Transcript
Productivity Improvements
Maximizing cavitation
Stack molds
Injection Machine Dry Cycle Reduction
Energy consumption
Enhanced cooling, ejection, and release:
materials with high rate of heat transfer
conformal cooling with advanced steel bonding
Consistent ejection
Productivity Trends
Gen 3.0 Prototype Closure Mold
• Standardized prototype designs
• 1 cavity & 4 cavity configurations
• Focused on part optimization
• Pre-qualified designs at optimal part weight & cycle
• Customized for specific applications
Closure Development
YearGen 12010
Gen 22012
Gen 32014
Closure 1881 1881 1881
Part Weight 2.45g 2.45g 2.45g
Cavitation 72 96 96
Cycle 4.7 sec 4.1 sec 3.5 sec
Parts per Year(millions) 441.2 674.3 789.9
Productivity Improvement - Closure Molds (UCL)
More durable (less maintenance)
DLC coatings
Static inner core
Stack component alignment subordinated to each individual stack
No service connections on the bottom of the mold
Clamping force directed through the mold plates not the core stack components
10-15% reduction in tonnage
Less complex mold (fewer parts and controls)
No Ejector box
No racks, pinions, needle bearings or cam followers
No stripper plate latches
No straight side locks
No limit/proximity switches
No slide actuation cylinders
No water manifolds
Faster cycle time
Gen 3.0 Tamper Evident Beverage Closure Mold Design
Cavitation Number Of Molds Number Of Stacks Location Annualize Capacity
16 1 16 Asia 98,918,400
32 6 192 Asia/EU 1,176,510,638
48 19 912 Asia/EU/SA 5,588,425,532
64 2 128 Middle East 784,340,426
72 7 504 Asia/SA 1,780,531,200
96 9 672 SA 6,220,800,000
Totals 44 2,424 15,649,526,196
Largest Installed Base of UCL Beverage Closure Molds
0
100
200
300
400
500
600
700
800
900
2010 2012 2014 2016
?Gen 1.0
Gen 2.0
Gen 3.0
Next Gen
Productivity Improvement of Gen 3.0 Closure Molds
Optimized cooling channels follow part geometry in 3D
Proprietary bonding process in stack manufacturing
Design based on heat transfer simulation yields faster cycle
Enhanced Cooling via KoolTrack™
OLD PART
Conventional
design
NEW PART
5 piece
collapsing core
design
Water Cooled Collapsing Core Design – Caps & Jars
• Productivity continues to improve driven by mold and machine technology
• Collaboration creates value and reduces part costs
• Increasing sophistication of mold design and manufacturing
• Ongoing part design improvements and weight reductions continue to drive overall part costs down
• Early mold maker collaboration in part development is key
Conclusions
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