BRAND LEADERS INASSISTED INJECTION MOULDING (AIM)

With AIM solutions from

Would you like to enjoy more designfreedom with your injection moulding parts?

Cinpres and Maximator

Cinpres & MaximatorA powerful combination

Two market leaders, two strong teams,one powerful voice

Combined strengths - World leaders

CinpresJon Butler - Managing Director of Cinpres Gas InjectionLtd UK: “Cinpres and Maximator are - and will remain -two separate companies, each with their own distinctivebrands. But our brand offerings are complementaryand work together, we can offer the customer a complete solution.”

As the first company to develop and patent gas injectiontechnology in the 1980s. Cinpres is the brand leader inwhat is now called Assisted Injection Moulding (AIM).Based in Middlewich, UK, the company supplies completegas and water injection solutions, including gas generatorsand gas compressors, as well as gas or water controllersto the plastic injection moulding and extrusion industries.

The company works with global OEM companies and theirsupply chains in the automotive, electronics, white goods,home & garden, packaging and other sectors to find newways to reduce the cost and enhance the quality of theirplastic parts or products.

Complementary Product OfferingMarket leader in high pressure technology meets brand leaderin Assisted Injection Moulding (AIM).

Complementary Geographical StrengthsCombined global strengths in Europe, The Americas and Asia.

Much Stronger Service DeliveryCombined world-wide infrastructure and engineering resources.

Process ExpertiseThe industry’s leading AIM experts under one roof.

Scope of Technology SolutionsB y far the most comprehensive range of solutions - incl. all gasinjection processes, water injection and foam injection.

Technology LicensingThe major share of AIM technology licensing available from onesource - no confusion in market. Supply chain safety.

R & DMuch stronger R & D effort through combined resources.

MaximatorHenning Willig - Managing Director of Maximator GmbH Germany: “I do not believe that there is any Assisted Injection Moulding (AIM) solution that we cannot now provide. We share a commitment to help customers reduce costs, improve quality and maximise profitability.”

Maximator is a leading supplier of high pressure testing,hydraulic and pneumatic systems. Employing 320 peopleat its Head Office and manufacturing facility in Germany, thecompany specialises in the development and manufactureof compressor stations, air-driven boosters, hydraulic-drivencompressors, water assisted moulding (WAM) systems,proportioning and dosing systems, gas nozzles and injectors.

Maximator has also developed a particular expertise ingas proportioning systems, which give very precise flowrate control for physical foaming applications in the plastics industry, but also for applications in food, beverage and tobacco industries.

A typical water injection part

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Comprehensive global supportMould Design & Mould Trial Support

Mould design support.Mould trial support with Cinpres process specialists.Available world-wide.

Assisted Injection Moulding (AIM) is part of a family oftechnologies that are operated with plastics processingmethods to improve product quality and significantly reduce cost.

The technologies include the injection of gas or water athigh pressure into plastic in an injection mould. This coresout sections of the part, leaving hollow areas. These reducepart weight and can provide much better distribution ofpacking pressure and eliminate sink marks. Gas can alsobe applied to the surface of a plastic part to replace mouldingmachine packing pressure with a uniform gas packingpressure, eliminating sink marks and reducing clampingforce and often leading to lower part weight and cycle time.

Other processes involve creating foam in plastic resins toreduce density, or thermal cycling of moulds to eliminateweld lines. The technologies can often be combined toachieve additional benefits, depending upon the application.

What is Assisted Injection Moulding?

Product Assessment Report (PAR)

Indication of suitability for AIM to meet customer objectives.Process selection.Illustration of potential benefits.

Production Start-up Support

Peace of mind through Cinpres attendance.Process optimisation.Equipment commissioning and training.

Flow Analysis for Gas

In-house resource, delivered by gas injection experts.Including consultation and liaison with customer and toolmaker, if required.

Equipment Supply

Nitrogen gas generation and compression equipment.Nitrogen gas and water controllers.Hydraulic power packs.Nozzles & mould accessories.

