Netstal will demonstrate the production of 44 oz stadium cups with IMLs on a hybrid Elion 3200 at the NPE in Orlando, USA (March 23 to 27 2015, Stand W903).Netstal will demonstrate its high level of system expertise in the thin-walled packaging sector at the NPE by producing 44 oz stadium cups with IMLs on an Elion 3200-2900 and highlight its extensive application know-how as a general contractor. "It is only thanks to our many years of experience and extensive IML knowledge that we were able to carry out this turnkey project for an American customer at all," said Mark Dal Pian, Vice President Sales & Marketing. Nijaz Husidic, Head of Sales for Business Unit PAC, added: "Production systems that deliver maximum availability, the shortest cycle times and the best product quality are our forte. Thanks to these factors, we will be able to safeguard our leading position in the thin-walled packaging sector in the future, too."
Proven thin-wall centering method
From a technical perspective, the production of drinking vessels is highly complex. When producing thin-walled packaging, the ratio of flow path to wall thickness (F/W) denotes the level of difficulty involved, which increases as the ratio rises. For the 44 oz cup, the ratio is 300:1. It requires a machine with corresponding injection performance in order to be able to fill the cavity quickly. In addition, any slight core shift, i.e. the lack of concentricity between the mold (= outer contour of the cup) and core (= inner contour), has a direct impact on product quality. "For this purpose, Netstal has devised a best practice known as thin-wall centering, which centers the core by means of rheological flow paths and varying melt pressure levels," explained Sven Hallauer, Project Leader for Business Unit PAC.Rapid project completion
The entire project – from the order through to the start of production in Kansas City – was completed in just six months. The manufacturing cell was fully assembled, commissioned and accepted by the customer at Netstal's headquarters in Näfels. The manufacturing cell is the result of a Swiss partnership: The machine is a Netstal product, the mold is made by Glaroform only a few minutes down the road and Beck Automation, which manufactures IML robots, is a short drive away near Zurich.
