COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures...

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COMPRESSION WHY BETTER?

Transcript of COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures...

Page 1: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?

Page 2: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?INDEX

HOWITWORKSWHATISITSAVEENERGY

WEIGHTCONSISTENCYDIMENTIONALCONSISTENCY

ITRUNSFASTERENJOYSIMPLICITYMOREFLEXIBLE

PROCESSALWAYSUNDERCONTROLADVANTAGESINTHINWALLCAPS

REFERENCES

Page 3: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?HOWITWORKS

CompressionmoldingisaFULLMOLDINGPROCESSPolymerisfullymeltedintotheextruderandfullymixedandhomogenizedthankstoextruderscrewdesignandstaOcmixerplacedattheendoftheextrusionlineCompressionmoldingisaHIGHPRESSUREFORMINGPROCESS(similartoinjecOonmolding)Fora28mmcap,theavailableforceforeachmoldingstaOonisupto4000kg,appliedonasurfaceof7cm2.ThereforethepressureappliedoneachmoldingstaOonexceeds400kg/cm2

Moltenpolymerisstronglypressedagainstmoldsurface

WHATISIT

Page 4: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?SAVEENERGY

Compression

Injec@on+16%

CompressionmoldingDOESNOTOVERHEATPOLYMERSInINJECTION,duetotheextremelynarrowpassages,meltedplasOcmustbeoverheatedtoreachtherequiredfluidity

Page 5: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?SAVEENERGY

LOWEREXTRUSIONTEMPERATUREmeanslessenergyisneededtobringtheplasOctoextrusiontemperature,andsincetheplasOciscolder,itisusedLESSENERGYtocoolit

EnergyconsumpOondependsoncaptype/weight,butCompressionkeepsitsadvantageinenergyconsumpOonalsowhencapsweightdecreases

HOT RUNNER

RESIDENCE

Page 6: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?SAVEENERGY

Ininjec@onWATERCOOLINGTEMPERATUREhastobearound10°,incompressionSACMIclientsareusingitataround30°,whichmeansenergysaving

0,00

0,02

0,04

0,06

0,08

0,10

0,12

0,14

0,16

0,18

SACMI CCM48 cool+ tools - S29W15 INJECTION 450 Tons 96 cav - S29W15

AbsorbedPowerCosts(kwh/1000caps)

water cooling power

direct power

morethan30%savingsinCM

Page 7: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?outsandingWEIGHTCONSISTENCY

incompressionallmouldsreceivePLASTICwhichTRAVELTHESAMEPATH,therearenohotrunners,justanozzle.IncompressionALLMOULDSARETHESAME,thereisnothinglikeperiphery,central,upperorlowermoulds

injec@on compression

MeasurementsfromSacmiatcustomer’sproduc@onplantresultscomingfrom1280individualmeasurements

CompressionInjec@on

Page 8: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?outsandingDIMENTIONCONSISTENCY

LESSDIMENSIONALVARIATIONincompressionduetolowertemperature.ClosuresproducedbyCCMmachinesarecolderthansimilarclosuresproducedbyinjecOonmachines.Colderthepart,lessistheshrinkage,narroweristhedimensionalvaria@on.

MeasurementsfromSacmiatcustomer’sproducOonplantresultscomingfrom1280individualmeasurements

CompressionInjec@on

Page 9: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?

HIGHERWEIGHTCONSISTENCYHIGHERDIMENSIONALSTABILITY

LESSSTRESSCRACKING

Higherefficiencyintheboelingline

HIGHEREFFICIENCYintheBOTTLINGLINE

“Nowyougottounderstandwhywepurchasesomanycompressionmoldedclosures!”Mr.JoeLadina-CocaColaCompany

“Idonotknowifthesecapsarecheaperornot,becausetheyaregiventomeandIgottousethem.ButIknowthatwithsuchcapsthebo>linglineneverstops!”Mr.Longo–formerplantmanager-SanBenedeeo

“ZEROcomplaintsfromtheplantsinoneyear.Notone,twoorfivebutzero.Notasingledefectoncaps”Mr.Juelg–Vitaquaplantmanager

“WeexportthisclosuretootherplantsofthegroupandthefeedbackhasbeenveryposiHveforus.Theclosurehasspectacularperformancesonthecappingprocesswitha98%ofefficiency”Eng.JulioBertran–Ananosgroupdirector

Page 10: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?ITRUNSFASTER…..

TheLOWEREXTRUSIONTEMPERATUREallowsthecaptobecooledinthemouldmorequickly.SHORTERCYCLETIMEmeansHIGHERPRODUCTIVITY(equalnumberofmouldcaviOes)

Compression2000caps/minina48cavitymachine

Injec@on

29mmFLATWATERCAP

Page 11: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?ITRUNSFASTER…….

AddiOonally,incompressionthemaxcycleOmewithopenmouldsis32%oftotalcycleOme,ininjec@onis45%.

Compression

Injec@on Givensamecap,compressionhasshortercycleOmecomparedtoinjec@on,buthighercooling@me

cycle@mebreakdown(29mmwatercap)

Page 12: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?

ThecompeOOveadvantageofcompressionhasbeenfurtherpushedupbyCOOL+,amodifiedcoolantliquidcirculaOonsysteminsidethemouldwhichensuresallpartsincontactwiththeplasOcarecooled(bothinnerandouterpunch).ItCOOLSBETTERandINLESSTIME.

