With a clamping force of 88,000 kN and an injection volume of 134,000 cm³, the servo-hydraulic two-platen machine Haitian Jupiter Series sets a new industry standard – a milestone in the development of giga injection molding machines.

JU88000, probably the largest injection molding machine in the world

• Footprint of the giant: 27.2 x 9.5 x 6.1 m
• Clamping platen: 5560 × 4920 × 1990 mm; weight: 138 t
• Injection unit: 13498 × 2514 × 2665 mm; weight: 85 t
• Machine bed weight of the clamping unit: 40 t
• Machine bed weight of the injection unit: 19 t

JU88000 Engineers

Haitian has taken on an unprecedented challenge with the development and construction of this machine and has mastered it with combined forces. Even during the design phase, the European team, led by Philippe Porret, Technical Director at Haitian International Germany, managed to exceed customer requirements. Among other things, they were able to significantly minimize the footprint and optimize the injection rate, enabling the machine’s performance to reach top international standards.

After extensive testing, the JU88000 received CE certification in September 2023. The commitment of the entire Haitian team to research, detail work and quality improvement played a crucial role in this significant push into new dimensions.

Robot is a Hilectro VD-150ID by Haitian Smart Solutions

Eric Chanal, the owner of Belli, personally traveled to Ningbo to inspect the machine and approve it during a formal acceptance ceremony. He was visibly impressed by his new giant: “Right from the start, Haitian was able to realize all my projects as I had expected. Nevertheless, one of my dreams has come true. Haitian really made it possible, and when I see Jupiter in front of me now, I still can’t believe it.”

Mr. Zhang Bin (right), Vice President of Haitian Group, presented Mr. Eric Chanal with a model of the JU88000 as a souvenir

https://www.templa-kunststofftechnik.com/

With the courage to change and the determination to overcome resistance, the ambitious production company Templa Kunststofftechnik has digitally interconnected its manufacturing and realigned its strategic positioning. Central momentum: energy-saving electric machines, proactive energy management, tools for greater sustainability and efficiency. And the willingness to trust in one’s common sense.

Founded in 2017, the company in Veitsaurach in central Franconia became successful as a supplier for a major toy brand. Then Corona came along, threw the order situation into disarray and caused the company to turn to being a contract molder – like so many others in the pandemic. Instead of busting their head in the sand, the team around Managing Director Peter Müller proved that even a medium-sized company can achieve a lot with a high degree of flexibility, a wealth of ideas and the courage to develop further.

Today, Templa Kunststofftechnik GmbH & Co. KG covers a wide range of competences, from product development to downstream assembly and packaging of the produced parts.

The machinery includes, among others, 22 plastic injection molding machines with clamping forces from 30 to 230 tons and shot weights from 0.1 to 500 grams, including six electric Zhafir Zeres type machines with clamping forces from 90 to 230 tons.

A wide range of materials is processed, such as thermoplastics with high filler contents (glass fiber/beads, talc), thermally sensitive plastics or high-temperature plastics (PPS, PPO, PEEK, etc.).

In total, Templa manufactures around 65 million plastic parts a year with just 12 employees on a production area of around 1,000 square meters, including hybrid components such as inserts, bushings, cores, etc. It quickly becomes clear that the team relies on lean, process-reliable production in plastics processing, right through to direct packaging of the produced parts in the delivery packaging. The entire peripherals of the injection molding machines are digitally networked, and zero-defect production has long been standard.

“Topics such as Company 4.0, Industry 4.0 or Production Strategy 4.0 are no jargon or trendy terms for us,” says Peter Müller. “They are part of our daily work and the basis of the company’s success. With our fully networked, automated and optimized processes, we can realize extremely short throughput times in injection molding and act quickly and flexibly, resulting in a very good price-performance ratio.”

The energy consumption of each individual machine is monitored and optimized using the Sensorfact energy management tool. This makes it easy to determine the power consumption of each machine and improve overall operating efficiency. It turns out that Zhafir machines have excellent consumption values in terms of energy, making them the “first choice” in production planning from now on. This arouses our curiosity; we want to know exactly and ask Peter Müller for a concrete comparison of consumption data.

In the comparison, the electric machine shows clear advantages

The setting is quickly defined: A technical part is to be produced from PP TV20 in a 28-second cycle, with a shot weight of approx. 90 g and a high demand for dimensional accuracy and quality. In competition are a hydraulic machine from a well-known manufacturer with 80 tons (green line) and a Zhafir Zeres with 120 tons (blue line), both equipped with hydraulic core pull and 6-fold hot runner control. Both machines run with a temperature control unit, which consumes about 1.5 KW which is also measured.