Process & Equipment Training

Periodical refresher courses.Process optimisation.2 day Part Design workshop.2 day Process Theory & Trouble-shootingworkshop.2 day Equipment Maintenance Training.

First OEMDiscussions

Part Design,Costing &

BiddingTool Design T1 Toolmaker

Mould Trial T2 CustomerMould Trial

Production Start-up

ProcessOptimisation

“Your response to our requirement was immediate. The original product had design issues that were preventing effective production; cycle times were too high and the scrap rate was unacceptable... with the recommendations of your engineers, we have been able to significantly improve part processing”An External Gas Moulding (EGM) customer

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EXTERIORWing MirrorsSide panelsDoor handlesLightingBumpersRadiator grillsRoof railsFoot platesMotorcycle rear grab bars

INTERIOROverhead grab handlesDoor handlesDoor/map pocketsInstrument panelsClutch pedals‘A’ and ’B’ pillarsGlove boxesSeating componentsRear parcel shelvesSat Nav faciaAir bag covers

UNDER BONNETAir intake manifold coversEngine cover and traysBattery lidsFluid pipes

RAIL & AIR TRANSPORTSeatback tablesLuggage area panelsOxygen mask panels

MEDICALBed sideboards/railsHospital bed tables Handwash dispensersDiagnostic instrument boxesSupport handlesCrutch components

PACKAGINGPalletsBottle cratesStorage boxesTrolley & bucket handlesShopping basketsCoat hangers

Polystyrene food trays

CONSTRUCTIONManhole covers & surroundsStreet kerbingSpirit levelsStadium seatsWindow vents

Rigid PVC pipingFibre optic & other cablesWindow profiles

Flat screen TV panel surroundFlat screen TV back panel and baseHi-Fi and car stereo faciaComputer keyboardComputer mouse

Computer flat screen surround and base.Laptop casesTelephone casingsPhotocopier panelsMobile telephone casings

Kitchen appliancesFurniture (tables and chairs)Games consolesToysVacuum cleanersBath panelsBathroom cabinets

Shower headsFaucet spouts and tap componentsBaby carrier handlesDIY ToolsGarden toolsGarden machinery

Office chairsCycle handle bar ends

Hosepipes

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Fridge, freezer and oven handlesWashing machine top panelsEnd capsClothes iron handles Control panels & facingsW

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INJECTION MOULDING APPLICATIONS EXTRUSION APPLICATIONS4

Cinpres & Maximator AIM equipment

Designing your AIM installation

There are four key stages to defining your equipment requirement for AIM. These are set out below withguidance on Cinpres and Maximator equipment available at each stage.

STAGE 1 HIGH PRESSURE NITROGEN SOURCE

The two main considerations for the selection of a nitrogen gas source are: (a) Nitrogen volume required at a given pressure. This is determined by a number of factors including part geometry, number of cavities, distance to mould,

and production volume. Cinpres can assist in estimating the required volume. (b) Nitrogen purity required. Generally from 98% to 99.5%, depending on customer requirement, to suit materials processed.

The options for nitrogen gas supply are:

Robust and reliable “PSA” process using carbon molecular sieve

Integrated air pre-treatment including high efficiency filtration and dryer

Packaged ready to run solutions available with flow rates up to 120sm3/hr (70scfm)

Optional nitrogen purity analysis

ROI / payback proposals available on request

No bottle change over or long term gas supply contract

GENTEC NITROGEN GENERATOR RANGEFor the generation of low pressure nitrogen gas at 5 Barg (72.5 psi) using a factory-compressed air supply

Liquid Nitrogen SupplySuitable for very high volumes and higher puritygas applications. Requires compression.The liquid nitrogen tank is usually installed by agas supplier under a long term supply contract.This option requires a liquid nitrogen compressoror a high pressure gas compressor from Cinpresor Maximator.

