Sumitomo (SHI) Demag Plastics Machinery GmbH

info-dpde@dpg.com
www.da-kapo.de

www.sumitomo-shi-demag.eu

All data and information provided in this brochure has been compiled and checked with due care and diligence. We believe the contents of this brochure to be accurate,
but cannot guarantee its accuracy. The description in this brochure may differ from the machines actual condition upon delivery.

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 Production efficiency
16 technology modules to ensure your success
www.da kapo.de

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 On-going technological further development and improvement of
the performance capability of our products are rmly rooted in our
company philosophy.
While increasing production efficiency has now become a
trend across the whole sector, this has always been part of our
tradition at Sumitomo (SHI) Demag.

By combining our mature range of machines with innovative and

tested technologies, our production efficiency experts can tackle
the challenging task of having an effective inuence on the numer-
ous factors, which lead to increased efficiency for your benet
and in terms of ensuring optimum cost-effectiveness, secure invest-
ments and the highest levels of production performance.

Our 16 technology modules activePlus have a direct effect on

the machine technology and production processes. This results in
tangible technical solutions, which we then prepare on a custom-
ised basis for your particular needs.
.

We provide the right details which

have a large effect in your production.
Dr. Tetsuya Okamura(CEO), Sumitomo (SHI) Demag

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 Production efficiency
a tradition, not a trend

Protecting the environment with innovative technologies and sus-

tainable solutions, preserving our resources and managing effi-
ciently: That is what Blue Competence stands for, the sustainabil-
ity initiative of the VDMA (German Engineering Federation), which
globally underlies the role of technological leadership for sustain-
able production.

As a member of the Blue Competence Initiative, Sumitomo (SHI)

Demag consistently makes an important contribution to the pro-
tection of resources and sustainability, both in terms of production
and also manufactured products.

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 activePlus intelligent solutions
with maximum effectiveness

Toggle activeDrive activeCool&Clean activeAdjust

Minimal energy intake even Minimisation of energy Extension of the intervals Cycle optimisation through
with fast mould movements losses in partial load and between oil changes and individually adjustable
idle speed operation lowering of wear of the regulation properties
hydraulic components

T
Toggle a
activeDrive a
activeCool&Clean a
activeAdjust

Without
activeFlowBalance

With
activeFlowBalance

Linear guides a
activeColourChange a
activeDynamics a
activeFlowBalance

Linear guides activeColourChange activeDynamics activeFlowBalance

Reduction of losses through
friction and optimum
mould protection through
the highest levels of platen
parallelism
Fast and efficient colour Highly precise process Balancing out of differing
change systematically conduct through shortest pressure ratios with parts
at the touch of a button sampling times critical to lling in multi-cavity
moulds.

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 Cylinder insulation
Reduced energy
consumption through
lowering of the heat
emission of the plasticising
cylinder
activeLock
Increased process consistency
through active closing of the
non-return valve
activeEcon
Representation and optimisation
of the process settings in terms
of energy consumption and
production costs
All-electric dosing drive
Increased level of effectiveness
through high performance direct
drive

Cylinder insulation
C a
activeLock a
activeEcon A
All-electric
d
dosing drive

O
Optimum
s
smartDrive a
activeRemote aactiveQ/active Q+
d
drive technology

smartDrive activeRemote Optimum drive technology activeQ/activeQ+

Increased energy efficiency Simplied machine operation Drive technology specially Sensitive and precise
through speed-regulated pump through visual integration of synchronised to the needs of protection of moulds
drive with hydraulic injection peripheral devices injection moulding machines through active mould
moulding machines protection

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 Production efficiency modules and
their effectiveness

Durability Energy efficiency Production Availability Product

performance quality

activeAdjust
activeColourChange
activeCool&Clean
activeDrive
activeDynamics
activeEcon
activeFlowBalance
activeLock
activeQ/Q+
activeRemote
Toggle
Linear guides
Optimum drive technology
smartDrive
All-electric dosing drive
Cylinder insulation

strong effect We manage to achieve maximum The overview makes clear the effects of the
production efficiency through effectively different activePlus technology modules
very strong effect
coordinating the ve key aspects of: on the ve aspects of production efficiency.
Durability
Energy efficiency
Production performance
Availability
Product quality

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 activeEcon

The benets to you:

The effects of process settings on
energy consumption and production
costs are made clear to see

activeEcon operating side from the NC5 plus machine controls

Making analysis of the energy consumption
of the individual phases of the injection
moulding cycle clear to see is the rst step
towards effective process optimisation.
With the activeEcon measuring and
analysis tool built into the machine
controls, targeted evaluation of the energy
consumption of the machine can be made
as required and the optimum energy
setting of the machine determined by
means of a Before and After Comparison.
A special feature of this solution is that the
programme automatically calculates the
effects on production costs. The energy
values recorded per shot can therefore be
projected to cover a production order and
factored into the unit costs or calculation
for an order.