The result is more than clear: the Zeres performs a good third more energy-efficient.

The screenshots of the power management make it clear: The power consumption of the Zeres (blue) is about 30% lower than that of the hydraulic brand machine, which underlines the clear advantage of Haitian International’s energy-saving technology. 

Peter Müller knew it all along: “When it comes to saving power, we switch on the Zeres’ first, which saves us real money.”

When asked about his expectations for the future development of the market and costs, Peter Müller smiles in a relaxed manner; he believes that his company is already in a fairly good position. “We are very efficient in the project, with a fast time to market. We have a high level of technical expertise in manufacturing, produce on energy-efficient machines, and our CO2 footprint, it’s already pretty small.”

Müller trusts the path it has taken, continuing to focus on openness to new things and innovative solutions. This has paid off in the long term, he says, citing a few examples:

• With a 3D scanner from GOM Metrology (part of the ZEISS Group), Templa and its tool suppliers have been able to “significantly reduce” their process lead times. Full-surface geometry capture through 3D scanning forms the data basis for inspecting molds and plastic parts in quality control, he said.
• The average correction loop of injection molds could be reduced by a whopping 50% to an average of 1.25 loops per mold using the CADMOULD and Varimos simulation software. “A significant time and cost savings for our customers,” notes Müller.
• In addition, he says, northern German Cleantower systems are now being used for optimized maintenance of the machines and tools. Creeping rust and lime deposits in the cooling channels “are thus a thing of the past,” and one always has “full cooling capacity and thus constant part quality.”

Peter Müller, Managing Director of Templa (left) and Christian Färber, Sales Partner of Haitian International Germany, take a look in the future.

A Hidden Champion with a clear mission

Templa’s success shows that even small companies can achieve remarkable results when they use advanced technologies while focusing on sustainability. When they move with the times or are undaunted in their search for new ways – forging ahead. Templa Kunststofftechnik is not only exemplary in terms of flexibility and energy management, but also a true hidden champion in the German SME sector. With a high degree of automation, remarkable efficiency, flat hierarchies and an attractive working environment, the company embodies the ideal type of a modern, thriving company

Peter Müller’s management style reflects his long-term view. He understands the value of flexibility in today’s market and ensures that Templa can adapt to changing circumstances without compromising quality and service.

Templa produces for a variety of industries, although with a slight emphasis on the toy and automotive sectors. The machines supplied by Haitian International Germany play crucial roles in this, as they enable a wide range of applications and their flexibility on the machine side enables the company to continue to meet customer requirements even if the market situation should change once again; crisis-driven or not.

In all of this, sustainability is not only a corporate requirement for the owner and family man, but also a personal mission. Living and working in the countryside, he knows all too well the value of nature and wants to do his part to ensure that all future generations can also experience the beauty and richness of nature.

Smart technology. Flexible integration. Sustainable solutions. The 5th generation of injection molding machines from Haitian and Zhafir sets new standards.

The ideal of future-proof plastics processing combines quality and efficiency for sustainable solutions. Digital intelligence is the key to achieving this. Engineers and IT experts throughout the Haitian Group are working continuously to improve the core technology platform of our injection molding machines to meet these customer needs. The new generation of machines from Haitian and Zhafir combines numerous innovations at the highest level, paving the way for a new stage in intelligent and connected manufacturing.

At Chinaplas 2023 in Shenzhen from April 17 to 20, the complete 5th generation machine family – the VE5, ZE5, MA5 and JU5 – is presented to the trade for the first time.

Smart Technology

Generation 5 intelligence marks a new level of excellence. Through the use of AI algorithms and the latest sensor technology, we are achieving intelligent optimization of production processes and giving our machines the ability to self-recognize, self-adapt, self-decide and self-reconstruct.

What’s more, the G5 offers many of these smart features as standard equipment.

Smart features as standard

HT Energy 2.0
Intelligent Energy Management 2.0 as standard. Display and management refinement of energy consumption. Establishment of an energy-saving ecosystem.

HT Clamp 2.0
Intelligent opening and closing 2.0 as standard. Self-learning algorithm for precise mold movements.

