Sustainable success with ENGEL e-mac injection molding machines

The Orthex Group, based in Finland, is a manufacturer of household goods with a strong focus on design, quality, and, sustainability. 

A key factor in Orthex’s sustainability efforts is the high product quality and appealing design of its products. "Even in our largest boxes, you can stack books without the bottom breaking. Not all plastic boxes on the market can handle that. Our products are not meant to be thrown away after just one use. People are becoming more aware of this, and that's a very positive trend," says Tom Ståhlberg, Operations Manager at the Lohia location. 

The boxes from the smart store compact clear series are injection molded from crystal-clear styrene-acrylonitrile copolymer (SAN) in Lohja, Finland. They are available in ten sizes, with shot weights from 100 to 1,000 grams. SAN is free of BPA and is approved for food contact, making the smart store compact clear boxes a common choice for refrigerator storage. Compared to other transparent materials such as polycarbonate, SAN offers major advantages.

Sustainability targets also define Orthex's production strategy. However, it is crucial that they do not increase unit costs.

In addition, high precision and a stable process are particularly important for crystal-clear parts, as streaks and bubbles are unacceptable in the final product. "SAN is more demanding than PP in terms of processing. Even the smallest irregularities, scratches, and deformations result in rejects," says Ståhlberg.

For the efficient production of these storage boxes, injection molding machines in the mid-performance and clamping force range were required, with the following characteristics:

• High precision

• Gentle plasticizing

• Low energy consumption

• High floor space productivity

• High level of automation

The specifications clearly indicated electric injection molding machines as the most suitable solution. ENGEL fully convinced Orthex with the e-mac series: The compact, all-electric e-mac was specifically developed for high productivity and efficiency in the mid-performance range, with cycle times exceeding 4 seconds. Therefore, Orthex invested in multiple e-mac injection molding machines in sizes of 160, 280 and 380 tons. 

Another testament to Orthex’s strong focus on efficiency is their guiding principle: "No over-engineering!" ENGEL supplied a customized complete solution tailored to the project specifications. The production cell can be adjusted to accommodate the various product sizes of the smart store boxes.

• High precision: The servo-electric drives of the e-mac's main movements enable exact positioning - shot after shot. The result: reliable and consistent process stability.

• Gentle plasticizing: Thanks to in-house development and production of plasticizing components, ENGEL offers optimized screws and non-return valves, even for challenging materials.

• Low energy consumption: High-quality drive components, such as low-friction ball screws, in combination with efficient servo motors, ensure low energy requirements of the e-mac injection molding machine.

• High floor space productivity: The e-mac series is one of the most compact injection molding machines available, featuring the widest tie-bar spacing in its clamping force class. Orthex received a highly automated complete solution with a minimal footprint. An all-electric injection molding machine, extensive automation - everything from a single source.

• High level of automation: The storage boxes are fully automated - removed directly from the mold at the injection molding machine, labeled, and packed for shipment. This highly efficient production at Orthex’s Nordic facilities ensures globally competitive unit costs.

Orthex keeps future generations in mind in everything it does. The drive to continually increase sustainability comes from within. As a testament to this commitment, the corporate group now ties the financing of new projects to its sustainability goals. "The more sustainable we are, the lower our loan costs," says Rosenlew. Key performance indicators negotiated with banks include the use of recyclates and bioplastics, measures to reduce scrap, and energy efficiency of production machines. The new all-electric e-mac injection molding machines provide Orthex with a high level of security in meeting these targets.