First premiered at K-2010, the high precision all-electric IntElect series has gone from strength to strength. Now one of the most popular and energy efficient all-electric injection moulding machines on the market today, with more than 75,000 electric machines installed globally, Sumitomo (SHI) Demag is gearing up to celebrate the line-up’s 10th anniversary.
Originally developed for the medical and electrical precision markets, the IntElect’s high torque, direct drive motors – developed in-house by Group engineers – and dynamics has helped to fill an important gap in the plastic production market.Tackling some of the key obstacles that may have previously deterred moulders from making the switch to all-electric, the first generation IntElect overcame the need for hydraulic cores, delivered accurate dosing and included a strong, fast and precise ejector mechanism. Today’s latest models are even more technically mature and very often pay for themselves in less than two years through precision and repeatability, claims Sumitomo (SHI) Demag’s UK Managing Director Nigel Flowers.
In the early days, the IntElect was hailed for its improved performance, dynamics and faster injection speeds and clamping. Standard versions were designed for applications formerly run on a hydraulic machine. A high performance version was also offered for more challenging moulding applications.
Mid way through the decade, the company unveiled its smart NC5 colour touchscreen. A range of technology hardware and software modules badged under the Active series were designed to maximise efficiency and output. Among them were ActiveDynamics, which works with the direct drives, converter and control system to provide faster response times. The ActiveLock adjustable non-return valve increases machine precision, while one of the most innovative – ActiveFlowBalance – balances pressure levels.
Nigel comments: “Maintaining continuous quality throughout the entire life cycle of the machine has been a critical advantage of the series. Deviations in validated processes, which can occur due to wear in the hydraulic system or changes in oil quality, are no longer factors that Quality Assurance managers need to worry about.”
Among the milestones, in 2016 launched a 500kN IntElect model targeted specifically at the automotive sector. Distinguishable by its darker blue cladding and 20% smaller in footprint than its predecessors, this was the first unveiling of an all-electric IM machine with a standard global platform.
The following year was the airing of a new and improved 400v drive system, designed to improve heat transmission. “What we unveiled in 2017 was a new IntElect drive that perfected the interaction between the injection unit, clamping unit and ejectors,” explains Nigel.
Following several years of testing, commercial evidence was also gathered to put the tangible benefits of the IntElect series into a true context. This is when the first domestic kettle boiling comparison was revealed. “Tests comparing the IntElect 2 to its IntElect predecessor and the Systec revealed that the IntElect2 series was the most energy efficient all-electric machine on the market. A claim the company continues to uphold.”
To mark the next era, in 2019, the Group unveiled a mid-sized IntElect (500 ton), in addition to an LSR and multicomponent version. And the medical market praised the cleaner, cooler and quieter IntElect S 180 ton with its new internal layout to accommodate large moulds in a very small injection units. “The ability to install small screws matched with a large mould space is a big advantage as it improves the dosing and injection performance, which is so critical when moulding micro components like pipette tips,” clarifies Nigel.
To adhere to the explicit ISO 13485 medical device quality management and validation standards, the IntElect S 180-ton also introduces new user parameters. This helps to ensure that processes are kept within specified ranges and operators cannot make adjustments unless they have been granted authorisation.
Since first launching in the UK and Ireland, Sumitomo (SHI) Demag has successfully captured more than 20% of the market share for all-electric machines.
