A story about quality: pipette tips from Hamilton
Hamilton has been producing liquid handling consumables for the global market at its new site in Domat/Ems since 2018. Hamilton relies on Netstal for the efficient production of its precise CO-RE II pipette tips. Satisfaction is not only ensured by the high-precision injection molding machines, but also by the reliable service and partnership-based cooperation.
The new Hamilton building in Domat/Ems makes an impressive impression with its glass facade. Even from the highway, you can see that this is not just an office complex like many others – it is also a production facility. And it is high-tech. Directly behind the glass facade, the Netstal machines are lined up lengthwise on the first floor. A beautiful and high-quality presentation.
Hamilton in Domat/Ems, Canton Graubünden, Switzerland
Hamilton manufactures pipette tips from its CO-RE II range using the all-electric machines in the Elion series. The innovative technology offers maximum precision when picking up and positioning tips. With an extremely robust and airtight lock-and-key mechanism, Hamilton tips are attached to the independent pipetting channels with virtually no effort. The optimum seal enables highly precise and uniform liquid transfer steps. Hamilton’s CO-RE II tips have a fine, thin tip that facilitates the dispensing of micro volumes.
An employee checks the cavities in the injection mold
However, it is not just the tips themselves that have been continuously developed. Hamilton also considers the entire underlying process technology, which is fully automated from the provision of the granulate through to packaging and storage, to be innovative.
"We are absolutely convinced of the high performance and precision of the Netstal injection molding machines. At the same time, we are very satisfied with the partnership-based cooperation and the services provided. If we have a problem, we can always rely on Netstal to work on a quick and optimal solution for us."
Simon Freitag, Plastics Specialist Hamilton Bonaduz AG
Hamilton CO-RE Tip Production in Switzerland, Domat/Ems
Safety and quality go hand in hand
Hamilton manufactures its consumables in an ISO Class 8 clean room that complies with ISO 14644, ISO 9001 and ISO 13485 standards. Hamilton does not rely solely on statistical quality analysis to ensure the highest product quality. Each pipette tip is monitored in the manufacturing process for the concentricity of its opening and the absence of burrs from the casting process. The medically equipped injection molding machines are adjacent to the centrally located clean room. The pipette tips enter the clean room via the removal systems. There, the tips are further processed separately by cavity and their quality is checked in-line. The next step is the packaging process. 96-well tip trays are loaded, packed in blister frame racks and sealed with a paper lid.
96-Well-Tip-Tray mit 300 μL CO-RE® II tips
The sealed blister frame racks are then transported to the fully automated packaging system above the clean room. Blisters and outer cartons are “married” by means of unique coding, so that complete traceability is always guaranteed. The packaging units are then transported on a conveyor belt to the high-bay warehouse, which is 40 meters high and has a capacity of 12,000 pallets.
300 % increase in capacity within 2 years
With the outbreak of the coronavirus pandemic in 2020, the global demand for consumables exploded to cope with the increased volume of PCR tests performed. At this time, the Hamilton team in Domat/Ems was also under great pressure. Within 2 years, the production capacity for pipette tips was tripled. This was achieved by doubling the number of injection molding lines and production personnel. Netstal was able to contribute to this success. Even in normal times, specially equipped injection molding machines are almost impossible to procure at short notice. At that time, the situation was becoming increasingly difficult due to interrupted supply chains. This is where Netstal’s used machine program came into play. To bridge the delivery time for the new machine ordered, a used rental machine was put into operation in Domat/Ems at short notice. Subsequently, further new machines were sent to Domat/Ems and the USA to produce pipette tips.
At its peak, production in Domat/Ems ran day and night in four shifts, 365 days a year. As demand has now fallen again somewhat, there is a break at weekends. An interruption that would not be necessary from the injection molding machines’ point of view.
About Hamilton
Hamilton Bonaduz AG develops automated pipetting robots for handling a wide variety of liquids. With our sensors, we are also an innovation leader in the field of process analytics. Hamilton Storage GmbH, which belongs to Hamilton Bonaduz AG, is a leading provider of automated sample storage systems for research laboratories, pharmaceutical and clinical diagnostic companies and government institutions.
Hamilton’s products are known for advancing the life science, clinical diagnostics, forensics, biotechnology and biopharma industries, offering reliability, performance and flexibility.
Hamilton utilizes state-of-the-art manufacturing facilities in Reno, Nevada, and Bonaduz, Switzerland, as part of its ongoing commitment to quality and has achieved global ISO 9001 certification. Hamilton is privately held with headquarters in Reno, Nevada, Franklin, Massachusetts, and Bonaduz, Switzerland, and offices around the world.
