Sustainable Success with ENGEL e-mac Injection Moulding Machines
ENGEL’s e-mac electric injection moulding machine series combines cost-effectiveness and sustainability. Household goods manufacturer Orthex uses the advantages of the series to achieve ambitious sustainability goals.
Initial situation
The Orthex Group, based in Finland, manufactures household goods focusing on design, quality, and sustainability.
“We aim to be climate-neutral by 2030 and are working hard to reduce our carbon footprint continuously. To achieve this, we are using new materials and investing in modern production facilities.” Alexander Rosenlew, CEO Orthex
The high product quality and attractive design of Orthex products significantly contribute to sustainability.
“Even in our largest boxes, you can stack books without the bottom breaking. Not all plastic boxes on the market can do that. Our products are not meant to be thrown away after a single use. People’s awareness in this direction is increasing, and that’s a very good trend,” Says Tom Ståhlberg, Operations Manager at the Lohia location.
Requirements
The intelligent store compact clear series boxes are injection moulded from transparent styrene-acrylonitrile copolymer (SAN) in Lohja, Finland. They are available in ten sizes with shot weights from 100 to 1,000 grams. SAN is free of PBA and has food approval, making bright store compact clear boxes suitable for refrigeration. SAN offers significant advantages compared to other transparent materials, such as polycarbonate. Sustainability targets also define Orthex’s production strategy, focusing on not increasing unit costs.
“We focus primarily on two aspects: High productivity through short cycle times and energy-efficient machines.”
Tom Ståhlberg, Operations Manager at the Lohia location.
In addition, high precision and a stable process are essential for clear parts because streaks and bubbles are unacceptable in the end product. “SAN is more demanding than PP in terms of processing. Even the smallest irregularities, scratches, and deformations result in rejects,” says Ståhlberg.
For the efficient production of these storage boxes, injection moulding machines in the medium performance and clamping force range with the following characteristics were required:
- High precision
- Gentle plasticising
- Low energy consumption
- High productivity per unit area
- High degree of automation
Injection Moulding Machine
The specifications indicated electric injection moulding machines as the most suitable solution. ENGEL was able to convince Orthex with the e-mac series: The compact, all-electric e-mac was developed specifically for high productivity and efficiency in the medium performance range with cycles over 4 seconds. Therefore, Orthex invested in several e-mac injection moulding machines in sizes of 160, 280 and 380 tons.
“Electric machine movements of the e-mac are extremely precise, and the cycles are consistent. This is why more and more processors are switching to all-electric machines even outside the high-performance segment.” Christoph Schützeneder, Product Manager for all-electric machines ENGEL Austria
Solution
Another proof of the high importance of efficiency for Orthex is their principle of “No over-engineering!”. ENGEL supplied a customised complete solution based on the specifications. The production cell can be adjusted to the different part sizes of the intelligent store boxes.
- High precision: The servo-electric drives of the e-mac’s main movements enable precise positioning – shot after shot. The result: high and consistent process stability.
- Gentle plasticising: Thanks to in-house development and production of plasticising components, ENGEL offers suitable screws and non-return valves, even for materials that are challenging to process.
- Low energy consumption: High-quality drive components, such as particularly low-friction recirculating ball screws, in combination with efficient servo motors, ensure low energy requirements of the e-mac injection moulding machine.
- High area productivity: The e-mac series is one of the most compact injection moulding machines. It has the largest tie-bar spacing in the respective clamping force class. Orthex received a highly automated overall solution with minimal floor space requirements. A full electric injection moulding machine, extensive automation – everything from a single source.
- High level of automation: The storage boxes are automatically removed from the mould, labelled, and packaged for shipping directly at the injection moulding machine. Production at Orthex’s Northern European facilities offers globally competitive unit costs.
In all its efforts, Orthex keeps future generations in mind. The drive to continually increase sustainability comes from within. As confirmation of its commitment, the group now links financing of new projects to its sustainability goals. “The more sustainable we are, the more favourable our loans,” says Rosenlew. Key performance indicators negotiated with banks include using recyclates and bioplastics, measures to reduce scrap, and the energy efficiency of production machinery. The new all-electric e-mac injection moulding machines provide Orthex with high confidence in meeting these targets.
How can mass-produced household goods such as plastic boxes be manufactured efficiently and sustainably?
Injection moulding is the preferred manufacturing process for producing plastic parts in high volumes, in a short time and at low unit costs.
There are several ways to increase efficiency and sustainability in injection moulding:
- Production of highly energy-efficient, electric injection moulding machines like the ENGEL e-mac
- Use of recycled or biogenic materials
- High product quality and thoughtful design to encourage long-term use by the end consumer
- High level of automation in production to minimise process steps
The production of Orthex‘s smart store boxes is a good example of using these potentials. ENGEL was impressed with a highly efficient, customised solution.
Contact ENGEL to Learn more about their innovations here.
