Authored By: SDI Plastics

The plastic injection moulding industry relies heavily on injection moulding to mass produce plastic parts for a wide range of applications. The quality of the end product depends largely on the capabilities of the injection moulding machine being used. This article provides a comparative analysis of some of the top injection moulding machines on the market to help plastic injection mould manufacturers evaluate their options.

Utilising technology and industry 4.0/5.0

The plastic injection moulding industry is undergoing significant transformations with the advent of Industry 4.0 and Industry 5.0, driven by technological advancements. Here’s how these changes are reshaping the sector:

• Smart Manufacturing: The integration of Internet of Things (IoT) devices and sensors in injection moulding machines allows for real-time monitoring and data collection. This ensures optimal machine performance, predictive maintenance, and improved quality control.
  
• Advanced Robotics: Modern injection moulding machines increasingly incorporate advanced robotic systems. These robots handle tasks such as material feeding, part removal, and packaging, significantly enhancing efficiency and reducing human error.
  
• Artificial Intelligence (AI) and Machine Learning: AI-powered analytics provide actionable insights by analysing data from production processes. Machine learning algorithms can predict maintenance needs and optimise production parameters for improved efficiency and reduced downtime.
  
• Digital Twins: Creating digital replicas of physical injection moulding systems enables virtual testing and optimisation. This helps in identifying potential issues before they impact production, thus saving time and resources.
  
• Human-Robot Collaboration (Industry 5.0): While Industry 4.0 focuses on automation and smart technologies, Industry 5.0 emphasises the collaboration between humans and robots. This ensures that while machines handle repetitive tasks, human workers can focus on more complex and creative aspects of production.
  
• Sustainability: Technological advancements are also driving sustainability in the injection moulding industry. Energy-efficient machines, coupled with smart systems that optimise resource usage, contribute to greener manufacturing processes.

By leveraging these technological advancements, plastic injection mould manufacturers can enhance their production capabilities, reduce costs, and stay competitive in an increasingly digital and automated industry.

Key considerations when selecting a plastic injection moulding machine

When investing in new plastic injection moulding equipment, plastic mould manufacturers need to carefully assess their production requirements and choose a machine that can handle their specific job parameters. Here are some key factors to consider:

• Shot size – The maximum volume of material that can be injected into the mould per cycle. Larger shot sizes allow you to produce bigger parts.
  
• Clamping force – The amount of force the machine can apply to keep the mould closed during injection. Higher clamping force is required for moulds with larger surface areas.
  
• Precision – How consistently the machine can produce uniform parts according to specifications. Precision is critical for tight-tolerance components.
  
• Repeatability – The ability to consistently reproduce the same results over multiple production runs. High repeatability reduces waste and defects.
  
• Speed – The cycle time or rate at which the machine can produce parts. Faster cycles translate to higher output.
  
• Flexibility – Capability to accommodate different moulds and material types with quick changeovers between jobs.
  
• Reliability & uptime – Duration between required maintenance and minimising downtime. Reliable machines have better uptime and uninterrupted production.
  
• Energy efficiency – Reduced power consumption cuts operating costs and is environmentally friendly.
  
• Automation – Integrated robotic systems for automated material handling and part removal boosts efficiency.

Comparing popular injection moulding machine brands

The injection moulding machine market is dominated by a handful of large equipment manufacturers with decades of industry experience. Here is an overview of the capabilities of some of the top brands:

Arburg

• German engineering and manufacturing
• Renowned for precision and reliability
• All-electric machines offer energy savings
• High-performance hydraulic machines with large clamping forces
• Extensive range with shot sizes from 15g to 55,000g
• Quick changeover mould systems
• Advanced control systems for monitoring production
• Options for integrating robots and automating material flow

Engel

• An Austrian company focused on innovation
• Tie-bar-less machine design improves access and visibility.
• Low friction drive technology enhances precision.
• The e-mac line features full electric operation and lower energy use.
• e-motion models optimised for high speed cycles
• Easy integration of automation modules like robots
• Sophisticated control and monitoring of processes

Milacron

• Broad product portfolio
• Roboshot line has integrated sprue picker robots
• Multilayer models for overmoulding parts
• High-speed PACEDERE series reduces cycle times
• All-electric and hydraulic clamping systems
• Mosaic control interface for centralised monitoring
• Quick mould changeover for flexibility

Nissei

• Japanese company with over 80 years of experience
• Hybrid machine line combines the advantages of electric and hydraulic drives
• Highly energy efficient operation
• High precision and consistency
• Reduced footprint machines maximise clean room space
• ANC robotic systems for automation
• Eco Monitor feature analyses energy consumption

Sumitomo (SHI) Demag

• German-Japanese brand with focus on technology
• IntElect line features all-electric machines
• Systec Servo drive system delivers high speeds, precision, and energy savings
• Modular automation cells with integrated robotics
• El-Exis SP hybrid models combine electric and hydraulic drives
• Open control architecture works with any peripheral devices
• Data monitoring of processes through the IntElect Mobile app

This summary of features for the top injection moulding machine manufacturers demonstrates the range of options available to plastic injection mould manufacturers looking to optimise production. While no single brand is ideal for every situation, this overview helps identify key strengths of each.

