Service & Solutions

Netstal Services
A Partnership to Last a Machine's Lifetime

Service & Solutions safeguards your product efficiency and your investment – for the length of a lifetime.

Highlights

Award Winner

Award Winner

NETSTAL receives the title of "Best medical injection molding packaging company" at the Global Excellence Awards 2021 from Global Health and Pharma. For the second time after 2019, the company is being honored for its innovative strength in the field of medical technology injection molding machines and applications.

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Accredited machine calibration according to (ISO 17025)

Accredited machine calibration according to (ISO 17025)

As an accredited calibration laboratory, we meet the requirements of the ISO 17025:2017 standard of competence. We calibrate your injection molding machines on site and prepare ISO 17025 compliant documentation for use in the audit.

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Trainings

Trainings

Well-trained employees ensure high production and machine safety. Our current training offer is only one click away. Find out more and register online.

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SMART OPERATION

SMART OPERATION

Smart Operation is the innovative operating concept for all NETSTAL machines with aXos controller technology.

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Injection Compression Molding

Injection Compression Molding

ICM provides unbeatable savings in cycle times as well as material and energy consumption, and increases the quality of produced packaging at the same time. Using a stack mold significantly increases the level of productivity.

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Products

ELIOS (4500 - 10000 kN)

Powerful, fast, and precise injection molding machine: performance, newly driven

ELIOS (4500 - 10000 kN)
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Hybrid, high-performance injection units

Hybrid, high-performance injection units

Ultra-high injection performance is required particularly for thin-walled products. In terms of dynamics and injection speed, the hybrid ELIOS series injection units are truly a cut above the rest of the market.

  • Hydraulic injection axis with rotating injection piston (spark)
  • Innovative and powerful twin-valve technology
  • Electric metering drive with water-cooled servo motor and spur wheel gearing
  • Position- and speed-regulated injection unit movement with torque-free nozzle contact pressure
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Innovative dual drive technology for clamping units

Innovative dual drive technology for clamping units

Actuation of the 5-point twin toggle is facilitated through a clever combination of electric and hydro-mechanical drive components. Accordingly, the basic principles of hybrid drive technology are consistently retained

  • Fast, dynamic travel sequences
  • Harmonic movements
  • Optimally designed drive components
  • Ideal speed and position regulation
  • Extremely energy efficient operation thanks to the recuperation of kinetic energy
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Adaptive drive unit

Adaptive drive unit

Energy efficiency is a prime factor, particularly given the ever increasing electricity prices. Through the clever combination of different drive technologies, the drive units achieve optimal efficiency values and still retain the necessary power reserves to meet even more demanding applications.

  • Servo motor with variable rotating speed
  • Dual-pump concept
    • Variable delivery piston pump
    • Constant delivery internal gear pump
  • Completely sealed oil tank
  • Oil cooling and filtering within an auxiliary circuit
  • Integrated storage system

 

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User orientation

User orientation

Thanks to its generous installation space and extremely stable construction, the ELIOS is perfect for highly demanding applications within the packaging sector. The comprehensive option package enables each machine to be customized and optimized to meet the commensurate requirements

  • Generous installation size
  • Stable and low wear construction
  • Comprehensive option package
  • Hydraulic mold auxiliary controllers
  • Individually actuated air valves
  • Integrated mold control circuits
  • Flexible mold-cooling installation options
  • Electric supply for system and peripheral components
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Fast and stable clamping unit

Fast and stable clamping unit

The ELIOS clamping unit operates with a 5-point twin toggle and is designed for extremely fast and dynamic mold movements and fast cycle times. The generous installation space offers enough room for the large molds often used in the packaging sector.

  • 5-point twin toggle with innovative dual-drive concept
  • Moving mold plate guided by firm, smooth-running linear guides
  • Mold height adjustment arranged on a support plate
  • Completely closed and sealed bearing points with circulating lubrication
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aXos controller

aXos controller

With a high-performance and flexible controller, you can get the maximum performance from your Netstal machine. aXos was developed to meet the increasingly complex demands of current and future applications. Innovative functions support the simple, quick and fault-free operation in the production environment.

