Thin walled packaging production with the Netstal ELIOS 7500-4200 24+24 Cavity Flat Lid at work. (video: Netstal)

It is possible to produce perfect thin walled packaging with Netstal Elios solutions at the lowest unit costs. Shortest cycle times, dynamic injection and best process stability are the key to success.

Innovative dual drive technology for clamping units

The thin walled packaging production with the actuation of the 5-point twin toggle is facilitated through a clever combination of electric and hydro-mechanical drive components.

Accordingly, the basic principles of hybrid drive technology are consistently retained:

Fast, dynamic travel sequences;
Harmonic movements;
Optimally designed drive components;
Ideal speed and position regulation;
Extremely energy efficient operation thanks to the recuperation of kinetic energy.

Fast and stable clamping unit

The Elios clamping unit operates with a 5-point twin toggle and is designed for extremely fast and dynamic mold movements and fast cycle times.

The generous installation space offers enough room for the large molds often used in the packaging sector.

This solution has 5-point twin toggle with innovative dual-drive concept, moving mold plate guided by firm, smooth-running linear guides with the mold height adjustment arranged on a support plate.

Solution completely closed and sealed bearing points with circulating lubrication.

Thin-walled packaging produced with hybrid technology with energy recuperation
It is possible to produce perfect thin walled packaging with the Netstal Elios solutions. (photo: Netstal)
The kinetic energy generated during the braking operations flows into the electric motor of the main drive where it is converted into hydraulic energy and stored. Because the energy thus recuperated is used in the overall system again, an energy saving of up to 50 percent can be achieved even under full load compared with an all-hydraulic machine.
There are several competitive advantages with up to 50 percent less energy consumption with outstanding cost-effectiveness in high-performance applications.

**Netstal Elios 7500 for highly demanding applications in packaging sector: user orientation**

Thanks to the so generous installation space and to the extremely stable construction, the Elios solution is perfect for highly demanding applications within the packaging sector.

The comprehensive option package enables each machine to be customized and optimized to meet the requirements with the generous installation size, stable and low wear construction.

The comprehensive option package, hydraulic mold auxiliary controllers and the individually actuated air valves have the mold control circuits integrated with options like flexible mold-cooling installation and the electric supply for system and peripheral components.

aXos controller technology: the Smart Operation concept for Netstal machines
The aXos controller to give the maximum performance. (photo: Netstal)
Smart Operation is the operating concept for all Netstal machines with aXos controller technology. The optional available feature supports in achieving the effectiveness goals. Guided, fast and safe operation reduces downtimes and reliably prevents operating errors.
The aXos controller
High-performance and flexible controller to give the maximum performance. aXos was developed to meet the increasingly complex demands of current and future applications. Innovative functions support the simple, quick and fault-free operation in the production environment.

The responsive Filling Control

Hybrid injection units with highly precise sensors for distances, forces and pressures are present in the Elios series machines. These technical solutions breaks all processes down to the thousandths of each unit of measurement.

The RFC injection control system (based on SYCAP technology) achieves maximum control through the dynamic resolution of rules in millisecond cycles.

Because all sensors used measure with great precision, continuously and in a coordinated manner, the machine can optimally control the entire injection process at any time. This is where the lightning-fast Netstal power control system comes into effect.

Force dependent v/p changeover is the most reliable method for overcoming material variations – and not just during very fast cycle times. the benefits are:

Faster cycle times;
Fewer rejects;
Greater availability;
Top overall equipment effectivenes.

The adaptive drive unit

The energy efficiency is a prime factor: the ever increasing electricity prices is an important reason.

Through the clever combination of different drive technologies, the drive units achieve optimal efficiency values and still retain the necessary power reserves to meet even more demanding applications:

Servo motor with variable rotating speed;
Dual-pump concept;
- Variable delivery piston pump;
- Constant delivery internal gear pump;
Completely sealed oil tank;
Oil cooling and filtering within an auxiliary circuit;
Integrated storage system.

Hybrid, high-performance injection units for thin-walled packaging products
Ultra-high injection performance is required particularly for thin walled packaging products. In terms of dynamics and injection speed, the hybrid Elios series injection units are truly a cut above the rest of the market with the hydraulic injection axis with rotating injection piston (spark), the innovative and powerful twin-valve technology. Other points are the electric metering drive with water-cooled servo motor and spur wheel gearing, the position- and speed-regulated injection unit movement with torque-free nozzle contact pressure.