Bottled Nitrogen SupplySuitable for lower volume and/or higher puritynitrogen applications - requires a high pressurecompressor or booster system, available fromCinpres or Maximator.

Generated Nitrogen SupplySuitable for medium to high volumes andstandard or high purity nitrogen applications.Separate nitrogen generation and compressionequipment and combined gas preparationsystems (GPS) are available from Cinpres orMaximator.

*Indicative only, depending on consumption

Model N2 purity Sm3/hr SCFM No of IMM machines*Gentec 15 98% 15 8.8 2-3

99.5% 9.6 5.6 1-2Gentec 30 98% 30 17.6 5-6

99.5% 18.5 10.9 2-3Gentec 60 98% 60 35.3 8-10

99.5% 38 22.4 4-6

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Model Sm3/hr SCFM No of IMM machines*Hicom 15 15 8.8 2-3Hicom 15D 30 17.6 4-6Hicom 30 30 17.6 4-6

*Indicative only, depending on consumption

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HICOM NITROGEN COMPRESSOR RANGEFor the compression of nitrogen supplied from bottles or a generator up to 350Barg (5075psi)

3 & 4 stage high pressure industrial nitrogen compressor

Twin compressor duplex systems available for maximum flexibility and backup

High pressure bottle storage rack options

Solutions available up to 2 x 120sm3/hr (2 x 70scfm)

Optional nitrogen purity analysis

These compressor stations are self contained pneumatic driven and hydraulic driven gas compression units in compact design.The compressor continuously delivers N2 into a storage tank and thus ensures that the pressure in this storage tank is alwayswithin the selected parameters.

PNUEMATIC DRIVEN COMPRESSION UNITFull use of cylinder pressure

Oil and grease-free compression

Without accessory electrical energy

Without cooling water

HYDRAULIC DRIVEN COMPRESSION UNITCompressor output 24sm3/hr (14.1scfm)

Gas recovery

Low-noise

VP120/500/300*Operating pressure: 20-500 bar (290-7250 psi)Output flow at 18 bar inlet pressure (260 psi): 7.2Sm3/hr (4.2 SCFM)Output flow at 300 bar inlet pressure (4350 psi): 24Sm3/hr (14.1 SCFM)

VH/400/500/ROperating pressure: 200-500 bar (2900-7250 psi)Output flow at 14 bar inlet pressure (200 psi): 24 Sm3/hr (14.1 SCFM)

Cinpres & Maximator AIM equipment

VP/VH NITROGEN COMPRESSOR RANGEFor the compression of nitrogen from bottles up to 500 bar

This system is suitable for mould trials and smaller production run applications. In addition to the features offered inPPC range, this system has an integrated Air Driven Intensifier (ADI) system to pressurise and maintain the bottlednitrogen supply pressure, using factory supplied compressed air feed.

Up to 4 outlets

Full colour 10.4” touchscreen

Can be used on up to 2 adjacent injection mouldingmachines simultaneously

Control of pressures up to 350 barg (5075 psi)

Multi-lingual display

USB data transfer port

Optional 620 barg (8990 psi) system for special applications

Optional integrated hydraulic power pack providing control of up to 4 mould actuators

Upgrade options for

Full scale production

GAS PREPARATION SYSTEM - GPS RANGEAll-in-one Gas Preparation System for the generation of nitrogen from factory compressed air supply and compression up to maximum pressure of 350 Barg (5075psi))

This system is suitable for series production applications where there is a high pressure nitrogen source at 350 Barg (5075psi) pressure. The unit controls the injection of pressurised nitrogen into the mould tool using Gasflow ProTM precision Phased Pressure Control (PPC) software.

PPC RANGEFor use with high pressure nitrogen supply from a HICOM nitrogen compressor or from a GPS Gas Preparation System

STAGE 2 CONTROL OF NITROGEN OR WATER INJECTION TO THE MOULD

Up to 4 outlets

Full colour 10.4” touchscreen

Can be used on up to 2 adjacent injection moulding machines simultaneously

Control of pressures up to 350 barg (5075 psi)

Signal option pack available for control of signals for cores

Valves can be removed and mounted on injection moulding machine

Multi-lingual display

USB data transfer port

CPC RANGEFor use with low pressure bottled nitrogen supply.