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 activeCool&Clean

The benets to you:

Oil service lifetimes of
40,000 operating hours
Reduced wear of the hydraulic
components
Reduced oil lter maintenance
costs and times

The high-performance activeCool&Clean load also considerably reduces wear in

cooling and ltering system ensures
optimum oil quality and long oil service
lifetimes of up to 40,000 hours.
A laminar, pulsation-free oil ow ensures
optimum dirt separation in a discrete low
pressure circle in the generously sized ne
mesh lter as well as optimum warmth
transfer in the cooler. This leads to long
lter lifetimes and intervals between oil
changes. Clean oil with a low particle
the other hydraulic components. The
reduction of down times caused by
maintenance work and the higher cooler
ow temperatures generated through the
optimum warmth transfer allow for all-year
re-cooling without any additional costs for
refrigerators an important contribution to
economical production.

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 activeDrive

The benets to you:

Reduced energy consumption with
energy saving of up to 50 % when
compared with standard hydraulics
Highest dynamics in every cycle
sequence
Best price/performance ratio
Considerably reduced exposure to noise
Also available as a retrot for Systec
machines

C: Converter P: Pump
M: Speed-controlled Motor V: Hydraulic Valve

activeDrive is an innovative drive in this way can as much performance be

concept for saving energy, consisting of
a frequency-regulated high-performance
engine combined with an hydraulic pump.
The dynamic performance adjustment
to all needs dictated by cycles ensures
optimum levels of effectiveness, as only
made available as is required in each cycle
sequence. The results are minimal losses
and signicant savings in energy, especially
in the partial load area as well as during idle
speed operation.

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 smartDrive

or
tting f
Retro chines
a
NC 4 m
The benets to you:
Reduction of energy consumption
Low maintenance costs through
reduced pump wear
Best price/performance ratio

smartDrive operating side from the NC4 machine controls

Using the smartDrive production
efficiency module means that dynamic
performance adjustment to all cycle-
determined needs can also be achieved for
machines with NC4 controls. Intelligent
evaluation of the pump signal allows
the pump engine speed to be regulated
according to the process requirements
via a supplementary converter. Operation
is completely built into the NC4 machine
controls and is undertaken using a simple
screen layout. Consistent product quality is
achieved via the process data and further
individual settings. In addition, by providing
the energy requirement needed in each
phase of the production run, high process
stability is ensured.

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 activeAdjust
The benets to you:
Individually adjustable regulating
properties
Reduced cycle times
Production performance increase
of 3 5 % in fast mode
activeAdjust operating side from the NC5 plus machi-
ne controls
Optimum drive technology
The benets to you:
High dynamics, precision and
reproducibility as well as availability
Optimum energy efficiency
Direct drive injection
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Optimum regulating properties can be
selected using activeAdjust without
any external assistance by using a slider
system. This provides the advantage of
enabling the injection moulding machine,
which is designed to cover a wide range
of applications ex works, to be individually
adjusted to your product. Acceleration
and deceleration ramps can accordingly
be optimally selected for a hard or soft
operating mode, according to mould.
This function provides a considerable
reduction in cycle time and produces
noticeable increases in production
performance. Highest parts quality is
achieved through the inuencing of the
dynamics at which the change is made from
injection to hold pressure. activeAdjust also
offers possibilities for optimising ejection
and dosing.
The optimum drive technology makes
a crucial contribution towards production
efficiency. The machine range from
Sumitomo (SHI) Demag is tted with
pioneering energy-efficient drives as
standard. This is how the El-Exis with its
hybrid drive concept fulls the expectations
placed on high-performance machines.
IntElects electrical drive technology
with high-torque direct drives and drive
components made by ourselves has been
especially developed and constructed for
precision injection moulding. Minimal
inertia combined with direct power transfer
ensure high levels of dynamism, freedom
from play and high system rigidity.
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activeQ and activeQ+ operating sides from the
NC5 plus machine controls
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activeDynamics
activeDynamics is the all-electric drive
technology developed by Sumitomo (SHI)
Demag. It ensures optimum interplay of all
the components involved in the drive train.
By ensuring perfectly synchronised engines,
frequency converters and machine controls,
extremely short sampling times of the axis
activeQ
The benets to you:
Sensitive protection of the mould even
during fast operating movements
Reduction of machine idle times
activeQ
Protecting the injection mould is one of
the key tasks of an injection moulding
machine. activeQ fulls this task and at
the same time ensures high productivity
due to short cycle times. Measuring and
monitoring the required forces during the
mould movement allows for active and
immediate reactions to be made to any
The benets to you:
High dynamics, precision and
reproducibility
Extremely short scanning times of the
axis regulators
regulators can be achieved.
When combined with the design focused
on high dynamics, this results in an
optimum total system, best adapted to
meeting the needs of injection moulding
machines.
deviations. Sensitive protection of the
moulds is therefore possible, even during
fast operating movements. Damage or
appearances of wear are discovered at an
early stage and any unscheduled standstills
caused by damage to moulds are effectively
prevented.
activeQ+
While activeQ takes effect when the mould
is being closed, activeQ+ also offers an
additional option, which also checks the
opening. This means that in the case of
stack moulds, sliders etc., the highest level
of security is provided for the means of
production and a valuable additional use is
created for our customers.
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 activeLock
The benets to you:
Improved precision and reproducibility
Fewer rejects
Increased process consistency
The non-return valve frequently forms the
weak spot with high-precision parts.
Traditional systems are only closed passively
through the injection procedure and the
injection pressure occurring. Fluctuations in
the melt viscosity then frequently also lead
to uctuations in the closing behaviour,
the melt cushion and therefore of the shot
weight and of the quality of the parts.
Active closing of the non-return valve
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is possible with activeLock. A dened
closing movement before the injection
during the turning back of the screw
completely closes the non-return valve
and ensures absolutely consistent closing
behaviour which can be actively inuenced.
The non-return valve is securely closed
during the entire injection and hold
pressure process. Process consistency is
increased, uctuations reduced and the risk
of rejects is minimised.
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 Toggle

