Plastics News - Show Daily - October 25, 2022 - 16

16 * Plastics News, October 25, 2022
SHOW DAILY
Boy saving energy at the press, in its factory
By Catherine Kavanaugh
Plastics News Staff
Dr. Boy GmbH & Co. KG has a
next-generation press that improves
energy effi ciency, a reformatted
control system to advance
Industry 4.0, and it has gone solar
at its injection molding press manufacturing
factory to offset steeply
rising electrical spending.
Sustainability, automation
and cost control are at the forefront
for the family-owned company
and its customers that
manufacture PET preforms, rubber
goods, liquid silicone rubber
products, devices in clean
rooms and more.
Founded in 1968, Dr. Boy has
delivered more than 50,000
presses worldwide with clamping
forces up to 125 tons.
At K 2022, the Neustadt-Fernthal,
Germany-based
company
launched a next-generation
press called Boy XS E - the Boy
XS was released 13 years ago -
with a more efficient servo-motor
pump drive.
" In addition to the energy benefi
ts provided by the drive technology
of the E-series, the servo
drive of the new BOY XS E also
scores with its high dynamics
and an extremely smooth running, "
according to Martin Kaiser,
head of technology at Boy.
The modified machine also
offers a more ergonomic design
and better accessibility. An extractable
drawer was integrated
into the front side of the
machine frame for service and
cleaning purposes.
At K 2022, Boy is exhibiting
two of the midsized presses
with one producing polypropylene
mounting bolts in a 15.6-second
cycle time and the other
dishing out NAS 30 material egg
cups in a 28-second cycle time.
The egg cups are removed from
the mold by a robot and placed
on a conveyor belt.
The Boy XS E is available with
The Boy XS E is available with two different clamping platen
confi gurations: a standard design for conventional mold sizes up to
160 millimeters as well as a special holder for micromolds.
Plastics News photo by Marco Stepniak
Right now, electricity is through the
roof. The expectation is that as soon
the winter starts hitting, there might be
companies that aren't going to survive.
If that happens to one of your suppliers,
you're going to have to fi nd another.
Everybody is a little on edge about what's
going to happen. "
Marko Koorneef
Boy Machines Inc.
two different clamping platen
confi gurations: a standard design
for conventional mold sizes
up to 160 millimeters as well as
a special holder for micromolds.
The new press also is
equipped with the next-gen Alpha
6 control system, which has
a larger screen and multitouch
technology. Target
quantities
and tolerances can be set, displayed
and monitored.
In addition to a wider screen, the
controller is fl exible and attractive,
according to Marko Koorneef,
president of Boy Machines Inc.
" The
DR. BOY GMBH
& CO. KG
Hall 13,
Booth A43
Alpha 6
is more
compatible
for
Industry
4.0 and
provides
mor e
communication with chillers,
TCUs [temperature control units]
and dryers, " Koorneef said.
In the future, a new cooling
water distribution system also
will be standard to digitally record
set flow rates on the machine
display.
The Boy XS E will replace the
Boy XS in 2023.
At another exhibit, K 2022
attendees can select two tool
bits to be placed into a T-grip
made of PA 6 with 10 percent
carbon fiber on a Boy 35 E W.
The bits are then inserted into
the T-handle by Boy's own LR5
pick-and-place robot.
" This is an example of what
Boy can do with parts in automation, "
Koorneef said, adding
labor shortages also are addressed.
" The automotive factories
have been automated for
years. It took jobs in the beginning,
but not anymore because
there aren't enough people. "
The LR5 robot, launched a couple
of years ago, Koorneef said,
and has been resonating with
processors wanting to operate
lights-out with full automation.
In the demonstration, the
gripper of the Boy LR5 removes
a bit holder from a feed unit
and inserts it in the open mold.
After it has been closed, 42.5
grams of PA6 CF10 is injected by
hot runner. The metal part then
is overmolded with the handle
and removed by the robot and
placed on a cooling station.
The cooled down T-handle
then is transferred by robot to
an automatic pick-and-place system.
The bits ordered by attendees
then are inserted into openings
of the handle and given to
the person via a conveyor belt.
The application combines insert
molding and automation in a
compact footprint, Koorneef said.
In another exhibit, a Boy 35 E
equipped with an electric stuffer
developed by the machine builder
takes one-component silicone,
puts it in a cannister and
then pushes it into the barrel
and makes a dental device.
" It's one of a kind. It's completely
integrated into the
controller so there's not two
separate controls, just one controller, "
Koorneef said. " I've sold
two of them, and this is No. 3. "
The electric stuffer is suitable
for any market, he added, with
manufacturers of automotive,
aircraft and connector components
among the buyers.
To reduce its own electrical
costs and be more sustainable,
Boy has installed solar panels
at the production part of its
headquarters site.
" It was a big investment, but
you've got to move in this direction, "
Koorneef said. " Everything
is so unpredictable. When
can you get steel? When can you
get this and that? Right now,
electricity is through the roof.
The expectation is that as soon
the winter starts hitting, there
might be companies that aren't
going to survive. If that happens
to one of your suppliers, you're
going to have to fi nd another. Everybody
is a little on edge about
what's going to happen. "
The solar power for the production
plant is just one of the
provisions Boy has made. The
company also has secured the
oil and gas it expects to use
through the winter.
" They're ready, " Koorneef said.
" Whatever happens, they are
good to go, but that doesn't mean
our suppliers have done the same
thing. That's what makes everything
so unsure, but we have tried
to prepare as best we can. "
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Plastics News - Show Daily - October 25, 2022

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