European moldmaker introduces new multicomponent tool technologyEuropean moldmaker introduces new multicomponent tool technology

For molders needing quick and efficient mold changeovers to accommodate changing batch sizes, Germany's Zahoransky Formenbau GmbH offers new multi-component platform injection molds, saying the new technology allows faster product changeover by simply exchanging mold inserts in the master mold.

"The new multi-component mold system is the first choice for users who make a variety of products or who produce large volumes, and need quality and economic efficiency," said Michael Schmidt, managing director of Zhaoransky. "With its versatility, the system offers an important value-add factor in production."

Zahoransky multicomponent tool

Each master mold is built in individually centered blocks with four cavities per block, according to information from Zahoransky. The inserts are slide-mounted on the master mold in an axial director for the required different injection points. The mold inserts are top-mounted and include a complete ejector package. The design allows for building new exchangeable inserts that match new products without having to return the mold to Zahoransky for adjustments. When changing the inserts over to a new product, there will only a brief interruption in production.

Zahoransky has built a large number of these multi-platform molds for companies in the personal care market, where as many as eight different types of products are made in a single mold.  Recently, Zahoransky received the Business Partner of the Year 2011 award from Proctor & Gamble, just one of 12 suppliers to receive this award from P&G's thousands of suppliers worldwide.

In addition to the easy product changeover, production capacity can also be easily adjusted. Identical cavity blocks both in the 4-, 8-, 12- and 16-cavity designs allow trouble-free enlargement or reduction in size of the mold. This is achieved by installing the mold inserts in master molds of different sizes. Depending on the required delivery volume, the parts are produced on the most optimum-sized injection molding machine.

The reposition handling mechanism in the mold is driven by a servomotor, which ensures a highly dynamic molding system, stated Zahoransky. The first shot parts are held and transferred by means of custom tooling nests with vacuum units and then carried and inserted into the next station.

In addition to rapid and efficient processes, the servodrive also allows for precise and flexible control of the reposition handling. Zahoransky SPC controls both the reposition handling and the external removal handling, if fitted, independent from the injection molding machine control.