Images: Hamilton Company
PET preform production: into the future with side removal
In September 2020, we presented the new PET line with side removal. Over the past three years, we have been able to convince existing and new customers of the benefits of the state-of-the-art preform system and successfully placed many systems on the market. We are now expanding the series with the PET-Line 5000.
“If you walk through our PET assembly hall, you mainly see our new side-entry PET Line. The predecessor model, which is based on the top-entry principle, can only be seen occasionally, reports PET Product Manager Stefan Kleinfeld. The market is opting for the most advanced technology. “With the higher productivity, lower power consumption, optimum processing of PET recyclates and excellent compatibility with existing molds and post-mold cooling stations, we offer our customers convincing arguments. We are very satisfied with the development of sales figures to date,” emphasizes Stefan Kleinfeld.
Our new video gives you an overview of the many advantages of the PET-Line:
PET-Line with 5000 kN clamping force extends the series
The future clearly belongs to the PET-Line with side discharge. In order to meet market requirements even better, we are expanding the series. In addition to the existing models with 3000 kN and 4000 kN clamping force, production of the 5000 kN clamping force variant will start at the end of 2023. Thanks to the greater plasticizing unit, preform manufacturers can fill large molds safely and precisely. To optimally meet different market requirements, our customers can combine the three clamping force sizes with different units. There are currently seven combinations to choose from.
Variants:
We provide you with expert support in configuring a PET-Line that optimally fulfills your tasks. Find the right contact person in your region:
Production of the predecessor model (PET-Line top-entry) will be discontinued as planned at the end of 2024.
A trusting and lasting cooperation
Manfred Schägner GmbH has relied on Netstal injection molding machines to produce food packaging and medical products for many years. In addition to the technological advantages of Swiss technology, the company values the trusting cooperation and good customer service.
“We have always felt that we are in good hands with Netstal. The machines are powerful and reliable. And if there is ever a problem, Netstal is always there for us and organizes a solution as quickly as possible,” say Christian and Manfred Schägner in unison. In Steinmauern, Baden-Württemberg, the family business with 70 employees produces food packaging, drinking vessels and various plastic articles for the pharmaceutical and medical industries. The company’s own mold construction facility to produce injection molds completes the portfolio. The company serves customers in Germany and abroad. Almost half of production is exported.
"We have been working with Netstal machines for many years. With Netstal, we consistently produce with maximum efficiency. In addition to the quality of the machines, we appreciate the excellent customer service."
Manfred and Christian Schägner
Sustainable food packaging produced efficiently
The machine park currently includes 28 Netstal injection molding machines with clamping forces between 600 kN and 4200 kN. “Our Netstal machines are linked to fully automatic removal systems and packaging systems. This is how we ensure a high standard of quality and hygiene in the production of food packaging and beverage containers,” explains Christian Schägner. The products should become ever more sustainable. That’s why, in addition to production, Schägner also places a strong focus on new developments, trials and research into recycling and the use of alternative materials and reusable items. All raw materials used are already fully recyclable.
Schägner products can be recognized by the familiar MS logo on the bottom. Items for multiple use are becoming increasingly important. Depending on the product, the beverage containers, plates and cutlery are designed for up to 125 wash cycles. Afterwards, the products made from mono-materials can be recycled.
Drinking cups from Schägner
Hygienic injection molding production with direct transport to the clean room
Schägner has been assembling some of its pharmaceutical products in a cleanroom since 1991. In 2021, a state-of-the-art class 8 cleanroom in accordance with DIN 14644 with approx. 500 square meters was put into operation to expand capacity. Due to the location of the cleanroom, it is now possible to transport the products manufactured in production to the cleanroom via encapsulated conveyor belts.
All-electric Elion 2200 in medical configuration
The product enter the clean room via encapsulated conveyor belts
“Modern and precise injection molding machines are a basic requirement for reliable production with stable production parameters. We recently invested in two new Elion 2200 machines in a medical version,” reports Manfred Schägner. The two all-electric machines are positioned directly next to the clean room. The finished products are transported directly to the clean room for further processing via an encapsulated conveyor belt. In order to meet the high standards, both machines are equipped with a laminar flow hood above the closing unit.
The assembly and packaging systems used meet the highest pharmaceutical standards and are a prerequisite for high-quality products. Schägner is certified to ISO 13485:2016 for the design and development, production and distribution of medical application aids for tablets, ointments and liquids.