Coolingcircuitforstandardmould

addiOonalcircuitforcool+mould

ITRUNSFASTER….WITHBETTERQUALITY

Page 13: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?

INJECTIONItisCOMPLICATED,asina128cavitymouldthereare128heatersatthenozzleandatleast32heatersinthemanifold,wherecouldbepresenceofBURNTPLASTICandBURNTGREASE

COMPRESSIONNohotrunner,nomanifoldmeans:LESSRESIDENCETIMELESSCOLORCHANGETIMENODOWNTIMEFORCLEANING

ENJOYSIMPLICITY

Page 14: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?

Nohotrunner,nomanifold

Nomoldingforcewasted

Moreviscous(lowerMFI)HDPEcanbeused

Lessstresscracking

0

100

200

300

0 5 10 15 20

ESCR(hoursbeforebraking)

MOREFLEXIBLE

MELTINDEX

WIDERRANGEOFRAWMATERIALSALLOWED

CompressionRangeofmeltindex

Injec@onRangeofmeltindex

29mmwatercapexample

Page 15: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?

Nohotrunner,nomanifold

Nomoldingforcewasted

Moreviscous(lowerMFI)HDPEcanbeused

Lessstresscracking

0

100

200

300

0 5 10 15 20

ESCR(hoursbeforebraking)

MOREFLEXIBLE

MELTINDEX

WIDERRANGEOFRAWMATERIALSALLOWED

CompressionRangeofmeltindex

Injec@onRangeofmeltindex

28mmCSDcapexample

Page 16: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?MOREFLEXIBLE

IncompressionitispossibletohaveDIFFERENTCLOSUREDESIGNSWHITHOUTCHANGINGTHEMOULD,becausethecaptoppanelthicknesscanbehandledviauserinterface

Page 17: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?MOREFLEXIBLE

IncompressionALLMOULDCAVITIESareALWAYSINPRODUCTION,becauseinfewminutesitispossibletochangeupperandlowerpartofthemalfunOoningone,aslongasallofthemareindipendent

QUICKERCOLORCHANGE(usingliquidmasterbatch)becauseincompressiontherearenohotrunnersneithermanifolds

Injec@oncaviOesnotinproducOon

Page 18: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?PROCESSALWAYSUNDERCONTROL

aslongasincompressioncapshaveanorientedpathintheoutlet,itispossibletochecktheminrealOmewithaFULLYINTEGRATEDVISIONSYSTEMandREJECTIMMEDIATELYFAULTYCAPS,withposiOveimpactdownstreamintheprocess.

Injec@onSystemforcapsinspecOon

CompressionSystemforcapsinspecOon

$$$

$

Page 19: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?

Compressionmoldinghasaflowlengthinherentlyshorter,asthemoldisopenandthetopwallofthecapmustnotbeconsideredforflowpath.Compressionmouldinghasnorunners,sonopressureiswastedthere.Injec@onmouldingofthinwallcapsrequiresspecialequipment,notthesameistrueforcompressionmouldingOurcompeOtorsclaimthatcompressionmoldingisnotsuitableformoldingthinwallcaps,becauseoflargethicknessvariaOoninherentlylinkedtoourtechnology.InparOculartheysaidthatthemoltenplasOcplacementisnotalwaysinthemiddleofthecavity(becauseofcentrifugalforce).BUTsincefewyears,themoltenplasOcissuccessfullyinsertedinthecenterofthecavity,byaroddirectly.

THINWALLCAPSproducOon

CompressionthicknessvariaOon

0,03 mm

Page 20: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?

Averyprecisealignment,isforsuremoreimportantforthinwallcaps.IntheInjec@onMoldingprocess,temperaturedifferences(higherthan5°C)betweenplatesmakingupamoldassembly,canbeasourceofalignmentproblems,duetodifferentthermalexpansion.Besides,thelargeristheIMmold,themoreseverecanbethisproblem.InCMthereisnoeffectofmachinesize(numberofcavity).InCompressionMolding,therearenomoldplatesbutjustindividualandidenOcalcoresandcaviOes.SinceCMhasnohothalfandcoldhalf,theeffectofheatexpansionisintrinsicallylowerthanIM.InCM,moldhalvesarealignedbyaveryeffecOvewayofcentering.Eachindividualcoreandcavitypairisalignedthrutaperedsurfaces,combinedwithafloaOngstripperring,whichensureandearlycontactbetweencoreandcavitycenteringprovisions.AnIMmoldcanweighthousandsofkilogramsandistypicallyarrangedhorizontally,thereforeinthecentersecOon,itmightbesubjecttohorizontaldeflecOonunderitsownweight.ThisdeflecOoncanbadlyaffectthealignmentofthetwooldhalves.ThelargeristheIMmold,themoreseverecanbethisproblem.ThisissueisintrinsicallyabsentinCM.CMmoldsarearrangedverOcallyandweighjustfewkilograms.InCMthereisnoeffectofmachinesize.

THINWALLCAPSproducOon

Page 21: COMPRESSION WHY BETTER? - Sacmi · produced by CCM machines are colder than similar closures produced by injecOon machines. Colder the part, less is the shrinkage, narrower is the

COMPRESSION

WHYBETTER?

Over1600presssesinstalledworldwide.

Withinflat-topbeverageclosuresproducedworldwide,morethan50%bySACMI’Stechnology

REFERENCES–thelargestcommunityofflattopbeveragecapsmanufacturers


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