COMPRESSION WHY BETTER?

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Oswin Henry
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2 INDEX HOW IT WORKS WHAT IS IT SAVE ENERGY WEIGHT CONSISTENCY DIMENTIONAL CONSISTENCY IT RUNS FASTER ENJOY SIMPLICITY MORE FLEXIBLE PROCESS ALWAYS UNDER CONTROL ADVANTAGES IN THIN WALL CAPS REFERENCES

HOW IT WORKS WHAT IS IT Compression molding is a FULL MOLDING PROCESS Polymer is fully melted into the extruder and fully mixed and homogenized thanks to extruder screw design and staoc mixer placed

3 HOW IT WORKS WHAT IS IT Compression molding is a FULL MOLDING PROCESS Polymer is fully melted into the extruder and fully mixed and homogenized thanks to extruder screw design and staoc mixer placed at the end of the extrusion line Compression molding is a HIGH PRESSURE FORMING PROCESS (similar to injecoon molding) For a 28 mm cap, the available force for each molding staoon is up to 4000 kg, applied on a surface of 7 cm 2. Therefore the pressure applied on each molding staoon exceeds 400 kg/ cm 2 Molten polymer is strongly pressed against mold surface

4 SAVE ENERGY Compression molding DOES NOT OVERHEAT POLYMERS In INJECTION, due to the extremely narrow passages, melted plasoc must be overheated to reach the required fluidity + 16% Compression

SAVE ENERGY LOWER EXTRUSION TEMPERATURE means less energy is needed to bring the plasoc to extrusion temperature, and since the plasoc is colder, it is used LESS

5 SAVE ENERGY LOWER EXTRUSION TEMPERATURE means less energy is needed to bring the plasoc to extrusion temperature, and since the plasoc is colder, it is used LESS ENERGY to cool it HOT RUNNER RESIDENCE Energy consumpoon depends on cap type/weight, but Compression keeps its advantage in energy consumpoon also when caps weight decreases

SAVE ENERGY In injec@on WATER COOLING TEMPERATURE has to be around 10, in compression SACMI

(kwh/1000 caps) 0,16 0,14 0,12 more than 30% savings in CM 0,10 0,08 0,06 0,04 water

6 SAVE ENERGY In WATER COOLING TEMPERATURE has to be around 10, in compression SACMI clients are using it at around 30, which means energy saving 0,18 Absorbed Power Costs (kwh/1000 caps) 0,16 0,14 0,12 more than 30% savings in CM 0,10 0,08 0,06 0,04 water cooling power direct power 0,02 0,00 SACMI CCM48 cool+ tools - S29W15 INJECTION 450 Tons 96 cav - S29W15

COMPRESSION outsanding WEIGHT CONSISTENCY in

TRAVEL THE SAME PATH, there are no hot runners,

compression injec@on In compression ALL MOULDS ARE

central, upper or lower moulds Measurements from

7 COMPRESSION outsanding WEIGHT CONSISTENCY in compression all moulds receive PLASTIC which TRAVEL THE SAME PATH, there are no hot runners, just a nozzle. compression injec@on In compression ALL MOULDS ARE THE SAME, there is nothing like periphery, central, upper or lower moulds Measurements from Sacmi at customer s produc@on plant results coming from 1280 individual measurements Injec@on Compression

8 outsanding DIMENTION CONSISTENCY LESS DIMENSIONAL VARIATION in compression due to lower temperature. Closures produced by CCM machines are colder than similar closures produced by injecoon machines. Colder the part, less is the shrinkage, narrower is the dimensional Measurements from Sacmi at customer s producoon plant results coming from 1280 individual measurements Compression

HIGHER EFFICIENCY in the BOTTLING LINE HIGHER WEIGHT CONSISTENCY HIGHER DIMENSIONAL STABILITY LESS STRESS CRACKING Higher efficiency in the boeling line Now you got to understand why we purchase so

9 HIGHER EFFICIENCY in the BOTTLING LINE HIGHER WEIGHT CONSISTENCY HIGHER DIMENSIONAL STABILITY LESS STRESS CRACKING Higher efficiency in the boeling line Now you got to understand why we purchase so many compression molded closures! Mr. Joe Ladina - Coca Cola Company I do not know if these caps are cheaper or not, because they are given to me and I got to use them. But I know that with such caps the bo>ling line never stops! Mr. Longo former plant manager - San Benedeeo ZERO complaints from the plants in one year. Not one, two or five but zero. Not a single defect on caps Mr. Juelg Vitaqua plant manager We export this closure to other plants of the group and the feedback has been very posihve for us. The closure has spectacular performances on the capping process with a 98% of efficiency Eng. Julio Bertran Ananos group director

10 IT RUNS FASTER.. The LOWER EXTRUSION TEMPERATURE allows the cap to be cooled in the mould more quickly. SHORTER CYCLE TIME means HIGHER PRODUCTIVITY (equal number of mould cavioes) 29mm FLAT WATER CAP Compression 2000 caps/min in a 48 cavity machine

11 IT RUNS FASTER. AddiOonally, in compression the max cycle Ome with open moulds is 32% of total cycle Ome, in is 45%. breakdown (29mm water cap) Compression Given same cap, compression has shorter cycle Ome compared to but higher

COOL+, a modified coolant liquid circulaoon system inside the mould which ensures all parts