Robust and durable machine manufacture

The benets to you: that is what the toggle provides. The
Low energy consumption, even with mechanical conversion ensures highest
dynamic mould movements level of dynamics and working speed with
High availability and durability minimal energy consumption and secure
locking without any additional energy
requirement. The central application of
force and the high rigidity have reliable
effects in the centre of the platen. The
forceful kinematics of the double toggle
Toggle
ensures short locking times and strong
opening forces. Particularly in the nal
positions, the large movement of the toggle
is countered by a relatively small movement
of the clamping platen, meaning that
the opening and closing procedures are
undertaken in a very sensitive manner.

All-electric dosing drive

Plastication is the largest consumer of
The benets to you: energy in an injection moulding machine.
The level of effectiveness of the largest At the same time, even the most up to
consumer can be doubled date hydro-engines have comparably low
Protective dosing through reduced levels of effectiveness. Corrective actions
speeds are created by the all-electric dosing
Higher shot weights possible drive. Direct drives operating without
gears are used in the process in many sizes
in the series. The level of effectiveness of
the primary consumer, the dosing drive,
All-electric dosing drive
can therefore practically be doubled using
Hydraulic drive Electric drive for dosing unit Electric direct drive it. Decoupling the dosing from the other
for dosing unit with gear-down for dosing
movements of the machine creates scope
Motor 1 Converter 1 Converter 1 for reducing the speed or increasing the
plastication.
Pump 2 Motor 2 Motor 2

Valve 3 Gear 3 total

~0.88...0.93
Hydro motor 4 total
0.8
total
~0.4...0.7
Reduction of elements in the efficiency chain to increase energy efficiency

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 Linear guides

The linear guides of the movable platen

The benets to you: with guidance carriages mounted on
Minimal friction roller bearings ensure minimal losses
Highest level of platen parallelism through friction and optimal platen
Reduced mould wear parallelism with their wide guidance base
and accessible side rails, even with heavy
moulds. Lubricant-free columns also cut
maintenance costs. The technology of
the linear guides therefore helps ensure,
in addition to low energy consumption,
Linear guides
minimal mould wear.

Cylinder insulation
The cylinder insulation sleeves, which
The benets to you: are obtainable and can be retrotted as
Fast pay-back options, lower energy losses through heat
Simple retrotting emission by the plasticising cylinder. This
Reduction of energy consumption and reduces energy consumption and shortens
heating performance of up to 40 % cylinder warm-up times. The durability
of the heating tapes is extended through
reduced switching cycles and the lower
emission improves the indoor climate. The
insulation sleeves can be easily mounted
Insulation sleeve
under the standard guard plate of the
plasticising cylinder and adjusted at its
heating zones. If the process requires it,
the insulation can be removed in individual
zones. Due to the savings in the region of
up to 40 % of the heating performance,
purchasing the cylinder insulation
frequently already pays for itself in the rst
year.

