• New concept: Processing of paper pearls instead of plastic granules
• Reliable process: Stable shot weight thanks to "aXw Control RecyclatePilot"
• Exemplary: Sustainable applications for packaging and the furniture industry
At Fakuma 2024, Arburg (Hall A3, Stand 3101) will be demonstrating how so-called "paper pearls" can be reliably processed on standard Allrounders instead of conventional plastic granules. The innovative injection moulding process paves the way for new, paper fibre-based applications and products in a wide range of industries, including the furniture industry. The exhibit, an electric Allrounder 370 A, will be producing positioning tools for furniture connectors by way of example. The "aXw Control RecyclatePilot" integrated into the Gestica control system ensures a stable shot weight by evening out variations from one material or batch to the next.
The first customers from the furniture and cosmetics industries and from the household goods and toy sectors have already recognised the potential of this innovative process for themselves.
Sustainable: Paper fibres instead of petroleum
Paper injection moulding and the development of paper pearls have been advanced by Arburg together with Model, a paper and cardboard packaging manufacturer. The technology combines the long tradition of paper with the latest injection moulding technology, significantly expanding the range of sustainable and environmentally friendly injection moulded products for a wide range of applications.
The fibre content of the paper pearls is over 50 per cent. The main component is primary or secondary (i.e. new or recycled) paper fibres that are combined with biobased and biodegradable plastic to make them injection mouldable. There is no need at all for any petroleum-based plastics. Due to the high fibre content, the end products should have a minimum wall thickness of three millimetres. They can be easily disposed of in a garden compost heap after use because they contain no additives that could interfere with the composting process.
High quality: Electrical machine technology
At Fakuma 2024, an energy-efficient production cell built around an Allrounder 370 A "Comfort" with a clamping force of 600 kN will be demonstrating the stable and reliable production of injection-moulded parts made from paper pearls. The Gestica control system used has several assistance functions. "aXw Control EnergyAssist" brings together all the key functions of the plasticising cylinder and mould. This ensures optimised switching on and off of all heating zones, significantly reduces the energy requirement in the heating phase and enables energy-efficient production.
The exhibit uses a 2-cavity mould from Lercher to produce "Slot Lock" positioning tools in a cycle time of around 60 seconds. These components are usually made of conventional plastic and are used as assembly aids when putting furniture together. The weight of the paper-injection-moulded parts is 19.7 grams. A Multilift Select 8 linear robotic system removes the parts from the mould and places them on a conveyor belt. The sustainable end product made of paper pearls is stable and can simply be composted after use.
Reproducible: "RecyclatePilot" evens out variations
"aXw Control Recyclate Pilot" in the Gestica control system ensures consistently constant mould filling and stable processing of alternative materials by reliably evening out material and batch to batch variations. The digital assistance function is suitable for processing extremely demanding plastics, particularly post-industrial recyclates (PIR) and post-consumer recyclates (PCR). Even when faced with batch to batch variations or non-homogeneous or unevenly dried virgin material, the "RecyclatePilot" provides excellent support during the injection moulding process and can significantly reduce the reject rate.
Another pilot function of this application is "aXw control PressurePilot", which ensures bionically optimised pressure control, thereby preventing underfilling or burr formation.
