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Company news

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21 Jun 2022

Fast, precise and well-connected: NETSTAL demonstrates injection molding technology at the highest level at K 2022

Under the motto "Global Excellence for Customer Success", NETSTAL will present itself to the industry with innovative solutions for high-performance injection molding. With outstanding application expertise, high-performance machine technology, innovative services and standardized OPC-UA integration, NETSTAL paves the way for its customers to maximum productivity and lowest unit costs.

Two high-performance production systems will catch the eyes of visitors at the NETSTAL booth in Hall 15 from October 19 - 26. "The guiding theme of our appearance at K is "Global Excellence for Customer Success". This is because processors face the challenge of increasing their productivity and minimizing the cost per part produced in the face of tough competition. The shortest possible cycle times, maximum precision and high machine reliability are key factors. But the efficient use of resources is also relevant, such as the lowest possible energy consumption or thinner wall thicknesses. In these and other areas, we support customers around the world with our new organization," says Renzo Davatz, CEO of NETSTAL and member of the Executive Committee of KraussMaffei.

Powerful solutions for high-precision applications in medical technology

NETSTAL will produce pipette tips in 64 cavities on an all-electric ELION 1200. The system solution includes a precision mold from Otto Männer and a high-speed handling system from Micro Automation. An electrically conductive compound from Premix, which was specially developed to produce pipette tips for in-vitro diagnostics, will be processed. Customers benefit from the many years of expertise of all system partners and receive a turnkey and highly productive complete system. The clock generator is the energy-saving, medically equipped ELION injection molding machine, which achieves a particularly fast cycle time of around 5.3 seconds for this application. The machine is equipped with the innovative 4-button SMART OPERATION control system. This option enables users to achieve additional productivity gains through automation, standardization and shortening of recurring process steps in shift operation. Equally interesting for medical technology customers is the regular calibration of injection molding machines in accordance with ISO 17025. NETSTAL has been an accredited calibration laboratory since the end of 2021. The new service includes the calibration of the machines at the customer's site. If required, also with comprehensive documentation for use in the audit.

Exhibition premiere of the accelerated ELIOS 4500

The further developed ELIOS 4500 celebrates its trade show premiere. Due to the switch to an all-electric mold closing, the dry cycle could be accelerated by 0.1 seconds. Users benefit not only from increased productivity, but also from optimized energy efficiency: in relation to the dry cycle, the average power consumption of the machine is reduced by 7kW. Another bonus point is provided by the 450mm shorter machine length. At the NETSTAL booth, the ELIOS 4500 will produce thin-walled 150ml IML yogurt cups from a certified renewable PP from SABIC. The material is based on tall oil, a waste product from paper production. It has identical processing properties to conventional polypropylene (PP) and can be returned to the resource cycle. One cup weighs just 6.5 grams. The 12-cavity mold, like the handling system, comes from IML Solutions. The cycle time will be around 5 seconds. The in-mold labels from Verstraete will feature digital watermarks from the Holy Grail 2.0 initiative. Codes invisible to the human eye will be printed on the entire surface of the labels. These contain machine-readable information about the contents, packaging material and origin. Different types of plastic are separated by type and sent for recycling.

Perfectly linked via OPC-UA interface

As an OPC-UA Foundation Member, NETSTAL is pushing the development of the interface standard for plastics machinery. OPC-UA enables the standardized, manufacturer-independent, and efficient data exchange of machines, devices and other systems in the industrial environment. At the booth, NETSTAL will present the complete peripheral integration of a Manufacturing Execution System from bfa solutions, temperature control units from HB-Therm and Gammaflux hot runner control units. In addition, NETSTAL will participate in the OPC-UA Showcase of the VDMA. All NETSTAL machines exhibited at K, including those on partner stands, will be integrated into the umati demonstrator. Visitors to the trade fair can use their smartphones to scan QR codes attached to participating machines and systems and thus obtain information on the machine, status, the job in progress and process values in real time in the umati app.

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21 Mar 2022

FIP in Lyon: NETSTAL demonstrates biodegradable packaging on all-electric high-performance machine

At FIP in Lyon (April 5 to 8), NETSTAL will present an innovative thin-wall packaging application. On the fully electric ELION 1200-510, drinking cups will be produced in two cavities. NETSTAL uses KANEKA Biodegradable Polymer Green Planet™, a 100% plant-derived biopolymer, for this sustainable application.

