K 2025: Groundbreaking digital production cell for medical technology

A decisive criterion was to implement the turnkey system with its numerous hardware and software options as quickly as possible in order to get products ready for series production in a targeted manner. The overall responsibility for the production cell with its hard- and software lay with ARBURG as the general contractor. The production cell presented at K 2025, centred around an electric ALLROUNDER 570 A “Comfort” with a clamping force of 2,000 kN in a clean room design, is a benchmark for medical technology. At the heart of the exhibit is an 8-cavity mould from Hack to efficiently produce injector pen caps made from medical PP in a cycle time of less than ten seconds. A suspended and therefore particularly space-saving fully integrated six-axis robot places the moulded parts separately according to cavities. If required, the operator can manually request random samples, which are then placed in a quality drawer.

The practical example shows that significant cost benefits can be achieved through comprehensive collaboration, project planning, early selection and requirement-specific design of the injection moulding machine, including the mould, peripherals and material. A major benefit is the consolidation of all data in the Gestica control system in combination with numerous pilot and assistance functions. All in all, these measures enable fast and safe set-up, joint maintenance management and preventive spare parts management as well as a high level of productivity. Short cycle times, consistent high component quality, perfect melt quality, and a very high overall equipment effectiveness (OEE) have been achieved. This is accompanied by a footprint of the turnkey system that is around 25 per cent* smaller compared to a production cell with standard automation and a six-axis robot, and around 50 per cent** reduction in energy consumption thanks to injection moulding machines and temperature control units designed specifically for the application. CO2 emissions and the product carbon footprint (PCF) are also reduced.

The GESTICA control system acts as a control centre for intelligent communication between the machine and its environment. All data, including mould sensor data, temperature control units and robotic system, is centralised here. The entire production cell can be operated centrally via the GESTICA screen and indicates as soon as any anomalies are detected. This makes work easier and safer for the user. They can quickly identify and assess when action is required based on the data provided. The production cell for Sanofi has numerous assistants and pilots: With the “aXw Control FillAssist”, the filling behaviour of the moulded part can be simulated directly in the machine control system, which saves a significant amount of time when setting up the mould. The “EnergyAssist” automatically heats up or deactivates the cylinder module and mould in a consistent and energy-saving manner, The “ARBURG FlowPilot” regulates the mould temperature. The “aXw Control MeltAssist” automatically calculates plasticising capacity utilisation and dwell times, and thanks to the “aXw Control CycleAssist”, the control system knows the programmed cycle sequence. Unproductive times can be eliminated at the click of a button, thus reducing the cycle time and part costs. The “PressurePilot” in turn ensures consistent mould filling.