HT Lubricate
Intelligent lubrication as standard. Multi-data algorithm for intelligent lubrication control and intelligent setting of lubrication parameters.

HT Analysis
Intelligent diagnostics and support. 2D code alarm and online help.

Flexible Integration

The intelligent Injection Molding Machine Generation 5 is equipped with a wide range of flexible integration functions as standard. Open interfaces support efficient connection with peripherals, automation units, etc.

With upstream and downstream data from the industrial value chain, an integrative production ecosystem is created that generates extensive information benefits for plastics processors. From plant status and production schedule, process control and quality traceability to full life cycle management including energy consumption, decision analysis, etc.

Sustainable Solutions

As one of the market leaders in the plastic injection molding machine industry, Haitian International sets clear priorities in fulfilling its social responsibility, protecting the environment, and conserving resources through research & development.

We continuously develop energy-saving and consumption-reducing technologies, promote upgrades of energy-saving equipment, reduce carbon emissions, and provide technological innovations and efficient solutions for degradable and recyclable materials.

Efficient competitive advantages

With our years of experience and smart innovations, we work to further reduce our customers’ operating costs, thereby increasing their production efficiency. Moderate acquisition costs for Haitian and Zhafir machines also remain among our core criteria. This will continue to be the case in the future. State-of-the-art production plants around the world, in-house manufacturing of core components, R&D in close cooperation with Haitian Drives Systems and Haitian Smart Solutions: Haitian International stands for affordable innovations and turnkey solutions from a single source.

Haitian International at Chinaplas 2023
Hall 12, 12G31

There is no doubt that the digital transformation towards Industry 4.0 will not stop at small and medium-sized enterprises. Rather, the topic should become the basis of future business strategies if SMEs want to remain competitive in the future. Nevertheless, many SMEs are hesitant about digitizing their workflows and production processes, for example, for reasons of time and cost. A strategic partnership between Haitian International and ICON s.r.l. now offers standardized and affordable MES solutions specifically for plastics processing SMEs, training included.

More efficiency through lean structures, sustainable cost reduction, increased competitiveness, resilience in uncertain times – there are many good reasons for small and medium-sized companies to devote themselves to the transformation processes and options of digitalization at full speed. MES solutions are quickly becoming the focus of technical design and planning, because MES (Manufacturing Execution Systems) can be used to collect, store, visualize and analyze a wide range of process and performance data. Many process parameters such as temperature, pressure, humidity, etc. can also be controlled via MES. The advantages of MES-optimized processes are as numerous as they are varied, and not only in production. Greater transparency and flexibility in planning, an overview of inventories in real time, or simply fewer human or manual errors (in data entry, for example) are further logical advantages of stringent operational digitization. Nevertheless, digitization in the German SME sector is bumpy and stalled. What are the reasons for this?

According to IT experts, the three main factors are: lack of expertise in the companies, lack of resources (personnel, time) and, last but not least, perceived imponderables in the question of costs. In addition, customer surveys and market studies have shown that services such as software customization, training and after-sales in particular are critical points. Added to this are the growing complexity of IT infrastructures and the threat of cyber attacks.

As a result, MES solutions have so far been used primarily by large companies, while mid-sized companies all too often find themselves overwhelmed by the complexity of the issue. “Even though the benefits of digital transformation obviously outweigh the risks, the challenges that need to be overcome remain daunting and are simply out of their league for many of our small and medium-sized processors,” reports Niels Herz, Sales Manager at Haitian International Germany. Regardless of company size and staffing, they need to be well informed and equipped with the necessary resources or expertise to master an implementation during ongoing operations. Data protection and security regulations are another issue, but above all, the significant investments in technology, hardware, software and personnel are obstacles that deter many business owners. Without question, the cost of digital transformation can be a significant burden for small and medium-sized enterprises, discouraging them from adopting Industry 4.0 technologies such as MES. Concerns about culture change and loss of meaning can also create significant resistance to digital transformation among employees and managers.

Digital turnaround for SMEs?