Good prospects for packaging manufacturers: With a particularly sustainable packaging application, NETSTAL will demonstrate the high performance of its ELION series machines at the FIP in Lyon. The ECOCUP drinking cup with a volume of 0.33 l is made of 100% plant-based polymer. At the NETSTAL booth N11/M14, the ecological cup will be running on an all-electric ELION 1200-510 in a two-cavity mold from French partner SN Caulonque. The high-performance application runs with a cycle time of less than 4 seconds. "Low Energy, High Performance" has always been the motto of the successful ELION series. The proven recipe for success consists of outstanding energy efficiency, perfect precision and the high reliability that users can rely on for many years.

Thin wall packaging made from certified biodegradable biopolymer

The performance advantages of NETSTAL apply without restriction to alternative materials. KANEKA Biodegradable Polymer Green Planet™ is a 100% bio-based polymer (PHBH) produced via a revolutionary bio-fermentation process using renewable plant oils as feedstock. The polymer accumulated in bacteria is extracted and purified by a water-based process. KANEKA Green Planet™ grades are certified "OK home" and "OK industrial" compostable. Moreover, the material shows excellent biodegradable properties under natural conditions such as in soil and marine waters and will biodegrade into biomass, carbon dioxide, and water through the digestive process of microorganisms available in nature. Hence, selected KANEKA Green Planet™ grades are also certified "OK biodegradable soil and marine." The innovative polymer PHBH has been listed in the European Commission's regulation "no.10/2011" for all food type contact since 2019.

NETSTAL at the FIP in Lyon: Booth N11/M14

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03 Mar 2022

Higher output and reduced energy consumption: NETSTAL launches the ELIOS 4500 with all-electric clamping unit

Powerful and particularly energy-efficient: With the hybrid high-performance machines of the ELIOS series, NETSTAL is excellently positioned in the application field for high-speed thin-wall applications with clamping forces between 4500 and 10000 kN. By intelligently redesigning the drive components, NETSTAL was able to significantly shorten the dry cycle time of the smallest model with 4500 kN and at the same time further reduce power consumption. Users benefit from increased productivity and lower unit costs.

Thin wall packaging manufacturers think in terms of efficiency gains in tenths of a second. Every cycle time reduction leads to increased productivity. Another factor influencing part costs is the energy efficiency of the production equipment. In these two key dimensions, NETSTAL was able to optimize the smallest model in the ELIOS series with 4500kN clamping force. "By intelligently redesigning the actuating elements in the clamping unit, we were able to completely eliminate the hydro mechanical part of the drive and thus realize a purely electric drive train. For our customers, this makes the ELIOS 4500 even more productive. At the same time, they achieve further savings in electricity costs," says Marcel Christen, Product Manager at NETSTAL.

4500 kN: Increased efficiency in high-performance applications

The result in figures: The drying time of the ELIOS 4500 is reduced by 0.1 seconds to a new 1.4 seconds. In relation to the Euromap dry cycle, energy consumption is reduced by 7 kW. The elimination of the hydro mechanical components for operating the toggle lever also results in an overall machine length that is 450 mm shorter. "This is an advantage for our customers that should not be underestimated, if the space saved in the production hall can be used profitably elsewhere," adds Marcel Christen.

5500 to 10000 kN: Hybrid performance for thin wall packaging

In the clamping units of the larger variants with 5500, 6500, 7500, 8800 and 10000 kN, the unique, patented drive concept for actuating the toggle lever continues to be effective. "For the higher clamping forces, the hybrid drive remains the ideal synthesis to ensure the optimum combination of speed and energy efficiency. It consists of an electrically driven double gear rack and pinion and a synchronously interacting hydro mechanical actuator that ensures the build-up of the maximum clamping force," explains Marcel Christen.

With the highest speed and the best energy efficiency on the market, the ELIOS has been delighting renowned customers worldwide since its market launch in 2016. The dry cycle time ranges between 1.4 and 2.2 seconds, depending on the model. The outstanding energy efficiency of the machines is ensured, among other things, by the recovery of kinetic energy, which is reused in the form of hydraulic energy in the overall system.

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