Optimized Hot Runner Systems for PCR Compounds

Oerlikon HRSflow has developed special hot runner solutions for post-consumer recycled (PCR) compounds. Their application prospects are demonstrated by two examples — a fruit crate and a garbage can for composting organic household waste. With these environmentally friendly projects, which were implemented together with various partners, Oerlikon HRSflow underlines its commitment to the circular economy.

For the production of the fruit crates, Mundimold, a Spanish moldmaker, processes an optimized polyethylene (PE) compound from APS, which is obtained from the recycling of Tetra Pak cardboard packaging. In the production of this demanding part — which was demonstrated at K 2022 on a servo-hydraulic Haitian Jupiter with two-platen technology and 4,500-kN clamping force — a servo-controlled FLEXflow valve gate hot runner system with four drops contributes to the high repeatability of the process. Optimum gate quality is ensured by a patent-pending TTC cooling bushing from Oerlikon HRSflow, preventing needle sticking even with short cycle times. The FLEXflow’s low energy consumption also supports energy-efficient production. Project partners were Haitian, Mundimold, Tetra Pak, APS and Oerlikon HRSflow. (Learn more about the production process at this video).

Another example is the Bokashi Organko Essential, an airtight sealable bucket for home composting. The 775-g part with 2.5 mm wall thickness is produced from PCR polymers using an Oerlikon HRSflow two-drop hot runner system. This is optimized for frequent color changes and designed so that remaining decontaminations in the recyclate do not cause damage, streaks or flow marks that could affect the aesthetic and functional result (courtesy of Plastika Skaza).