12 IT RUNS FASTER. WITH BETTER QUALITY The compeoove advantage of compression has been further pushed up by COOL+, a modified coolant liquid circulaoon system inside the mould which ensures all parts in contact with the plasoc are cooled (both inner and outer punch). It COOLS BETTER and IN LESS TIME. Cooling circuit for standard mould addioonal circuit for cool+ mould

could be presence of BURNT PLASTIC and BURNT GREASE COMPRESSION No hot runner, no

13 COMPRESSION ENJOY SIMPLICITY INJECTION It is COMPLICATED, as in a 128 cavity mould there are128 heaters at the nozzle and at least 32 heaters in the manifold, where could be presence of BURNT PLASTIC and BURNT GREASE COMPRESSION No hot runner, no manifold means: LESS RESIDENCE TIME LESS COLOR CHANGE TIME NO DOWNTIME FOR CLEANING

14 No hot runner, no manifold MORE FLEXIBLE No molding force wasted More viscous (lower MFI) HDPE can be used WIDER RANGE OF RAW MATERIALS ALLOWED Less stress cracking 29mm water cap example ESCR (hours before braking) 300 Compression Range of melt index Range of melt index MELT 10 INDEX 15 20

15 No hot runner, no manifold MORE FLEXIBLE No molding force wasted More viscous (lower MFI) HDPE can be used WIDER RANGE OF RAW MATERIALS ALLOWED Less stress cracking 28mm CSD cap example ESCR (hours before braking) 300 Compression Range of melt index Range of melt index MELT 10 INDEX 15 20

16 MORE FLEXIBLE In compression it is possible to have DIFFERENT CLOSURE DESIGNS WHITHOUT CHANGING THE MOULD, because the cap top panel thickness can be handled via user interface

MORE FLEXIBLE In compression ALL MOULD CAVITIES are ALWAYS IN PRODUCTION, because in few minutes it is possible to change upper and lower part of the malfunooning one, as long

17 MORE FLEXIBLE In compression ALL MOULD CAVITIES are ALWAYS IN PRODUCTION, because in few minutes it is possible to change upper and lower part of the malfunooning one, as long as all of them are indipendent cavioes not in producoon QUICKER COLOR CHANGE (using liquid masterbatch) because in compression there are no hot runners neither manifolds

INTEGRATED VISION SYSTEM and REJECT IMMEDIATELY FAULTY CAPS, with posiove impact

18 COMPRESSION PROCESS ALWAYS UNDER CONTROL as long as in compression caps have an oriented path in the outlet, it is possible to check them in real Ome with a FULLY INTEGRATED VISION SYSTEM and REJECT IMMEDIATELY FAULTY CAPS, with posiove impact downstream in the process. Injec@on System for caps inspecoon Compression System for caps inspecoon $$$ $

THIN WALL CAPS producoon Compression molding has a flow length inherently shorter, as the mold is open and the top wall of the cap must not be considered for flow path.

19 THIN WALL CAPS producoon Compression molding has a flow length inherently shorter, as the mold is open and the top wall of the cap must not be considered for flow path. Compression moulding has no runners, so no pressure is wasted there. Injec@on moulding of thin wall caps requires special equipment, not the same is true for compression moulding Our compeotors claim that compression molding is not suitable for molding thin wall caps, because of large thickness variaoon inherently linked to our technology. In parocular they said that the molten plasoc placement is not always in the middle of the cavity (because of centrifugal force). BUT since few years, the molten plasoc is successfully inserted in the center of the cavity, by a rod directly. 0,03 mm Compression thickness variaoon

Besides, the larger is the IM mold, the more severe can be this problem. In CM there is no effect of machine size (number of cavity).

20 THIN WALL CAPS producoon A very precise alignment, is for sure more important for thin wall caps. In the Injec@on Molding process, temperature differences (higher than 5 C) between plates making up a mold assembly, can be a source of alignment problems, due to different thermal expansion. Besides, the larger is the IM mold, the more severe can be this problem. In CM there is no effect of machine size (number of cavity). In Compression Molding, there are no mold plates but just individual and idenocal cores and cavioes. Since CM has no hot half and cold half, the effect of heat expansion is intrinsically lower than IM. In CM, mold halves are aligned by a very effecove way of centering. Each individual core and cavity pair is aligned thru tapered surfaces, combined with a floaong stripper ring, which ensure and early contact between core and cavity centering provisions. An IM mold can weigh thousands of kilograms and is typically arranged horizontally, therefore in the center secoon, it might be subject to horizontal deflecoon under its own weight. This deflecoon can badly affect the alignment of the two old halves. The larger is the IM mold, the more severe can be this problem. This issue is intrinsically absent in CM. CM molds are arranged verocally and weigh just few kilograms. In CM there is no effect of machine size.

21 REFERENCES the largest community of flat top beverage caps manufacturers Over 1600 pressses installed worldwide. Within flat-top beverage closures produced worldwide, more than 50% by SACMI S technology

Section N. Application Information. Thermal Manufacturing Solutions. Extrusion N-1. Injection Moulding N-2 N-3. Other N-4

Section N. Application Information. Thermal Manufacturing Solutions. Extrusion N-1. Injection Moulding N-2 N-3. Other N-4 Thermal Manufacturing Solutions Section N Application Information Extrusion Injection Moulding Other Electrical Heating Of Plastic Injection Molds Heating And Cooling Of Cores Electrically Heated Platens