Broanmain Plastics has unveiled the installation of its first fully automated injection moulding machine cell, marking a significant step towards enhanced automation and efficiency. The move comes in response to industry forecasts predicting that automation will become more accessible, faster, and smarter by 2025. At the end of last month, the company received a 320-ton Haitian injection moulding machine, complete with a Hilectro cartesian robot, to support its production processes.
The company, which specializes in mass-produced plastic components, is focusing on sustainability by reducing waste and improving resource efficiency. This initiative is designed to maximize productivity while minimizing the environmental impact of each unit produced at Broanmain’s Dorking facility.
The newly installed machine features an electric screw motor, part of the Generation 5 Mars servo-hydraulic system, which replaces traditional hydraulic screw drives known for their high energy consumption. The shift to this energy-efficient system aims to significantly lower energy use, with the machine also offering quieter operation and improved precision and reliability for mass manufacturing.
“Compared to fixed pump hydraulic machines, these energy-efficient servo-hydraulic moulding machines can save processors like Broanmain over 70% in energy consumption,” said Veronica Edmunds, Head of Haitian UK Sales Team.
Thomas Catinat, Operations Manager at Broanmain, emphasized that the selection of the 320-ton machine was driven by the need for additional manufacturing capacity and the ability to handle larger components for new projects. The automation capability, particularly for handling 1kg parts, was crucial in streamlining production.
Given the weight of the parts, each must be carefully removed from the tool to avoid any damage. The Hilectro cartesian robot ensures the consistent and efficient demoulding of components, which will be placed on a conveyor. This setup provides the flexibility for Broanmain to adapt to future production needs, including potential lights-out manufacturing.
Broanmain is committed to optimizing production efficiency to avoid waste and reduce environmental impact. Managing Director Jo Davis noted, “Broanmain is constantly assessing the efficiency of production runs to ensure finite resources are not being wasted or causing unnecessary pollution.”
Catinat further highlighted the machine’s versatility, noting that it can accommodate tools from both 250-ton and 500-ton machines, bridging production gaps efficiently. Before and after energy tests on the machine will be conducted to demonstrate the system’s energy savings and performance. Haitian expects that Broanmain will see a return on investment within the year, thanks to the integration of automation and the HT-X-tend software that comes with the Generation 5 series.
The Generation 5 system also features an intelligent control system designed to optimize the entire moulding process, ensuring repeatability, efficiency, and the lowest possible energy consumption, ultimately extending the lifespan of both the machine and tooling.
Looking ahead, Broanmain anticipates a rise in lights-out manufacturing, with a significant portion of manufacturers expected to adopt such processes by 2025. However, Catinat emphasized that Broanmain’s focus will be on implementing lights-out processes to increase production flexibility and improve worker safety. The new cartesian robot eliminates the need for full-time operators at the machine, allowing for faster cycle times and uninterrupted production, enhancing both productivity and safety.
“We are not aiming for full lights-out production but are instead focusing on lights-out processes that allow us to increase manufacturing capacity and respond more effectively to customer demands,” Catinat concluded.