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ELION (800 - 4200 kN)

Powerful, precise and efficient injection molding machine

ELION (800 - 4200 kN)
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Adaptive drive unit

Adaptive drive unit

Particularly in light of the steadily increasing cost of electricity, energy efficiency is an extremely important factor. Through the sophisticated combination of different drive technologies, the drive units achieve optimal efficiency values and still provide the required performance reserves for demanding applications.

  • Variable speed servo motor
  • Double pump design
    • Piston variable displacement pump
    • Internal gear constant delivery pump
  • Completely closed oil tank
  • Oil cooling and filtering in the secondary circuit
  • Integrated storage system
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Media options

Media options

In order to individually adapt each machine to specific requirements, a wide range of modules with different options is available to you:

  • Hydraulic auxiliary controllers (core tractions)
  • Central cold water distribution
  • Individual circuit water piping from cooling water battery or heating/cooling units
  • Pneumatic valves with separate pressure controller
  • Power socket outlets for peripheral devices
  • Diverse signal interfaces
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aXos controller

aXos controller

With a high-performance and flexible controller, you can get the maximum performance from your Netstal machine. aXos was developed to meet the increasingly complex demands of current and future applications. Innovative functions support the simple, quick and fault-free operation in the production environment.

> More Information

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Hybrid high-performance injection units

Hybrid high-performance injection units

Extreme injection performances are particularly in demand for products with very thin walls. With regard to dynamics and injection speed, the hybrid injection units of the ELION series are far ahead of the field.

  • Hydraulic injection axis with rotating injection piston (Spark)
  • Innovative and powerful two-valve technology
  • Electric metering drive with water-cooled servo motor and spur gear
  • Position and speed-controlled injection unit movement with torque-free nozzle contact pressure
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All-electric high-performance injection unit

All-electric high-performance injection unit

The all-electric injection units of the modular ELION series stand out with their extraordinarily high precision and reproducibility. Due to the robust and powerful design of the injection drive, a very high injection dynamic is reached even at full load.

  • Dynamic and highly precise injection axis with servo motor and dual-toothed rack drive
  • Electric metering axis with highly efficient high torque motor
  • Stable and smooth linear guides
  • Position and speed-controlled injection unit movement with torque-free nozzle contact pressure
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Electrical clamping unit

Electrical clamping unit

The clamping units of ELION were developed for quick cycles. Extremely short movement times are possible thanks to the unique operation principle. The clamping unit still moves very harmonically.

  • Centrally positioned 5-point toggle lever with crank drive (ELION principle)
  • Moving mold plate guided on stable and smooth linear guides
  • Mold height adjustment positioned on fixed mold plate
  • Bearing points completely sealed and closed with circulatory lubrication

ELION MED (800 - 2800 kN)

All-electric injection molding machine for medical technology applications

ELION MED (800 - 2800 kN)
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Precisely positioned and dynamic ejector

Precisely positioned and dynamic ejector

The stable and rigid ejector lever mechanism is driven via a highly dynamic servo motor. In combina-tion with highly sensitive angles, as well as position sensors and sophisticated control technology, the ejector of the all-electric ELION provides outstanding precision and reproducibility.

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Closed drag chains

Closed drag chains

For optimum cleanroom suitability, closed drag chains are exclusively used for the medical ELION version.

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All-electric high-performance injection unit

All-electric high-performance injection unit

Thanks to the unique transmission principle with double toothed-rack gear and a highly precise force measurement integrated into the injection axis, the ELION injection unit provides outstanding precision combined with absolute reproducibility. The result is a shot-to-shot consistency that is otherwise un-heard of on the market.

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Special medical paint

Special medical paint

The ELION with MED-Kit has an optimized plate surface design and special paint that facilitates sim-ple and cleanroom-compliant cleaning.