Things are different in the Far East, and not just culturally. In China in particular, digitization is advancing rapidly. In the process, the Haitian Group, one of the leading business enterprises in the Middle Kingdom, has established itself as an innovation leader and has now created Haitian Smart Solutions, a highly specialized division for digital turnkey solutions. In response to the global digitalization backlog, the Smart Solutions specialists have created “Go Factory”, a free standard, streamlined monitoring tool for monitoring and optimizing manufacturing processes. Apart from this, comprehensive MES solutions and cloud systems from Haitian Smart Solutions have also long been part of the standard and are already widely used there in smart factories. Valuable best-practice know-how, therefore, with which two strategic partners have recently developed a cost-effective and optimized MES solution for Europe’s SMEs: Haitian MM Italy s.r.l., Haitian’s long-standing sales partner for plastics processors in Italy, and ICON s.r.l, an innovative IT provider and system developer focusing on MES. The goal was to develop production asset management software at an attractive price, virtually from plastics experts for plastics experts. The result is a simple flexible software that enables dynamic and constant communication between all production processes. Production managers receive comprehensive information in real time, which helps them to avoid production errors, waste of resources and unnecessary manual interventions.

In general, all machines can be connected, even those that are not 4.0-enabled. “The first step is to remotely install MES ICON on a virtual machine on a customer server; then we proceed to connect the machines to MES ICON; the machines that can be connected to MES ICON are both the 4.0-capable ones (e.g. with OPC-UA, MODBUS, etc. protocols) and the non-4.0-capable ones, which in this case require the hardware of the WBOX (or WEBOX) module,” explains Maurizio Zanni, General Manager at ICON.

In addition, ICON offers external system training for all players involved in the production process.

According to the manufacturer, more than 400 medium-sized companies have already opted for ICON’s MES solution and “finally tackled” the topic of digitalization.

How the Dutch plastic injection molding company Smit Plastic BV has been swimming against the tide for many years and why it is still successful.

In business, it’s like real life: Between the turbines of the industries, the vast majority of businesses quietly turns their wheels. Inconspicuously and without any special features worth mentioning. At least it seems so. If you take a closer look behind the scenes, you will discover friendly people with heart and mind – and with the clear intention of reconciling profitability, sustainability and, above all, humanity. With a strong commitment and will to shape things in the interest of future generations. Smit Plastic BV in Tiel, the Netherlands, is such a company, a prime example in many respects.

The strategic location to the south of Utrecht, directly between the freeway junction and the canal port, gives an initial indication of what is important to the owner family: flexibility, independence, pragmatism. At first glance, the company headquarters itself suggests a “classic contract injection molder,” and indeed several million plastic parts have already been manufactured here. A huge “belly-shop” of more than 1,700 plastic products of the most diverse kinds. Technical parts, packaging, articles for the consumer goods sector – including the company’s own products and new ones still in development.

We are standing in the production hall with Mark de Krieger, he is the technical manager at Smit Plastic and also manages sales. His brother Marcel de Krieger is responsible for the commercial area. Both have taken over the family business from their father. But of course Gerard de Krieger, although officially retired, still assists his boys as a senior consultant. A man with his experience can still provide important impetus. And they all benefit from this, after all, new tasks, including challenges, are always being added. The machine park is correspondingly broad: 36 injection molding machines fill the room, with clamping forces ranging from 250 to 13,000 kN. The large Haitian machines immediately catch our eye – twelve in number, automated with robotics from Sepro.

As a matter of principle, they pursue a two-brand strategy, says De Krieger, if only to avoid being dependent on one supplier. The first Haitian arrived in 2006. “We had obtained a Haitian HTF, directly from China, on our own,” De Krieger smiles. “CE certification and robot adaptation were done at home in the Netherlands. We were able to do the service ourselves because the machine was quite simply built. But apart from that, the machine has run for 15 years without any major problems. We have invested just 1 valve and about 400 euros in labor in all these years. And the machine has been producing in 24/7 mode since 2010. New oil once a year – and that’s it.”

In 2-shift operation, they process all materials across the board, except PVC. Instead, they focus strongly on the area of bioplastics and develop packaging solutions for food & beverage in street vending (takeaway and to-go area).

Social responsibility on a broad basis

Currently, Smit Plastic BV employs about 90 people, almost half of them with handicap and no full-time employees. A fully-fledged inclusion company. The atmosphere is family-like, everyone gives their best. They’ve been doing this since 2007, says De Krieger, “out of free will, out of conviction.” They do not receive any financial support from the state for this. Nevertheless, the decision in favor of inclusion means a considerable amount of extra work, because these employees need additional support and assistance due to their disabilities. In Tiel, they are gladly given it, because “everyone has the right to develop their talents.”

