Injection moulding Controller-related approaches for reliable recyclate processing

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Arburg GmbH + Co KG

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Ramada Acos

Fluctuating material properties in recyclates pose a major challenge in injection moulding. To ensure consistent part quality and process stability, Arburg has developed intelligent control solutions, enabling efficient and reliable processing of PIR, PCR, and regrind materials.

Reproducibly manufacturing moulded parts out of virgin material from shot to shot and batch to batch at a consistently high part quality is state of the art, but usually places high demands on the controller technology. When it comes to processing content such as post-industrial recyclate (PIR), post-consumer recyclate (PCR) and bioplastics, the material and processing properties can vary considerably. Control concepts that ensure constant mould filling and, ultimately, consistent quality of the end products are therefore required if recyclates are to be used efficiently. For this task, Arburg has developed digital pilot functions for its machine controllers that keep the injection moulding process stable during the injection and holding pressure phase.

Various committees, movements and initiatives are pushing for the establishment of closed-loop recycling systems. Even if this is not yet economically viable, the goal is to significantly reduce the use of fossil resources in the medium and long term. In this context, recyclate processing is becoming increasingly important. However, the growing range of materials, their different origins and preparation, as well as their non-homogeneous processing behaviour, make this challenging (Fig. 1). The same can also apply to batch to batch variations with virgin material or inadequately prepared granules, for example due to uneven or insufficient drying of the material.