Assessing the right fit: key considerations for plastic injection moulding machines

When selecting a plastic injection moulding machine, manufacturers must carefully evaluate various specifications to ensure the equipment meets their production requirements. Here are the essential factors to consider:

Moulding Capacity: Shot sizes vary from 5 grammes to over 55,000 grammes, with larger capacities required for bigger parts.

Mould Compatibility: Clamping force, measured in tonnes, determines the size of moulds that can be accommodated. Look for machines with high clamping force, such as Engel’s 6,500 kN option.

Mould Flexibility: Tie bar spacing, ranging from 350 x 350 mm to 1,300 x 1,300 mm, allows for moulds of various sizes. Wider spacing provides more flexibility.

Production Efficiency: Dry cycle time, the time needed for injecting and cooling material, affects production rates. Faster dry cycle times increase hourly part production.

Injection Speed: Measured in mm/s or cubic inches/second, faster injection rates reduce cycle times and boost productivity.

Screw Performance: Screw diameter, ranging from 14 mm to over 100 mm, affects plastic feeding and injection. Opt for machines with efficient screw designs.

Energy Efficiency: Electric power consumption, such as Arburg’s Allrounder, which operates with as little as 0.5 kWh of power, can significantly reduce energy costs.

Reliability: Ensure the manufacturer has a solid reputation for producing reliable machines that require minimal downtime and maintenance. Check for reviews and industry recognition.

Longevity: Look for machines built with durable materials and components that can withstand long-term use. Consider warranties and service agreements that cover extended periods.

Consistency and Precision: Repeatability, measured in mm, ensures consistent part quality. Look for machines with high repeatability, such as Engel’s ±0.003mm.

By carefully evaluating these specifications, plastic injection mould manufacturers can make informed decisions and select the ideal machine to meet their production needs, ensuring efficient and high-quality part production.

Integrating automation – robots and conveyors

Today’s most advanced injection moulding machines are those with integrated robotic systems for automation. This provides significant advantages to plastic mould manufacturers such as:

• Increased output – By using robots to handle parts after ejection, the machine finishes cycles faster and maximises parts produced per hour.
  
• Improved quality – Robots consistently handle, manoeuvre, and stack finished parts with precision, avoiding defects.
  
• Minimised labour – Automation reduces the need for manual inspection and handling of parts after moulding.
  
• Flexibility – Robotic systems can be programmed to accommodate different parts and manage changeovers between product runs with minimal downtime or retooling.
  
• Ideal for high volume production – For mass produced plastic components, automated injection moulding with integrated robotics results in huge efficiency and productivity gains.
  

Some of the top models integrating advanced robotic automation include:

• Engel e-mac: Can be equipped with Engel easix multi-axis robots with a payload capacity up to 20kg.
  
• Arburg Packaging Version: Comes standard with 6-axis Selogica robots that can pack and stack parts.
  
• Sumitomo (SHI) Demag: Available with integrated SDR robots for handling and assembly.
  
• Milacron Roboshot: Line designed specifically for all-electric machines with sprue picker robots.
  
• Nissei ANC Series: Featuring compact 6-axis robots and conveyor systems for automated mass production.
  

As product volumes increase, integrating robotic systems allows plastic injection mould manufacturers to scale up efficiently. This overview of leading options should help identify the ideal injection moulding machine specifications for your company’s production needs and budget. Automating material handling and part removal is key to maximising output, quality, and consistency when moulding large batches of plastic components.

In conclusion

This comparative look at top plastic injection moulding machine brands and specifications demonstrates the range of considerations for plastic injection mould manufacturers to weigh when investing in new equipment. While technologies and capabilities continue to advance rapidly in the industry, identifying an ideal machine still depends heavily on the specific production parameters, volumes, and requirements that are unique to your business.

Rather than navigating this complex equipment decision alone, partnering with an established plastic injection moulding services provider can help simplify the process. SDI Plastics has over 50 years of expertise in plastic injection moulding. Their experienced team can assess your production goals, part designs, and technical requirements, and recommend a moulding machine solution to perfectly fit your needs. 

SDI Plastics offers complete design and prototyping services, precision mould manufacturing, a wide range of secondary finishing and assembly options, and the flexibility to seamlessly scale up to high volume production with automated robotic systems.

For plastic injection mould manufacturers ready to upgrade equipment or amp up production, leveraging outside expertise can get your injection moulding capabilities to the next level while avoiding costly missteps. Partnering with the right plastic injection moulding manufacturers like SDI Plastics help you deliver on your business goals and vision, while producing your product at the highest level of quality.