By combining advanced hot runner and coating technologies, this project - a 6.6-liter bucket with a wall thickness of just 1.1 mm - demonstrates how productivity and process efficiency can be enhanced in injection molding.
Produced from post-consumer recycled polypropylene (PCR-PP), this lightweight thin-wall part benefits from shorter cycle times, reliable processing and consistently high part quality.
This case study highlights the complementary contributions of Oerlikon HRSflow and Oerlikon Balzers, developed in collaboration with Dijkstra Plastics, R&D Plastics and Piovan.
STARgate HRS™ is a disruptive pin-less solution that manages flow rate through a revolutionary diaphragmatic-based design and movement, delivering optimal cooling performance.
The case study demonstrated that, thanks to STARgate HRS™ technology, the cycle time for this bucket application was reduced by 20%, resulting in higher production efficiency and productivity.
Moreover, its innovative configuration enables faster color changes, reduced waste and lower pressure losses, as well as quicker assembly and maintenance operations compared to traditional solutions. Additionally, it allows for smaller nozzle diameters and reduced mold pocket sizes, making it an exceptionally compact solution.
Less than a year after its official launch, customers using STARgate HRS™ have reported significantly shorter cycle times and lighter molded parts. These benefits are achieved through reduced wall thickness, made possible by more efficient and uniform filling during the injection molding process.
Furthermore, the range of processable polymers has expanded to include materials such as PMMA and ABS.
STARgate HRS™ relies on an innovative opening and closing mechanism to deliver its performance benefits. To further enhance the long-term reliability of this mechanism, Oerlikon Balzers contributed its expertise in surface technologies.
The PVD coating BALINIT® MOLDENA was selected for its high wear resistance and low affinity to plastics, helping to reduce sticking effects and maintain consistent operation under demanding production conditions.
These properties contribute to stable processing and reliable overall system performance over extended production runs.
