Interview: Added value of digital solutions in injection moulding

The injection moulding companies that approach us have very different levels of maturity in terms of digitalisation and we deal with each case individually. On the one hand, we advise companies that already use an MES (Manufacturing Execution System) to take the next steps in the areas of process monitoring and parameter analysis.

On the other hand, we are also approached by companies that want to take the first step towards digital solutions for their plastics production and connect their machines. Most of the companies are at the beginning and are in the process of building up the necessary know-how and capacities to be able to implement a digitalisation project. This means everything from a simple status display to complete networking with 400 recorded parameters per machine and shot.

The most important goals are to reduce waste and minimise downtime. The lack of qualified personnel is also driving companies to implement digitalisation measures, because these bundle expert knowledge and support employees in production. Energy saving and sustainability are also topics that motivate companies to deal with digitalisation.

In practical terms, for example, the Braun company was able to reduce weight fluctuations in the production of razor swing bridges from 0.02 g to 0.003 g with the help of iQ weight control. This corresponds to an 85 percent improvement in weight consistency. By using iQ clamp control, dewatering specialist Dallmer was able to achieve a 33 percent reduction in clamping force from 1200 to 800 kn.

The example of Blum is also particularly impressive. Here, iQ flow control can achieve annual electricity savings in the six-figure euro range. BIC achieved enormous time savings in production monitoring by using the MES TIG authentig. Within 15 minutes, the shift supervisor receives an overview of the process stability and productivity of 50 injection moulding machines.

These are just a few examples of many that concretely show how digitalisation and networking contribute to more efficiency, flexibility and sustainability.

It is important to divide projects into phases and thus minimise complexity. In this way, success is visible more quickly, the employees' confidence in the project increases and they go into the next phase motivated.

Another criteria for success is an assigned project manager on the client side who oversees the implementation and is responsible for adherence to the project plan. It is also a must to involve the employees accordingly and educate them about digitalisation. It is not a means of supervision, but a support for the employees.

Hardly any other injection moulding machine manufacturer has more experience with Industry 4.0 than ENGEL. ENGEL was the first supplier worldwide to develop and present an end-to-end solution for the digitalisation and networking of injection moulding processes.

ENGEL presented its first intelligent assistance system - iQ weight control - in 2012, even before the concepts of Industry 4.0 and digitalisation had become widespread. Today, 8,600 injection moulding machines worldwide are equipped with intelligent assistance systems from ENGEL. More than 3,000 customers use the e-connect customer portal to network more than 8,000 machines. More than 12,000 machines are connected to the MES authentig of the ENGEL subsidiary TIG. The success of our customers proves us right and keeps us going.