marks. And all on two cavities."
"This required a very uniform melt and a very short injection time. The machine from KraussMaffei played a significant part in making this possible," added Stefan Scheuerer, Director Sales Africa for Schoeller Allibert.
The success could be readily measured. MCG had specified a cycle time of 30 seconds, quite a challenge for the product size (424 x 334 x 310 mm). At machine acceptance, KraussMaffei was able to run a stable process at a cycle time of 28 seconds. The investment has already paid off. Three identical systems just like this one are now successfully producing crates at MCG's Johannesburg location.