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Integrated air pre-treatment including filtration and high efficiency dryer

Robust and reliable “PSA” process using a carbon molecular sieve

3 & 4 stage high pressure nitrogen compressors

Twin compressor duplex systems available for maximum flexibility and backup

Complete with high pressure storage

Solutions available from 15nm3/hr to 60nm3/hr

Optional nitrogen purity analysis

Output 15sm3/hr (8.8scfm) @ 98% nitrogen purity, 350barg (5075psi)

Solutions available up to 2 x 120sm3/hr (2 x 70scfm)

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LC (LIQUID COOL) CONTROLLERFor use in combined gas/water injection applications alongside an existing PPC or CPC controller

This is an add-on system for existing or new gas injection installations, introducing water circulation intothe process to further reduce cycle times.

Cinpres & Maximator AIM equipment

2 water outlets

Monochrome screen with multi-function display

Multi-lingual display

Built in heat exchanger and water filter

The water-assisted system combines two equipment concepts in one system by providing both volumeflow and pressure control. This innovation remarkably extends the range of potential applications in theplastics industry.

Volume-flow and pressure-controlled system

Curve form freely programmable with ramp func-tion

Compact design for 2 cavities

emptying of components by blow-out

Separate volume monitoring of each cavity also during pure pressure control

TIK-WIT process selectable via touch panel

WATER ASSISTED SYSTEM - WID/2/300/1,5

GIC MODULEGas Injection Control Process Monitoring

The process monitoring module is positioned between control module and mould. The introduced N2 volume and the recirculatedN2 volume are exactly measured. Thus, the system is capable of detecting gas outbursts, injector impurities and mould leakages.This is the first device for operators to determine and monitor their gas consumptions.

Process monitoring in conformity with DIN ISO 9000

Monitoring of gas consumption

Detecting of mould leakages

Cost reduction

GOOD/BAD criteria via Interfaces

Also conditionable for multicavities

NITROGEN FLUSHING MODULE – SM/500/1-4For pressurised flushing of AIM products with nitrogen

Cycle times can be reduced due to the cooling effect of the flushing process. The flushing velocity is adjustable by meansof a throttle. An extra flushing connection and an external valve for fast pressure bleeding are available as an option.

Cost savings due to reduction of cycle time

Simple user interface

Defined interface to all injection moulding machines

1, 2 and 4 cavity design available

The proportioning station doses N2/CO2 exactly into the extruder. The gas volume is measured at the pressure side.Volume control is insensitive to temperature and optimally adapts to pressure fluctuations with uniform quantityproportioning. The measured values are visualised.

Precise flow-rate control

Easy operation

Automatic adjustment to extruder pressure reducesstart-up process

High degree of foaming

A high-dynamic control valve responds promptly to process changes

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Cinpres & Maximator Gas extrusion equipment

STAGE 3 PROCESS CONTROL

2, 4 or 6 Hydraulic circuits

Adjustable pressure control up to 180 barg (2610 psi)

Oil temperature and level signals

Simple interfacing with suitably equipped Cinpres gas controller

The connection with the injection moulding machine is made via an interface. Limit switches in the mould areprocessed as signals in the PLC and thus ensure safe operation (HAG unit)

Impact on the Process. The above-described advantages reduce production fluctuations under the same product, material and process conditions.