Further processing in cleanroom class ISO 8
Schägner offers its customers in the pharmaceutical industry everything from a single source. From the initial exchange of ideas, through the planning, development and manufacture of the production tool, to the production and packaging of the product, everything is done in-house. Standard products are supplied to well-known companies in the pharmaceutical industry worldwide. These include applicators for creams, tablets and rectal cannulas. Customized special products have also been part of the range of services for decades. These include special applicators for capsules and tablets, tubes for liquid medicines in the field of veterinary medicine, dosing spoons and infusion bottle holders.
When you talk to Christian and Manfred Schägner, you can tell that Schägner and Netstal are simply a good match. We would like to thank them for their trust in Netstal and look forward to many more years of successful collaboration.
Photos: Manfred Schägner GmbH
Packaging highlight: 200 g ICM thin-wall cup
The Swiss Emmi dairy fills various products such as yogurt or skyr in 200 g pots, which are produced using conventional injection molding. When evaluating more cost-effective and sustainable alternatives, a cup produced using the injection compression molding (ICM) process came into play. Even in direct comparison with a thermoformed cup with a cardboard sleeve, the Netstal solution offers numerous advantages.
Solution from Netstal:
The ICM application was realized in cooperation with several system partners. We presented it as a running application at Fakuma 2023. For this we adapted a hybrid Elion 1750 to the injection compression molding process. The ICM mold with 4 cavities comes from Glaroform. Beck Automation provided the IML handling system with integrated camera inspection. The laminated PP label from iPB detaches itself during the recycling process.
Industry partner Emmi filled pre-produced sample cups on its filling line shortly before Fakuma and delivered them to Friedrichshafen. On our exhibition booth we served our guests finest blueberry skyr filled in show cups. Tasty proof that our solution works perfectly in practice.
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Results ICM compared to 200 g cups in standard injection molding:
- The cycle time is reduced by approx. 14 % compared to standard injection molding
- Plastic consumption falls by approx. 34%
- 27 % more parts per packaging unit
- 33 % less CO2 equivalents1
Results ICM vs. 200 g thermoforming cup with cardboard sleeve
- Plastic consumption is reduced by approx. 20 % (both cups without label)
- The labeled ICM cup is around 40 % lighter than the labeled thermoformed cup (5.96 g vs. 9.87 g)
- Around 22 % lower power consumption per kg of material throughput
- 150 % more parts per packaging unit
- 28 % less CO2 equivalents1
- One-step process: the finished labeled cup comes directly from the injection moulding machine
Conclusion:
With this application, we can prove that cost efficiency and sustainability go hand in hand in injection molding. The thin-walled ICM cup has a significantly better carbon footprint, even compared to the thermoformed cup with a cardboard sleeve.
Because it is made of 100% PP, it is completely recyclable. This has been certified with the top grade A+++.
Download: Recycling certficate (German)
Injection compression molding offers manufacturers of plastic packaging unique opportunities. You too can increase your efficiency and optimize the ecological footprint of your production with ICM.
Our experts will be happy to provide you with individual advice.
1 Estimated carbon footprint for polymer, label, production in Germany (8000 h / year), transport distance 628 km
Our highlights at Fakuma 2023
Visit us at Fakuma (Hall B3, Booth 3119), where we will be using the injection compression molding process to produce thin-wall packaging specially designed for the circular economy. This process allows you to produce packaging with minimal wall thickness and save valuable resources. With the new Axos 9 control generation, you can take efficiency and precision in your production to a new level. Visit our booth and get inspired.
Discover lightness: Our innovative 200 g yogurt cup presents itself in a feather-light design. With its part weight of only 5.4 g, it sets new standards. What makes this cup particularly sustainable: both the cup and the label are made of 100% recyclable polypropylene (PP). This allows for easy recycling and strengthens your contribution to the circular economy. Unlike conventional in-mold labels, the label does not stick in the recycling process. It detaches without affecting the PP recycling stream. Thanks to efficient separation of the ink particles from the pure PP, high-quality regranulate can be produced.
The use of injection compression molding (ICM) reduces the weight of the cup by an astonishing 34%. This innovative approach goes hand in hand with our sustainable vision. In addition, by combining the ICM process with product optimizations, we have reduced the packaging volume by an impressive 27% – another step towards sustainability and resource conservation.
