Engel’s Compact Clearmelt Setup for PUR-Coated Parts

Injection moulding Engel makes clearmelt production more compact and flexible

2026-06-02 Source: Engel 3 min Reading Time

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High-quality polyurethane-coated plastic components can now be produced with a more compact clearmelt setup. Engel’s new machine concept places the PUR equipment closer to the mould, cutting feed-line length, simplifying installation and improving flexibility in production.

The new system concept for clearmelt, shown here on an Engel Duo 5500 Combi M injection moulding machine, requires around 25 percent less floor space and operates with considerably shorter PUR feed lines. (Source: Engel) — The new system concept for clearmelt, shown here on an Engel Duo 5500 Combi M injection moulding machine, requires around 25 percent less floor space and operates with considerably shorter PUR feed lines.
(Source: Engel)

Machine manufacturer Engel has developed a new machine concept for clearmelt systems based on the Duo Combi M two-platen injection moulding machine. The aim is to make the clearmelt process more cost-efficient, compact and easier to implement, especially for processors working with polyurethane surface layers and multi-colour applications.

According to Engel, clearmelt technology has been established in series production for many years. In the process, plastic components are flooded in the mould with a transparent or coloured polyurethane layer. This gives the parts high-quality, scratch-resistant surfaces directly during injection moulding. Functional films can also be integrated. In many applications, downstream painting or coating processes can therefore be replaced. Engel states that “the new machine concept enables shorter PUR feed lines and thus saves considerable costs”.

The process combines decoration, protective function and component geometry in a highly integrated production step. It is gaining importance in the automotive industry, where new vehicle concepts require larger, high-quality and robust interior and exterior components.

The key change in the new machine concept is the arrangement of the injection unit and PUR equipment. The technical basis is the Combi M design of Engel’s Duo two-platen injection moulding machines. In the new layout, the standard injection unit on the fixed-platen side is omitted. Instead, the PUR equipment is positioned there. The thermoplastic component is injected from the moving side of the machine, while the PUR mixing head is arranged on the fixed platen.

This brings the PUR technology closer to the mould. As a result, the PUR feed lines are shorter, while the system periphery becomes more compact, easier to handle, faster to convert and less expensive to operate.

For users, the shorter PUR line routing is one of the main advantages. Because the PUR equipment is positioned directly at the fixed platen, flow paths and line volumes can be substantially reduced. According to Engel, this lowers investment costs and reduces installation effort, as complex piping is no longer required. The effect is particularly relevant for multi-colour applications, where a separate pipe would otherwise be needed for each colour. In the new concept, these lines can be designed much shorter and moving hoses are avoided. When the PUR equipment is changed, hose connections only have to be briefly disconnected.

The system concept is also available in a mirrored version. This allows the injection unit to be positioned so that the material supply remains on the customary side and fits into the processor’s existing in-plant logistics. Engel says additional modifications to the production environment are therefore not required.

Colour change in less than ten minutes

The new system concept also enables more flexible use of colour units. In the previous configuration, these units were permanently assigned to one machine. Unused colour lines had to circulate continuously to prevent colour particles and additives from settling. This is no longer necessary. Flushing processes to disconnect the colour units from the production cell are also eliminated.

According to Engel, colour changes can therefore be completed in less than ten minutes. Operators can distribute the units across several systems more flexibly, reduce downtimes and make better use of existing resources.

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Existing clearmelt moulds can continue to be used. They only need to be turned around, so processors do not have to keep adapted mould variants for different system layouts in stock.

Despite the layout optimised for clearmelt, the systems are not limited to clearmelt applications. Based on the proven Duo Combi M design, they can also be used for standard injection moulding applications. This increases flexibility in production planning and reduces investment risk. A later retrofit with an injection unit on the fixed side is also possible.

In addition to the technical benefits and lower investment costs, the new layout reduces the production footprint by 25 percent, according to Engel.

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The first systems based on the new concept are scheduled to go into operation in autumn. From November, a clearmelt production solution for large exterior parts will also be available for customer trials at Engel’s technical centre in Shanghai.

With the new machine concept, Engel is positioning clearmelt as a more compact, flexible and cost-efficient process for high-quality polyurethane-coated plastic components. For processors, the main benefits are lower peripheral costs, more flexible use of colour units, shorter changeover times and broader machine applicability.

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