Oerlikon HRS Flow's Innovative Hot Runner Technologies at K 2025

Oerlikon HRS Flow at K 2025 From aesthetic parts to compact systems: Hot runner highlights at K 2025

2025-08-04 Source: Oerlikon HRS Flow 4 min Reading Time

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Oerlikon HRS Flow showcases breakthrough hot runner technologies at K 2025 — including live demos of Stargate, Glow and Flexflow systems for high-quality, efficient injection moulding.

The new Up Nozzle series: with a 15 mm gate-to-gate pitch and 12 mm cut-out, it is ideal for low shot weight applications and hard-to-reach gate areas.(Source: Oerlikon HRS Flow) — The new Up Nozzle series: with a 15 mm gate-to-gate pitch and 12 mm cut-out, it is ideal for low shot weight applications and hard-to-reach gate areas.
(Source: Oerlikon HRS Flow)

At K 2025, taking place in Düsseldorf/Germany from 8 to 15 October, Oerlikon HRS Flow will showcase at Hall 1/Stand C72 its Stargate HRS hot runner technology, which enables precise control of melt injection into the mould cavity through a revolutionary Valve Gate concept. Another new development is the Glow HRS solution, which allows for the direct injection of aesthetic parts in amorphous materials. Systems from the global hot runner specialist will also run live at partner companies, including an injection moulding tool for automotive parts that delivers a flawless surface and minimizes secondary operations. Beyond, visitors can expect to see interesting developments in application-specific solutions for multi-cavity systems. These include the Up Nozzle series, which is specifically engineered for compact, tight-space applications with low shot weights, and new solutions designed for luxury and eco-friendly parts in the beauty and personal care industry.

The upcoming K 2025 is organized in close cooperation with Oerlikon HRS Flow’s sister brand, Oerlikon Balzers, highlighting the group's integrated approach to innovation and excellence.

Gallery

Oerlikon HRS Flow's dedicated hot runner solutions for luxury cosmetic packaging with wall thicknesses of up to 12 mm.(Source: Andrea Piovesan/ Oerlikon HRS Flow)

A radical change in injection moulding — patented solution

With its newly developed Stargate HRS hot runner technology, Oerlikon HRS Flow will present its revolutionary concept for the injection moulding industry to the public for the first time. This technology is a groundbreaking development in the injection moulding of PP, PE, PS, and other amorphous thermoplastics. Compared to conventional designs, production, assembly and maintenance of various components are unnecessary; cycle time is significantly reduced; colour changes are easier; and power consumption and pressure loss are reduced. Additionally, the thickness of the back plates can be reduced. Stargate HRS hot runner technology also enables short filling and packing times. At K 2025, this technology will be on display at BMB, an Italian injection moulding machine manufacturer (Hall 13/Stand A33), during the production of a bucket. This project was made possible by Oerlikon HRS Flow, BMB, the Dutch plastics processors Dijkstra Plastics, Oerlikon Balzers, Piovan and R&D Plastics.

Avoiding halos and weld lines

Another innovation to be unveiled for the first time at K 2025 is the patent-pending Glow HRS technology, which enables the production of high-quality parts by direct injection, avoiding halos and weld lines. With precise surface temperature control and a compact design, this cutting-edge solution easily adapts to a wide range of applications.

Paint-free, premium automotive parts

At the booth of injection moulding manufacturer Haitian International Germany (Hall 15/A57), Oerlikon HRS Flow will give a live demonstration of how the Flexflow HRS servo-controlled needle valve technology can be used to get high-quality automotive parts directly from the mold. This will be illustrated by the manufacturing of a car wheel arch. Developed in collaboration with DNP Group (producer of automotive decoration film printing) and Inevo (mould maker), this joint project impressively demonstrates that the painting of large-format injection-moulded parts can be eliminated, minimizing the need for expensive post-processing, even when using recycled materials. Other advantages of Flexflow HRS technology include quick color changes and reduced material waste.

New nozzle series and PET thick wall solution now available

With its compact gate-to-gate pitch (down to 15 mm), the new Up Nozzle series from Oerlikon HRS Flow is specifically engineered for tight spaces with low shot weights. With a 12-mm nozzle cutout, the series delivers exceptional performance in hard-to-reach gate areas. These features make the series ideal for industries such as beauty and personal care, packaging, beverages, and technical applications.

At their booth, Oerlikon HRS Flow will present crystal-clear, eco-friendly parts produced with dedicated hot runner solutions for luxury cosmetic packaging. These components benefit from advantages of the technology, including crystal clarity, significant wall thicknesses of up to 12 mm, and high process repeatability.

Advanced injection moulding technology live

At the Engel booth (Hall 15/B42-C58), a three-drop system from the Ga series of Oerlikon HRS Flow’s Diamond Lux line of hot runner solutions will be demonstrated for producing a rear light concept application. In this process, a decorative foil is back-injected with Plexiglas 8N from Röhm and then overflooded with PUR. The foil enhances the visual design of the final product. This project is a collaboration between Zechmayer (toolmaker), Leonhard Kurz (LED and surface design integration), Engel (injection molding machine producer), and Röhm (material supplier).

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Date: 08.12.2025

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A cable clipper made of PA6.6-GF30 that weighs just 1.2 grams will be produced in a 16-cavity mould at Haitian’s booth in Hall 15/A57. The hot runner configuration consists of 16 Oerlikon HRS Flow SA Series nozzles with an open gating system. These nozzles were specially developed for processing glass fiber-reinforced plastics, ensuring perfect cavity filling and outstanding process repeatability.

Boy’s booth (Hall 13/A43) will feature the injection molding of a conical blood filter using a Jestar medical demonstration mold on a Boy 35E injection moulding machine. This process utilizes Oerlikon HRS Flow’s Multi Valve Plate (MVP) technology in conjunction with a 16-drop Multiflow HRS system from the SP series. This technology offers synchronized valve actuation and reduced drop-to-drop spacing, enhancing precision in small weight applications.

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