Sustainable cups, efficiently manufactured
Experience our environmentally friendly cup, produced with energy-efficient production processes. The thin-wall packaging for dairy products is produced in 4 cavities and requires only 2.7 seconds per cycle – thanks to our Elion 1750 machine with hybrid injection unit. At Netstal, we focus on reliable performance and set standards in terms of energy efficiency. Our machines work precisely and economically to conserve resources and ensure sustainable production. With the optional adaptive system pressure reduction, we have further improved the efficiency of our hybrid machines. The new function is a technological highlight that always determines the optimum point in automatic mode and adjusts the pressure in the hydraulic system accordingly. This results in minimized energy consumption to provide the required system pressure, depending on the application. At Netstal, we are committed to sustainable solutions that are both efficient and environmentally friendly.
The application is the result of a successful cooperation with renowned high-end system partners. These include Glaroform, Beck Automation, SABIC, IPB Printing, motan, Regloplas and Uniform Color. Together we have worked on this future-oriented solution. A key development partner in this collaboration is Switzerland’s Emmi AG, one of the largest dairy product bottlers and a pioneer in the food industry. The specifications for this innovative packaging were developed in close consultation with Emmi to meet the highest demands of the food industry. Particular attention was paid to maintaining the previous appearance of the cup while optimizing recyclability.
Operate the machine intuitively with the new Axos control system
Experience intuitive machine operation with the new Axos 9 control. At Fakuma, we are bringing Axos 9 to the machines of the Elion and Elios series. Call up the full performance potential of your Netstal machine. The integration of Smart Operation makes machine operation in the production environment fast, safe and extremely effective. Smart Operation is still available as a paid option in Axos 9.
Further packaging application with Netstal in Hall A3
Don’t miss a detour to Hall A3 either. A fully electric Elion 2200 awaits you, which we will present at our Turkish mold partner Ceylan. There, 150 g margarine trays with IML decoration are produced in 4 cavities. The cycle time is 3.8 seconds with a precise shot weight of 42 g. The IML system used, which includes side removal, camera control and packaging unit, comes from Eurasia Robotic in Turkey. Stop by and see this turnkey production line live at the Ceylan booth in Hall A3, Booth A3-3105.
Plan your trip to Fakuma and schedule an appointment with us:
Introducing: Our new brand identity
As of today, Netstal has a new brand identity. The values of leading, reliable and value-creating form the core of our tradition-rich brand. In doing so, one mission is our top priority: We want to work with you to increase your production efficiency and maximize your value creation. With Netstal, you get not only leading injection molding technology of the highest Swiss quality, but also a reliable partnership at eye level.
You can find out more here here
With a contemporary corporate design, we are visually communicating this positioning to the outside world. You have probably already noticed: The heart of the new brand identity is the graphically revised company logo. In the modernization process, we have been careful to respect our tradition. The familiar diamond shape, which has been opened up at the sides and forms a harmonious frame for the lettering, remains clearly recognizable. In a figurative sense, this also says that we are opening ourselves up to new opportunities and challenges. These include topics such as digitalization and sustainability, as well as the conscious use of the valuable material plastic. At the same time, we remain true to our core competence, the injection molding machine.
All technical data available online
From now on you can get information about our products and services here on our new website. A highlight is certainly new download center, which you can reach here:
Here we offer you a clear overview of all current series and their technical data. With practical filters you can limit the selection according to application area, drive technology, shot weight and column distance. In the English language version, the data sheets are available for download with either metric or imperial units of measurement. A note for you: The data sheets also contain a download link to the foundation plan.
New series coating for injection molding machines
With the change to the Axos 9 control generation, we are also applying our new design to the current machine portfolio. The dominant colors for non-medical machines are dark blue and white. Three-dimensional logos in chrome steel look emphasize the high quality of Netstal machines. Please feel free to visit our product pages for more views.
Visit us at Fakuma
Trade shows are and remain particularly important events for us. Nowhere else can we share our enthusiasm for injection molding with so many customers in such a short time. For these important personal encounters, we have created the best setting with our new and sustainable trade show concept. The booth, which is divided into two areas, impresses with its simple naturalness and modern spaciousness. In the front area, the focus is on the running machine exhibit for sustainable thin-wall packaging. The catering area has been spatially demarcated to allow for consultation meetings in as quiet an atmosphere as possible. We cordially invite you to visit us in Friedrichshafen. You will find us at our new regular place in hall B3 at booth B3-3119.
For more info on our trade show appearance, click here: Fakuma 2023
We hope that you will be as enthusiastic as we are about our new appearance. If you have any questions about this or any other topic, please do not hesitate to contact us. Please do not hesitate to contact us.
