Milacron Holdings Corp. (Cincinnati, OH), an industrial technology company serving the plastics processing industry, announced a “powerful proprietary partnership” with iMflux, a subsidiary of the Procter & Gamble Co. that developed a proprietary control system that enables a new way of processing injection molded parts. iMflux operates in a 200,000–sq ft facility in Hamilton, OH.
Clarios, formerly Johnson Controls Power Solutions (Milwaukee, WI), is using the patented iMflux process in one its U.S. manufacturing facilities. By the end of this year, the company aims to nearly double the number of machines to achieve breakthrough value and substantial improvements, said Milacron.
The iMflux closed-loop process provides absolute shot-to-show repeatability through two techniques: process and control. The low constant pressure process removes many inherent issues provoked by conventional molding processes. iMflux’s control process responds in real-time to changes appearing in the mold and material. The processing technology is referred to by the company as the “Green Curve.”
iMflux monitors true plastic pressure and adjusts screw velocity throughout the cycle to maintain constant pressure. The part design and mold will guide what velocity is needed to protect the fill pressure. Constant driving pressure is conducted across all cavities of multi-cavity molds and even families of molds. Every cavity from the First-to-Fill or Last-to-Fill will experience the same driving pressure, offering the same cavity-to-cavity part quality.
Milacron noted that some of the benefits of the iMflux process control include reduced injection pressure, reduced machine tonnage requirements, faster cycle times and improved product quality. The process also automatically adjusts for viscosity variations to eliminate large swings in viscosity.
iMflux can be connected to any of Milacron’s Mosaic+ control systems, across any entire manufacturing line on a global scale. ServTek can retrofit Mosaic+ control systems onto older machines to complete the addition of iMflux.
iMflux can compensate for fluctuations in the process between the mold and the machinery, as well as the material being fed into the hopper. This assists the use of Bio-Resins, post-consumer and post-industrial recycled materials. It produces parts at the same volume in less time, with lower energy demands per part.
Light-weighting is a technique to cut part weights while protecting or improving part properties. iMflux allows plastics to flow further and through thinner wall sections without the risk of freezing off. The process also molds at considerably lower pressures, generally in the 20 – 50% range, explained Milacron.
Using this technology, Clarios has seen an “uptick” in their production output, improved cycle times, a minimized amount of resources used due to lower scrap and significant advances in part quality.
“The Green Curve has proved invaluable in our effort to establish more processes using sustainable resins,” stated Brandon Meadors, engineering manager, Clarios. “Not only have we been able to increase our percent of regrind used, but we are seeing more consistency than ever before.”