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Clean purge

Clean purge

Netstal's patented "clean purge" nozzle hood significantly reduces particle discharge during purging by automatically controlling the volumetric flow. A key factor for cleanroom applications.

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Media distribution

Media distribution

The MED-KIT includes a flexible distribution of media (water, air, power) completely integrated into the hood.


A comprehensive "options kit" is available for individual adjustments:

  • Hydraulic auxiliary controllers (core tractions)
  • Central cold water distribution
  • Individual circuit water piping from KW battery or heating/cooling devices. With high-temperature hoses upon request
  • Pneumatic valves with separate pressure regulator
  • Power socket outlets for peripheral devices
  • Various signal interfaces
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Electrical clamping unit

Electrical clamping unit

The ELION clamping units are developed especially for fast cycles. Their unique operating principle facilitates extremely short movement times. However, the clamping unit still moves in a very harmoni-ous manner.

 

  • Centrally arranged 5-point toggle lever with crank mechanism (ELION principle)
  • The moving mold plate is guided by firm, smooth-running linear guides
  • Mold height adjustment arranged on a fixed mold plate
  • Completely closed and sealed bearing points with circulating lubrication
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aXos controller

aXos controller

With a high-performance and flexible controller, you can get the maximum performance from your Netstal machine. aXos was developed to meet the increasingly complex demands of current and future applications. Innovative functions support the simple, quick and fault-free operation in the production environment.

> More Information

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Cleanroom-suitable mold installation space

Cleanroom-suitable mold installation space

The ELION clamping unit is designed for use within a clean production environment. All bearing points are completely sealed and the lubricating oil runs through a hermetically sealed circuit. This means that any contamination of the mold installation space can be effectively prevented.

MED-KIT options:

  • Galvanized sealed mold plates
  • Stainless sheet metal covers to facilitate laminar air flows
  • Laminar flow hood
  • Special paint for simple and cleanroom-compliant cleaning

The all-new PET-LINE with removal to the side

The most modern and efficient preform system in the world

The all-new PET-LINE with removal to the side
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Powerful injection unit

Powerful injection unit

The highly energy-efficient, two-stage injection unit enables shorter cycle times thanks to an optimized and adapted plasticizing and injection process. Intrusion and automatic metering ensure homogeneous and constant melt quality, low AA values and gentle material feed.

Your advantage:
Thanks to the optimized design of the new PETX screw, users benefit from the large process window and a robust plasticizing process also for rPET and additives.

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CYCLE GUARD

The optional available Cycle Guard monitors permanently the power supply and provides sufficient energy in an emergency. Cycle Guard does not require batteries or accus and is therefore particularly low-maintenance and cost-effective in operation.

  • Brief power failures or fluctuations in the grid lasting milliseconds are reliably bridged.
  • If the outage lasts somewhat longer, then sufficient power is provided to reliably and controllably shut down the cycle. Preforms are fully injected and demolded. Meterage for the next shot is stopped and the entire system is controllably brought to a halt. After a short system check, production can be quickly restarted.

Your advantage:
Cycle Guard increases machine availability in harsh industrial environments and reliably secures your productivity at lowest unit costs.

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Latest generation aXos control system

Latest generation aXos control system

Would you like to operate your PET system as safely and intuitively as possible?

The completely new aXos control unit provides an innovative combination of touch operation and haptic keys. Navigation always takes place on the central touch screen. Movements, on the other hand, are triggered via haptic keys with explicit feedback. "NETSTAL SMART OPERATION" comes as standard and enables simple, fast and safe start-up and production at all times.

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Smartly engineered detail solutions

Smartly engineered detail solutions

Don't the details often make the difference?

With the new PET-LINE we have created the most powerful PET system that enables our customers to produce the best preforms at the lowest unit costs. For this, every manufacturer needs a system that is intuitive to operate and easy to maintain. In order to achieve this, we paid attention to every detail when developing the system, no matter how small.

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Electric clamping unit

Electric clamping unit

The electrically driven clamping unit with five-point twin toggle lever impresses with low energy consumption, maximum speed and perfect precision.