Environmental compatability, since no chemical propellants are used

Cost-effective

Chemically and physiologically inert

Temperature-independent

EXTERNAL HYDRAULIC POWER PACK – HPP2, HPP4, HAG/160-210For use in combination with a gas controller for control of hydraulic actuators, valve pins and retractable gas and water nozzles

GAS DOSING STATIONTYPE EX3000 – 10KG/HR, TYPE DSD500 – 20-40KG/HR

STAGE 4 GAS AND WATER NOZZLE SOLUTIONS

MACHINE GAS NOZZLE (MGN)For injection of nitrogen into the plastic part via the sprue and runner system

Robust proven design with unique shut off mechanism

Custom made adaptors can be designed to suit injection moulding machine end caps

Can be used for mould trials to demonstrate gas benefits

IN-MOULD (SIG) GAS INJECTORSCinpres “Sealed Injection of Gas” (SIG) fixed nozzles for injection of nitrogen into the mould cavity or runner system using all process methods

Robust proven design with cinpres-patented sealing system

Custom designs available

RETRACTABLE (SIG) GAS AND WATER NOZZLESCinpres “Sealed Injection of Gas” (SIG) retractable nozzles for injection of nitrogen or water into the mould cavity with mechanical venting of the medium by retracting the nozzle assemblyhydraulically. Suitable for all process methods.

Cycle time savings

Robust proven design with patented sealing and retraction

Full seal option to prevent blockage with problematic materials

High flow versions for large core outs

Custom designs available

GAS INJECTORNitrogen is charged - controlled by the control module - through the mold lines into the injector. The velocity of flow makes the needle move forward.

The freely movable needle extracts the moulding time and the cleaning cycle. Additional gas channels prevent the melt from forming a skin around the injector. Upon pressure relief the needle moves backwardsand wipes off impurities.

Self-cleaning function

Fast replacement with open mould

High reproducibility

Made in Germany

PIPEWORK, HOSES AND FITTINGSFor safe distribution of high pressure nitrogen in your factory.

Site surveys available

Site installation of high pressure pipework

Isolation and vent manifolds

‘Quick connection’ hose solutions

INJECTION MOULDING MACHINE CONNECTION SOLUTIONSFor interfacing between controller and the injection moulding machine

Interface cabling (custom lengths available)

Linear displacement transducers (LDT)

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AFTER SALES SERVICE

Design, Consultancy and Tooling Projects experts are availableworldwide to advise how gas assisted moulding can benefityour product and company - from concept to production. CAEplastic and gas flow analyses are provided when appropriate.

Mould Trials

Mould trials may be undertaken at our global facilities or supervised by our technicians at a moulder’s factory.

Comprehensive training for customers including:

Factory technicians – in the operation of all Cinpres andMaximator equipment and processes

Maintenance engineers – in the servicing and maintenanceof Cinpres and Maximator equipment

Design engineers - in the design of AIM products to take full advantage of the potential economic and technical benefits

Sales people – in the advantages and benefits of AIM as well as the scope for design flexibility, with a view to increasing sales with new product applications.

DESIGN CONSULTANCY & TOOLING SERVICE

Cinpres and Maximator provide you with a high-quality product. In addition, you will also benefit from our excellent after-sales service irrespective of the location of your site.

You can rely on outstanding technicians and fast-track spare part deliveries.

The Cinpres and Maximator after sales service includes:

Maintenance of compressors and controllers

Installation of systems and piping

Commissioning and training

Repairs and refurbishment

BRAND LEADERS INASSISTED INJECTION MOULDING (AIM)

Your local office/agent:

GLOBAL HEAD OFFICE &MANUFACTURING CENTRE

Prosperity CourtMiddlewich CW10 0GDUnited Kingdom

tel: +44 (0) 1606 839800fax: +44 (0) 1606 839801

email: sales@cinpres.comweb: cinpres.com

HEADQUARTERS/PRODUCTIONMAXIMATOR GmbH

Lange Straße 699734 Nordhausen, Germany

tel: +49 (0) 3631 9533-0fax: +49 (0) 3631 9533-5010

email: info@maximator.deweb: maximator.de

Cinpres & Maximator locations worldwide

For further contact details please also visit our websites on cinpres.com and maximator.de

Manufacturing Locations

OfficesAgents