We come to the current economic situation and the worrying price developments for gas and oil, for energy par excellence. While Haitian was chosen for its cost advantages and efficient consumption rates, electric machines have not been an issue. “We haven’t needed electrical performance so far. However, given the energy prices, we are in discussion with Mark Waterreus.” (Managing Director of Haitian Representation Netherlands). After all, contract moulders usually line up broadly, he says. If one industry gets into a slump, others can make up the dent. “But in times of energy crisis, it just hits everyone.” And then we’re on the subject of environmental policy, one of the central themes at Smit Plastic, “an integral part of the company’s policy.” Not as mere theory, but rather as lived practice – quite pragmatically. Without chemical cleaning agents. With waste reduction wherever possible. And of course, energy efficiency continues to be a big issue for them, “so energy-saving technologies are essential.”

When asked where he sees the company in five years, De Krieger says, “A year ago, I would have said we wanted to double it. But because of the crisis mood, I’ve become cautious.” He looks thoughtful for a moment, but then adds, “We bought another building next door that we want to fill.”

Read more: www.smitplastic.nl

Household products like these storage boxes are part of Smit Plastic’s crisis-proof core business.

One of the own products is a stackable flower pot

Ease of operation plays an important role in the purchase decision, along with the attractive price/performance ratio

Since 2006, a Haitian machine of the HTF Series has been producing without significant problems

Premium Sound Solutions – the name says it all. The company develops and manufactures high-quality audio boxes, speaker systems and innovative sound solutions for ultimate entertainment and safety on the road. For efficient manufacturing solutions, PSS pursues its very own strategy to optimize its value chains around the globe: the vertical integration of its own injection molding machines based on the Haitian Jupiter series.

Premium Sound Solutions (PSS) is a global leader with extensive expertise in the research, development and manufacture of innovative sound products for the automotive industry and end consumers.
The company employs approximately 3,000 people worldwide in product development and state-of-the-art manufacturing. Every year, around 80 million loudspeaker systems leave the company’s 7 locations worldwide, from Europe to North America and Asia.

The Esslingen site, with approx. 70 employees and sales of EUR 30 million, sets the pace in the future concert of PSS sites worldwide in the injection molding sector. While Belgium, Hungary, China, Malaysia and Mexico mainly manufacture loudspeakers, the focus in Germany is 100 percent on the automotive sector, specifically subwoofer boxes and pedestrian warning systems. These systems, which have been an integral part of the body design of e-mobility for some time, generate artificial driving sounds so that electric and hybrid vehicles can be perceived by pedestrians, cyclists and other road users in good time in road traffic.
For Pedestrian Warning Systems, PSS is a market leader in terms of unit sales, revenue and quality.

We chatted with Jens Maschkiwitz, Managing Director Germany and Team Leader Global Process Engineering at the PSS Group, and Ingo Fischer, mold and injection molding expert at PSS in Esslingen.

Felix Rudelt (right), sales representative at Haitian partner Färber-KT, inspects a sound system housing together with Jens Maschkiwitz (center) and Ingo Fischer (left) – straight off the production line of a Haitian Jupiter machine.

Mr. Maschkiwitz, Mr. Fischer, you have expanded the local production to include injection molding machines. How did this development come about?

Maschkiwitz: Our strength is our innovative power. We want to drive the market forward with innovations and consolidate our position through differentiation. In 2020, for example, we took on two new products in Esslingen, the subwoofer and the Pedestrian Warning System (PWS), sound systems in electric vehicles to better protect pedestrians. For these products, the vertical integration of injection molding machines simply made sense. Both products are now the focus of PSS in Esslingen.

And you run both products on Haitian machines.

Fischer: That’s right. We had been involved with injection molding technology for quite some time, so we already knew Haitian. For the Pedestrian Warning System, we set up a fully automated assembly line and inject the parts in-house, as an in-line process, to completely manufacture the PWS. The second new production is the subwoofer for the Tesla (Model Y) from Brandenburg. Here, the process also starts with injection molding and then leads to complete final assembly.

Pedestrian Warning System – that sounds quite novel?

Fischer: Yes, that’s right. We helped develop the products here in Esslingen and then also worked out the technical implementation. I dare say that we are already the market leader in terms of unit numbers and quality.

Maschkiwitz: Demand will certainly continue to rise, in line with the increase in the e-mobility trend. And quite independently of subsidies for e-cars from the government, we also see the electric trend developing strongly internationally. Even if the current situation is very uncertain, especially for e-mobility, because of the energy cost crisis. However, we see ourselves as relatively broad and well positioned, and we plan for the trend to continue to rise in the coming years.

