For over a decade, activeFlowBalance (aFB) has assisted injection moulders to address common manufacturing defects like short shots, flash and warping

Technical Sales Manager Kris Thacker briefly explains how the software works and the savings that plastic processors continue to make.

Developed by Sumitomo (SHI) Demag for use in their all-electric machine range, adoption of aFB has allowed major manufacturers in the automotive and medical sectors to reduce reject rates by up to 40 per cent. Additionally, the integration of this software with IntElect series offers significant environmental benefits, including a 40% reduction in clamp force and up to 85 per cent less energy consumption.

It works by managing the transition from the injection phase to the holding pressure phase to ensure even filling across all cavities without adding external pressure. Rather than adjusting injection profiles manually, the seamless aFB process:

  1. Holds the screw in a fixed position for a set time after the injection process is complete. This is possible due to Sumitomo (SHI) Demag’s highly precise direct drive and control system.
  2. Utilises the melt compression that is already inside the barrel during the hold phase.
  3. Holds the screw still. As no additional pressure is applied to the material, this allows the existing cavity pressure within the melt to stabilise and balance throughout the entire system.
  4. Stabilises the pressure. The compressed melt expands and automatically flows into the cavities that are currently under-filled. Simultaneously, no additional pressure is applied to the cavities that are already full.
  5. Automatically switches back to the standard holding pressure setting when the pre-selected aFB time expires.

Existing IntElect machine users can easily retrofit aFB to their fleet. The software can be implemented with minimal input from a technician. Although the savings are beneficial to all mass moulders, aFB is especially useful for parts and components requiring dimensional stability and accuracy. It can also reduce reject rates in thin wall parts with long flow paths, and small parts with high sprue weights.

“A primary benefit of aFB is that it allows for a reduction in clamp force by as much as 40 per cent. Because the technology achieves a more even fill without incurring pressure peaks, the machine does not need to exert as much force to keep the mould closed. This in turn extends the lifespan of the machine and tooling,” explains Kris.

For a full demonstration of activeFlowBalance in production, book a visit to the Sumitomo (SHI) Demag centre in Limerick or Leighton Buzzard.

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