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June 21, 2002

2 Min Read
Two-shot modular molding


Kunststoffwerk Kutterer GmbH & Co. KG (Karlsruhe, Germany) wanted to increase the output on a two-component shampoo bottle cap program it was running but didn't have the capacity or desire to buy a second multicomponent press to team with its existing two-component machine. The molder produces about 2.7 billion caps every year for OEMs in the pharmaceutical and cosmetic markets like L'Oreal, Unilever, and Wella. For this particular program, a 3500-metric-ton machine was molding 4.7g shampoo caps with a .2g strip of coloring for added style. The parts were created in a 24-cavity hot runner mold that used core pulls and cycled parts in 13.5 seconds (see photo, top). Enter Windsor Kunststofftechnologie. Part of the Cannon Group, Windsor offered the option of its PlugXPress modular injection unit, which can be retrofitted to any standard injection molding machine to make that machine a multicomponent press. Kutterer decided to add the WKT1 PlugXPress to an existing 3500-metric-ton press and used its 24-mm-diameter screw to plasticate a maximum shot weight of 46g (see photo, below).


With only eight weeks to get the program running, a new multicomponent press was not an option because of the time needed for delivery and setup. Windsor delivered thanks to the modular design of the PlugXPress, which can be integrated quickly and situated at any angle to the press. This allows for the addition of other PlugXPress units, making two, three, or even four-component injection molding possible. Kutterer says the Windsor unit produced caps identical to the multicomponent machine in terms of quality and performance.

Contact information
Windsor Kunststofftechnologie
Hanau, Germany; +49 (6181) 9003-0

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