And that’s where the choice fell on Haitian for injection molding machines. Why?

Maschkiwitz: Our goal is to consolidate the local site. The focus is on vertical integration and a “one-piece flow” with the goal of 100% automation.
We were convinced by a few key factors at Haitian. The global footprint, for example, the price-performance ratio, the availability worldwide, also the consistent specification. The machines are the same everywhere, and they have many languages in the HMI. A good sales and service contact. Mr. Fischer will have a more differentiated view of this, since he comes from an injection molding background.

Fischer: What I like about Haitian is their expertise. They have developed so many machines that the maturity level of the machines is already very high, also because a lot of feedback from the market flows in.
There is little to report on support, because the machines run smoothly. And operation is relatively simple. We received a short training course at the time, free of charge and good.

Subwoofer box for Tesla in 60-second cycle, with maximum shot weight at 0.35 kWh/kg

For the Pedestrian Warning System, the entire production line runs completely automated, except for material filling.

How are the production processes set up on the machines?

Fischer: Each machine runs a certain group of products, we then change the product daily. In terms of material, we mainly process PP with various additives, such as glass fiber.
We produce the subwoofer box for Tesla in a 60-second cycle, with maximum shot weight at 0.35 kWh/kg. For the Pedestrian Warning System, the entire production line runs completely automated, with the exception of material filling.

Maschkiwitz: We operate automation with “heart and mind”. That means we try to achieve 100 % depth of added value. But with a sense of proportion.

And if I have understood you correctly, you will also transfer this concept to other sites?

Maschkiwitz: That is indeed our intention. We still see great potential in the penetration of our value chain. The vertical integration of injection molding machines is only logical. As Mr. Fischer has already said, technical products such as sound boxes simply lend themselves to this.

What dimensions are you planning?

Maschkiwitz: We operate around 80 production lines worldwide, but of course this will take some time; we in Esslingen are the spearhead of global process engineering at PSS. Ultimately, there will probably be around 50 injection molding machines in operation worldwide. However, it remains to be seen whether these will all be Haitian machines. We are still in the early stages, currently working here in Esslingen with two large Jupiter machines, the third has already been ordered. The fourth machine is planned for the end of 2023, which would mean that the site would be exhausted for the time being. But here, too, we appreciate the advantages of Haitian International’s good global presence in the various markets, which is why we have currently classified Haitian as a “Preferred Supplier” – also due to its expertise and cost-effectiveness.

In the upcoming generation of machines, Haitian plans to integrate numerous “Smart Features” into its machines. What role does smart technology play at PSS?

Fischer: Audio boxes are basically relatively simple products, hardly any visible parts. The top priority is process stability. Our machines have to produce on a reliable basis, and they do.

Maschkiwitz: Sensibility is paramount, quite clearly. Our Haitian machines run stably, but we are of course curious about innovations, insofar as these are part of the standard scope of the machines.

How important is sustainability in the strategic planning of the PSS Group?

Maschkiwitz: All in all, sustainability starts with local production – local for local. This means that we also invest vertically in all locations in order to save logistics costs and not have to drive everything around the world. In this respect, we think along similar lines to Haitian International.

Fischer: Lightweight construction and saving resources are other topics. How do you manage to reduce large-volume sound boxes in terms of space and materials without compromising the sound? Of course, recyclability and the circular economy are also key topics. For example, how can alternatives be created for loudspeakers, which are often glued several times, in order to return the material to the cycle?

More information at www.premiumsoundsolutions.com

A customer visit to Emperor Mouldings B.V. in Alphen aan den Rijn, the Netherlands.

Brothers Maarten and Peter Keijzer, heads of Emperor Mouldings B.V., embody a new generation of injection molders: focused, efficient and relaxed – with a new understanding of work-life balance. In the Zhafir Zeres Series, they see the best prerequisites for making injection molding processes as efficient as possible and driving production automation forward.

Growing up in his parents’ injection molding business, Maarten Keijzer knew very early on that he wanted to run an injection molding company. The fact that his father then sold the business turned out to be a good decision in retrospect, as Maarten quite inevitably had to found and build up his own company. He took this step in 2019, initially alone, but since 2022 his brother Peter has been completely on board.