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 activeFlowBalance

The benets to you:

Machine function with simple operation
for balancing out different pressure ratios
in the cavities
Considerable reduction of rejected parts
(burr formation, under-lling)
Avoidance of mould damage through
even and optimum pressure ratios
Without activeFlowBalance

With activeFlowBalance

Cavity ll level
at switching point

An uneven and uctuating balancing of during the transition from injection to

the multi-cavity moulds can be successfully
balanced out using activeFlowBalance.
Negative effects such as burr formation,
under-lling and mould damage are
avoided in future. The activeFlowBalance
machine function makes use of the
expansion of the compromised melt
hold pressure, which leads to partially
lled cavities being lled more through
their lower counter-pressure. The ll
levels balance out naturally and without
extending the cycle time.

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 activeRemote

The benets to you:

Simplied, central operation of
machine as well as robot and
peripheral technology through
integration into the NC5plus controls
Simple integration of all types of full
touch screen devices
Increased efficiency of the entire
system
Very exible equipping also for
complex automation tasks

smartRemote operating side from the

NC5 plus machine controls

activeRemote is an intelligent extension The capturing, processing and visualisation

tool of our intuitive NC5 plus switching
centre for increasing exibility while
controlling and integrating peripheral
technology of all kinds. Useful
functionalities and the most varied partner
systems are integrated into the operating
interface via VCN (Virtual Network
Computing).
of production and process data allows for
comprehensive supervision and control of
every single production phase. Faults in the
production run immediately become visible
and can be rectied directly, before rejects
are created.

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 activeColourChange

The benets to you:

Up to 5 different liquid colours can be
automated
Fast, fully automatic colour change in
only a few cycles and without machine
idle time
No adjustment of the process settings
required
High savings in personnel, material and
energy costs with very high levels of
product exibility
Lowest rejection rate

Problem-free colour change in the shortest time

With the new and innovative
activeColourChange colour system,
we combine the advantages of liquid
colours with the advantages of standard
plastication. This allows for plastic parts to
be coloured homogeneously and efficiently,
virtually at the touch of a button. The
special feature of the process lies in the
fact that the fusing procedure and the
colouration process run separately. That
ensures a very consistent dosing procedure,
even with the smallest amounts of colour,
in the case of full plastication without
the screw undergoing smearing. The
complete change of colour is concluded in
just a few cycles. Due to the closed system,
the operator does not come into contact
with the liquid colour and no cleaning costs
occur in principle.

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 Production efficiency modules and
their use

Systec < 1.300 kN Systec 1.300 kN El-Exis SP IntElect < 2.200 kN IntElect 2.200 kN
activeAdjust D D D
activeColourChange
activeCool&Clean D D D
activeDrive
activeDynamics D D
activeEcon
activeFlowBalance
activeLock
activeQ D D D
activeQ+
activeRemote
Toggle D D D D
Linear guides D D D D D
Optimum drive technology D D D D D
smartDrive Retrot for NC4 machines
All-electric dosing drive D D D
Cylinder insulation
Not available or not necessary Optionally available D Standard

We can provide you with many intelligent are available for which machine series
and, above all, effective options to increase respectively.
production efficiency by using our high
performance technology modules.
The overview shows you which modules

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 Producing in ways which are exible, fast, high-quality and
cost-effective is more important today than ever. Our high-
performance machine range and our 16 innovative
activePlus production efficiency modules provide an excellent
basis for this.

Yet that is not enough: Solution-focused planning, high investment

security and the targeted creation of competitive advantages are
what we aim to provide for you and which we aim to achieve with
our well-founded expertise, which extends beyond just purely
technical matters.

Our production efficiency experts with their comprehensive

specialised knowledge of machine, control and operating
technology as well as a range of services offering you that extra
something required are much in demand. In addition, the strong
engineering expertise to be derived from our network of partner
companies of leading manufacturers of peripheral and mould
technology as well as process integration are also there to provide
you with support.

Technologies and processes individually

adapted to your operating frameworks our
added extra to help keep you in the lead.
Shaun Dean (COO), Sumitomo (SHI) Demag

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 Production efficiency and more Your
production efficiency experts

Automation
Optimum cost-effectiveness and efficient
production solutions are best achieved
with overall solutions which have been
thought through. Sumitomo (SHI) Demag
linear robots and intelligent multi-axis
robotics as well as all other needs for up-
and down-stream processing steps are
covered by us in close cooperation with our
network partners. Our experts ensure that
everything ts together.