Netstal awarded EcoVadis Bronze
We waited with great excitement for the result of our first evaluation by EcoVadis. Accordingly, we were delighted to receive the bronze medal. Our sustainability performance is thus considered "good".
We reduced our CO2 footprint by 80%
EcoVadis is the world’s largest provider of sustainability assessments for companies. The assessments are not only about the important topic of environmental protection. In total, EcoVadis considers 21 sustainability criteria from the areas of environment, labor and human rights, ethics and sustainable procurement. In the area of environmental protection, we have achieved quite a bit in recent years. Compared to 2019, we have reduced our CO2 emissions by 80%! Of central importance was the switch to climate-neutral district heating from the Bilten waste incineration plant. As a result, we were also able to switch the process heat required in production from gas to district heating. Michael Rocholl, Head of Quality and Process Management, explains: “This has enabled us to completely decouple ourselves from gas. The remaining CO2 emissions are attributable to electricity consumption and the currently operated vehicle fleet. With additional measures, we will further reduce our energy consumption.”
In view of global warming with longer dry periods, we are also paying attention to our own water consumption. Whereas a decade ago this was still 200,000 m3, last year we were able to reduce the flow to around 75,000 m3. “In 2023, we want to reduce our consumption to around 60,000 m3. We have launched a preliminary study to derive suitable measures,” says Michael Rocholl.
In terms of sustainable procurement, we already rank among the top 7% of all companies assessed in the special machinery sector. By further concretizing our guidelines, optimized risk assessments, internal training, and intensified monitoring, we want to further increase our overall EcoVadis score in the coming years.
Highest-performance injection molding technology, sustainably manufactured in Switzerland
By scoring well in our first attempt, we are not only demonstrating a strong commitment to environmental protection and society, but also strengthening our own future viability. This is because more and more companies expect an EcoVadis rating from their suppliers and take it into account in their purchasing decisions. Renzo Davatz confirms: “We will continue to work on our sustainability. They can be confident that they are always making the best choice with our technologically leading injection molding machines. Not only do they offer them the highest performance capability and outstanding energy efficiency, but they are manufactured in Switzerland to ever higher sustainability standards.”
As a customer, you therefore benefit several times over with Netstal: You produce with maximum efficiency on our particularly sustainably manufactured machines. This in turn will have a positive impact on your own EcoVadis ranking.
An investment that pays off: Adaptive system pressure reduction makes injection molding machines from Netstal even more energy efficient
A new option is now available for hybrid Netstal machines: Adaptive system pressure reduction permanently determines the optimum operating pressure in the hydraulic system. The retrofittable feature lowers power consumption while maintaining at least the same productivity, reduces the CO2 footprint and pays for itself in a short time.
Can it be a little less? In order to handle peak loads without any problems, the hydraulic system of hybrid Netstal injection molding machines is designed for a maximum operating pressure of 250 bar. Depending on the application, a lower value would also be sufficient. This is where we come in with the new system pressure reduction and make our machines even more energy efficient. In automatic mode, the adaptive control system determines the optimum point at any time and adjusts the system pressure accordingly. With the same or even increased productivity, the energy consumption for providing the system pressure is reduced to a minimum. A lower load on the components can also have a positive effect on machine availability, maintenance intervals can be planned more efficiently, and the machine can produce for longer time.
Smaller carbon footprint and higher cash flow
In addition, there are further ecological and economic advantages for Netstal customers. The lower energy consumption of the machine also reduces the user’s ecological footprint. Depending on the regional electricity mix, less CO2 is emitted. In most cases, the small surcharge pays for itself within a few months. The payback period varies depending on the region and electricity costs. In some countries, investments in more energy-efficient and climate-friendly production facilities are subsidized with government grants.
We will be happy to calculate your individual savings potential and show how you can manufacture identical products at a lower cost and with a smaller CO2 footprint. Finally, lower consumption costs and subsidies have a positive effect on the company’s cash flow. The lower load on the equipment helps extend the life of the machine. The acquisition costs per year of use are lower. Likewise, at the end of the targeted useful life, a higher price can be obtained on the used machine market. Netstal machines are already considered to be particularly stable in value. With the new adaptive system pressure reduction, we once again provide you with more added value and increase the distance to our international competition.
Adaptive system pressure reduction is optionally available for all hybrid Netstal injection molding machines running the latest aXos version (release 8.6.0).
Retrofitting of existing machines is possible: Please get in touch with your local service contact or with Soroush ZanjaniPoor.