Faster and more efficient. The All-electric injection molding machine wins the race


by Chorus Engineering

Faster and more efficient. The All-electric injection molding machine wins the race

Ski boots by Rossignol and Lange - known to all skiers. Toys of the brand Chicco by Artsana are a benchmark for parents with small children: big phone with funny beeps, colored rings and blocks. All these products so different one to the other have one thing in common: they are produced in the same plastics molding factory Omnia Plast in Bucharest, Romania.

The company is part of the Italian group Sunino and is a Newcomer on the market. On a production area of 9,170 square meters, since five years, are being produced plastic injected items. The manufacturing process includes also pad printing and assembling. Most products are exported, mainly to markets in Europe and USA. Omnia Plast has secured a stable position as a unit specialized in plastics processing. The parent corporation Sunino succeded to establish on the market in South East Europe.

PHOTO 1. Catalina Bivolaru, Product Manager at Chorus Engineering, Alexandru Grancea, Production Manager at Omnia Plast and Alexandru Pavel, Customer Care Engineer at Chorus Engineering (from left to right) are discussing the last details and already plan new business for the next period of time using Injection moulding machines from Sumitomo (SHI) Demag.

In line with the program

Up to May 2014 just 20 hydraulic injection molding machine were in operation. Horizontal machines working with a clamping force between 400 and 4,000 kN and vertical ones with clamping force between 3,500 and 5,000 kN. But market is growing, thriving business and for the production manager Alexandru Grancea appeared the need to broaden his park of injection molding machines.

“First we thought to invest in several hydraulic machines. But I found that all-electric machine promise much higher productivity, accuracy and efficiency. Thus we have oriented quickly to these ones. In this respect we accessed European funds within a project for increasing productivity and competitiveness. At the auction organized in the project after having analyzing the offers of those participating to the tender I found that all-electric machines IntElect of Sumitomo (SHI) Demag Plastics Machinery GmbH, Schwaig are better than those of the competition.” Alexandru Grancea, Omnia Plast Production Director

Currently, eight injection molding machines IntElect with clamping force between 1,000 and 2,800 kN are working in the production unit of Omnia Plast. The implementation of the contract, from design to commissioning was carried out through the representation Sumitomo (SHI) Demag in Romania, Chorus Engineering SRL. Considering technical assistance activities, Mr. Grancea has only words of praise: "The team Chorus Engineering has always been perfectly organized, had great ideas and was able to meet the short delivery time that I was asking."

Reducing operating costs

The eight new injection molding machines process TPU, PP, ABS and polyamide. From these materials are manufactured toys, ski boots and components for baby strollers. Before commissioning, the production of all articles has been tested at Sumitomo (SHI) Demag in Germany to ensure the customer with an optimal settings of the machines. With the Intellect 160-680, equipped with thefunction activeFlowBalance and activeLock, OmniaPlast manufacture ski boot heels of TPU with afour-cavity-mold. Thanks to the valve with functionactiveLock is guaranteed that from the first moment of melt injection phase cannot drain back into the sockets of the transporter melt. Sporting articles need high accuracy and consistency of the process, in order to meet tolerances and thus ensure the safety of the athlete. The function activeFlowBalance uses compressed melt expansion at the transition from injection pressure to the pressure further, so partial cavity filling is made better thanks to a reduced counter pressure. Filling levels of the cavity mold compensate quickly without any extension of the cycle. Mr. Grancea praise these features: "We could reduce the manufacturing cycle of the heel of ski boots from 62 to 44 seconds, the cavities are filled evenly and have much less waste." thankful, also added: "this is no longer need of additional efforts to reduce production costs and energy. " Despite the higher acquisition costs of these all-electric injection molding machines versus the hydraulic alternative, the investment pays back also for Romania very rapidly. Higher production, scrap reduction, reduced energy consumption, excluding of almost any kind of machine downtime and simple maintenance lead together at reduced operating costs. Mr. Grancea is totally satisfied with his decision: "The machines are easy to operate, our personnel quickly understood the use of the control system and on my side, I'm excited about their accuracy."

PHOTO 2. The component parts for Rossignol ski boots represent also a part of production range of Omnia Plast

Accuracy in the spotlight

Chorus Engineering monitored the commissioning of the IntEllect machines and provided the training. A process engineer from Sumitomo (SHI) Demag has carried out the fine adjustments. Some final optimizations and additional training of the staff at machine site have filled the activity program of the first weeks of operation of these eight new "recruits."

Meanwhile production entered at a normal pace and Mr. Grancea is already thinking to some new markets such as automotive and electronics. "We want to expand production and attract new customers in these areas. To this end and in the future I will opt for all-electric machines from Sumitomo (SHI) Demag because these industrial segments require high precision manufactured items. For me, the question of low energy consumption as well as a low number of rejects are decisive. These are important factors for success. "

PHOTO 3. Precision plastic parts for ski boots and toys are produced with the highest precision using Injection moulding machines from Sumitomo (SHI) Demag

PHOTO 4. Omnia Plast adjustment responsible, Mr. Stanciu Daniel together with Chorus Engineering and Sumitomo ( SHI) Demag Engineers, Mr. Virgil Strambeanu and Mr. Ralf Schottle put a critical eye on the first products coming out of injection machine. All of them are very pleased with the result.

Sunino Group has been working for seven years with Sumitomo (SHI) Demag. Eleven injection molding machines for packaging have been already operating since a long time in the Italian production facility if this international corporate. And now a successful partnership continues in Romania thanks to the sales agent Chorus Engineering, who brought the professional competence and commitment of the people of Schwaig in Romania.

Strong partner

Since 1997 specialist in plastics, Chorus Engineering srl has established headquarters in Bucharest, Romania. A family company offering turnkey solutions for numerous applications. Starting from design up to commissioning, customers can confidently rely on the competent services of experts from Chorus Engineering. However the commitment does not stop there: maintenance, supply and installation of spare parts, technical support or relocation of existing production lines are also part of the company's offer. Since 2003 Chorus Engineering is selling injection molding machine of Sumitomo (SHI) Demag, Germany. A happy symbiosis between common responsability and technical know-how that ensures success to projects of success.