Your advantage:
The harmonious and smooth-running kinematics ensure minimum wear and tear of your valuable preform mold. Maximum availability thanks to simplified mold installation and change. The extremely robust design assures several million cycles per year and many years of reliable continuous operation.

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Fast post-mold cooling unit

Fast post-mold cooling unit

The new sideways positioned post-mold cooling unit enables shorter cycle times due to its high dynamics. Up to 4 post-cooling stations are available.

Your advantage:
The integrated conveyor belt and the low-rebound ejection ensure that preforms are removed with absolute reliability. The efficient internal and external cooling assures a very high preform quality.

PET-LINE with removal to the top

The reliable and economical top-entry preform system

PET-LINE with removal to the top
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Removal unit and post-cooling

Removal unit and post-cooling

  • Dynamic and quick removal gripper with integrated cooling
  • Transfer unit with optional integrated calibration of the neck area and pre-blow stage (Calitec and Preblow Option)
  • Highly efficient cooling station with up to 4 post-cooling cycles
  • Parts release onto conveyor with container change function
  • Removal and post-cooling unit integrated completely into the machine controller
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Two-component version

Two-component version

The PET-LINE 2C is a high-performance injection molding system for barrier applications and two-component preforms with decorative effects. The lateral injection unit can simply be deactivated. This provides complete flexibility and, if necessary, it can also produce monolayer and standard preforms for water and carbonated soft drinks (CSD) with up to 72 cavities.

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Cycle Guard

Cycle Guard

Cycle Guard monitors permanently the power supply and provides sufficient energy in an emergency.

  • Brief power failures or fluctuations in the grid lasting milliseconds are reliably bridged
  • If the outage lasts somewhat longer, then sufficient power is provided to reliably and controllably shut down the cycle. Preforms are fully injected and demolded. Meterage for the next shot is stopped and the entire system is controllably brought to a halt. After a short system check, production can be quickly restarted.

Your advantage:
Cycle Guard increases machine availability in harsh industrial environments and reliably secures your productivity at lowest unit costs.

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2-stage injection units

2-stage injection units

The injection unit of the PET-LINE is a unique in-house-development. The extremely high throughputs of a preform system are only made possible in the first place thanks to the unique design.

  • High-performance plasticizing unit with electric metering drive
  • Intrusion technology for maximum metering performance
  • Injection piston with hydraulic actuation (ShotPot principle)
  • Innovative and powerful valve technology
  • Highly precise and quick digital control of metering and injection processes
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Adaptive drive unit with optimal energy efficiency

  • Variable speed servo motor
  • Double pump design
    • Piston variable displacement pump
    • Internal gear constant delivery pump
  • Completely closed oil tank
  • Oil cooling and filtering in the secondary circuit
  • Integrated storage system
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Calitec® – the smart way to reduce cycle times

Calitec® – the smart way to reduce cycle times

In order to improve the preform post-cooling, the demolded preforms are actuated with internal pressure via the transfer gripper.
That ensures a more intensive and, most importantly, uninterrupted post-cooling of the preforms. A calibration of the external preform diameter is carried out at the same time

Your benefits:
Faster cycle times and optimal preform quality

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Toggle lever clamping unit

Toggle lever clamping unit

The clamping unit of the PET-LINE is based on the proven mechanical system of the SynErgy and was optimized in the course of different evolutionary steps with state-of-the-art digital control technology.
It is tailored to the specific requirements of PET preform molds and thereby offers optimal framework conditions.

  • 5-point dual toggle lever with hydraulic actuating cylinder for quick and harmonious movement sequences
  • Robust and stable design
  • Stable support of moving mold plate on sliding guides and columns
  • Perfectly designed for large and high-cavity molds

How to find us

How to find us

Contact

NETSTAL Switzerland
NETSTAL Maschinen AG
Tschachenstrasse 1
8752 Näfels

+41 (0) 55 618 6111