Experience Netstal at Plástico Brasil
Plástico Brasil will open its doors at the São Paulo Expo from March 24 to 28, 2025. Visit Netstal at booth D078 and find out how we can optimally support you on your journey to maximum production efficiency.
Header image: Feira Plastico Brasil
The demand for high-quality packaging for food and beverages has been rising steadily in South America for several years. The same applies to components for medical devices and diagnostics. Netstal is growing accordingly in the region because more and more plastics processors want to take advantage of our leading injection molding technology and outstanding service support. With Netstal, manufacturers of PET preforms, beverage closures, thin-wall packaging and medical products are able to maximize their production efficiency reliably and sustainably.
Visit us at Plástico Brasil at stand D078 and find out how we can support you:
- Maximize productivity: With technology from Netstal, you produce in higher quantities than ever before. You produce reliably with the shortest cycle times in long-term continuous operation.
- Minimize unit costs: With our highly efficient injection molding systems, you reduce your unit costs and increase your competitiveness in a competitive market environment.
- Reduce energy costs: Thanks to the recuperation of kinetic energy and the optional system pressure reduction, Netstal machines impress with the lowest energy consumption compared to the competition. You save energy costs and reduce your ecological footprint.
- Increase availability: Our recipe for success to increase your system availability. Reliable technology that produces at maximum speed and with maximum precision. If the worst comes to the worst, our service team is there to support you, either on site or online.
- Enable circular economy, optimize sustainability: With Netstal you improve the ecological balance of your products. On our PET-Line, you can easily process up to 100% rPET in a large process window. And for thin-wall packaging, you can achieve additional material savings or process a higher proportion of recycled material with our Elios or Elion.
We look forward to discussing your next project with you and developing a customized injection molding solution for your application.
Beverage closures: System pressure reduction achieves 14.6 % energy savings
Reduce energy consumption with the adaptive system pressure reduction from Netstal. With the retrofittable option, you can reduce manufacturing costs and lower your company's CO2 footprint.
Initial situation:
This case study is about a 26/22 cap for carbonated beverages (GME 30.38), which is produced with a 96-cavity mold on an CAP-Line 4500-2900 (Elios). The HDPE cap weighs 1.46 grams and the cycle time is 2.95 seconds.
Solution from Netstal:
With active system pressure reduction, the energy consumption of the machine was reduced by 14.6 % in our comparative test. Due to the reduced adaptive system pressure, which is always based on the optimum operating point, only as much hydraulic energy is provided as is necessary for the product (see information box below).
In the test run, we were able to impressively demonstrate that production becomes more energy-efficient without any loss of stability and reliability. The system pressure reduction leads to lower operating costs, more sustainable production and is quickly amortized.
Chart legend:
- p2 = upper system pressure (today 250bar)
- p1 = lower working pressure or system pressure
- p0 = precharge pressure
Adaptive system pressure reduction
The hydraulic system of Netstal injection molding machines is designed for a maximum operating pressure of 250 bar in order to be able to cope with peak loads without any problems. Depending on the application requirements, a lower pressure would also be sufficient. In this case, this was an operating pressure of 170 bar, which ensured an optimum effect with the still high basic dynamics of the injection unit. This is where Netstal comes in with the new system pressure reduction and optimizes energy efficiency. In automatic mode, the adaptive control system determines the optimum point at all times and adjusts the system pressure accordingly. The energy consumption for providing the system pressure is reduced to a sensible minimum while maintaining the same level of productivity. This saves electricity costs, improves economy and reduces the CO2 footprint of your production.
Injection Compression Molding: Who will be first?
A plastic cup as a food container has several journeys ahead of it - and it's always about efficiency. The efficiency with which it is produced, stacked and transported to the bottler. The efficiency with which it runs through the filling line there and is transported to the supermarket shelves together with its contents. And the efficiency with which it finally passes through a sorting and recycling plant on its way back into the cycle.
In the PDF article in the trade journal “Plastics Insight”, you can read why an ICM thin-wall cup is more efficient and sustainable than a thermoformed cup with a cardboard sleeve.
ICM thin-walled cup (Fakuma 2023)
The article describes an application that we presented at Fakuma 2023. Watch the video to find out the key highlights of this exciting packaging solution.