Advice and ideas
The goal of continuously increasing
productivity requires solution-focused
thinking from the start and begins with the
injection parts and the technologies being
deployed. Our experts work with you to
develop the best solution
for your production.
Designing
Our application experts draw up your
individual system design against a
detailed background in terms of technical
procedures and taking into account the
factors dependent on the process. The best
security for deciding in favour of the right
investment for you.
Customer service
Highest quality and lowest possible unit
costs mean it is necessary for the machines
to run and always to be at the cutting edge
of technology. Our experts assume the
responsibility for ensuring this.
ErgoCheck
Our experts will put your machine through
its paces at regular intervals or whenever
you want. ErgoCheck checks all process
parameters relevant for ensuring quality
and all basic and security functions.
EnergyCheck
We measure the energy consumption
of individual production stages and of
the entire injection moulding process in
a detailed analysis. This means that it is
possible to calculate beforehand how much
can be saved by integrating in one of our
production efficiency modules.
Retrot
Being fully up to date in technological
terms does not immediately mean
having to invest in a new machine. Our
comprehensive retrot programme allows
your machine to be optimally updated by
equipping it with injection and clamping
units or controls.
Training courses
As well as technology, the human factor
also provides a crucial contribution to your
success. Constantly increasing requirements
mean that staff need on-going training and
accreditation. This includes being trained to
become aware of potential opportunities to
increase production efficiency.

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 Sumitomo Heavy Industries

1969 1990
Complete range of injection
moulding machines First electric injection
moulding machine
(SE series, hybrid)

1949 1963 1967 1972 1983

Extruder for Extrusion facilities First injection Sandwich injection Injection moulding machine
wire coating for blown lms blow-moulding moulding machine for CD optical data carriers
machine

1950 1956 1963 1971 1972 1975 1983

First injection mouldingFirst single-screw injection First thermoset processing on First programmableFirst multi-component First PLC-controlled Introduction of p/Q
machine (Anker) moulding machine in the Anker screw injection moulding injection moulding machine injection moulding control pump (DFE)
world (Anker) machines machine machine
(punched tape)

1961 1967 1973 1979

First elastomer processing 5-point First digitally controlled First PLC-controlled injection
on Anker screw injection toggle injection moulding moulding
Demag Plastics Group moulding machines machine (digital machine with screen
hydraulics)

Production efficiency A milestone on the road to increasing

tradition, not a trend
We have made a key contribution towards
shaping injection moulding technology
from the start and can count ourselves
among the pioneers when it comes
to production efficiency. In 1956, our
predecessor company, Ankerwerk Gebr.
Goller in Nuremberg, constructed the rst
one screw injection moulding machine.
efficiency in machines was already reached
in 1967 with the development of the rst
5-point toggle.
We are still consistently following the path
of developing innovative technologies.
Production performance, availability, energy
efficiency, durability and product quality are
what we regard as the ve crucial aspects
of our innovations and the key for ensuring

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 Der Zukunft voraus
Ready for the future

Sumitomo (SHI) Demag

2006
SL screw
2009
1993 1999 2005 Combination DFEE pumps and 2011
frequency-controlled drive Over 100,000 injection
PET injection Lockable non- All-electric ultra-high-
activeDrive moulding machines
moulding system return valve performance injection
Schwaig plant becomes in the global market
moulding machine
Centre of Competence for hydraulic
and hybrid machines 2010 2012
1998 2003 2008 Hybrid high-speed injection NC5 plus
All-electric injection All-electric 2C moulding machine El-Exis relaunch control
moulding machine injection moulding All-electric SP
(SE-S series) machine large machine
CL 7000, 550 t Expansion of IntElect smart
series up to 450 t

1992 1996
Ergotech modular Multi complete
system machine modular system
machine
1998
Hybrid El-Exis S high-speed
injection moulding machine
Active mould protection activeQ
2012
2003 2008 2009 2011 SE-EV
New all-electric
All-electric IntElect Merger of Sumitomo Wiehe plant becomes Lockable injection moulding
injection moulding Heavy Industries and Centre of Competence non-return valve machine from Sumitomo
machine Demag Plastics Group for electric machines activeLock
High-torque IntElect smart combines
2010 Flow front
IntElectmulti rst
Individual control all-electric multi component
direct drives IntElect with drive
system activeAdjust
monitoring injection moulding
technology from SHI activeFlowBalance machine
2005 Periphery integration
activeRemote
Optimised activeColourChange
All-electric drive system Change of colour
dosing drive activeDynamics at the touch of a button

the sustainable success of our products.

From the very start, they have determined
and accompanied our entire product
development and enable us and our
customers:
to be ready for the future.

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