Both had precise ideas from the start: “No employees for as long as possible, but to bring production to the maximum, so far that we can still manage everything with just the two of us.” The main products are clips of agricultural use; the end customers are greenhouse operators. In addition to the agricultural industry, they still supply the commodity sector and technical parts. The bottom line is that they focus exclusively on small shot weights in high volumes. This is because highly efficient processes, “production-friendly” products and automation in places where it is worthwhile and serves the work-life balance are important to them. Maarten Keijzer: “I certainly experienced many things in my father’s company that I wanted to do differently. The principle ‘Only those who work hard will make it’ may have had its justification in those days. Today, we have other options. In the age of digitalization and its tools, it’s easier to design efficient and lean processes.” The recently introduced automated foiling of cartons is a good example of this, he said. “This robot saves us a lot of valuable time.” They are currently considering an AGV, which would then take the full cartons out of the magazines at night, increasing piece counts.

Passion for technology: Maarten (left) and Peter Keijzer with a Venus model made of Lego that they added robotics and peripherals to.

About meaningful growth and scalability

Since its founding in 2019, Emperor Mouldings B.V. has grown steadily, in output, turnover, set-up. “If the demand is there, it would make no sense not to grow,” the Keijzers agree. “But always with moderation and purpose.” Nevertheless, growth is not generally the big goal, they say; rather, they are concerned with the “sporting challenge” of spraying the maximum number of products with the existing machines and their 2-man power. “There is room for eight machines in our production. That’s still a size we can handle with two people. And should the market require more, we’ll see how far we can go with our manpower.”

Growth in this, their sense, presupposes that processes are optimized for maximum efficiency. That cycle times are reduced to the maximum and 24/6 non-stop operation runs smoothly to the maximum, with a clearly focused product group: simple small parts in large quantities.

Accordingly, they have aligned their machinery and supplemented it with pinpoint accuracy. The heart of production is currently formed by five electric Zeres machines with four times 900 and once 1,200 kN clamping force (another is on order). All run with integrated controls (Success Series 7 and 11) from Sepro Robotics. The molds are equipped with external hotrunner systems from PSG, and a specially programmed error-stop function intervenes if the temperature in the metering unit is too high. This also guarantees them near-zero error production at Emperor Mouldings. Original quote Maarten Keijzer: “We’ve had just 1 carton of rejects so far in 2022.”

“The electric Zeres fits very well with our philosophy: technology to the point for production to the point. The price-performance ratio is also unbeatable in our eyes. Our first 90-tonne Zeres has already gone through more than 6 million cycles without a significant malfunction.” Maarten Keijzer, Emperor Mouldings B.V.

Performance against rising energy costs

While the young company has come through the pandemic relatively well and relaxed, the energy crisis is having an even more serious impact on its core market, the Dutch agricultural industry. Rising energy prices are likely to bring many greenhouse owners to their knees, by next winter at the latest. “Our warehouse is full and the market is saturated for now. That means that of our machines, only two out of five are currently running. The reason for this is that the agricultural industry is suffering extremely from rising energy prices and many end customers have already announced that they are closing their greenhouses for the winter.” The two brothers nevertheless take the situation calmly: “A crisis is also always an opportunity. Up to now we’ve had full capacity utilization, now we’re using the quiet phase for new customer acquisition, internal projects that have fallen behind, or we’re happy to have more family time.”

Of course, rising energy costs are also making themselves felt in their own injection molding operations, but their stringent decision to use electric machines and the low shot weight of the small parts keep their energy consumption within limits. In any case, they optimize their injection molding processes for maximum energy savings to keep their carbon footprint as small as possible.

First certified industrial compostable clipring made of PLA’

Apart from that, they keep on working on continuous automation of production, keyword: increasing efficiency. “The electric machines are a tremendous help for us to produce in this high efficiency. Our father had hydraulic machines, he still had to ramp them up with some lead time and wait until the oil temperature was right, sort out some cycles of scrap and so on. We turn our Zeres family on Monday morning and don’t turn them off until Saturday night. Machines and the Success line from Sepro are an ideal match. From the first shot, production is error-free,” explains Maarten Keijzer.

In his opinion, another important building block for higher efficiency is material-optimized processes, in which he gained valuable experience in his previous job at a material supplier. “Our injection units are all equipped with a shut-off nozzle, so we can maximize parallel functions during energy-intensive plasticizing. Every second saved has an immediate impact on energy costs.”

In addition to all their commitment to energy savings and efficiency, they are equally consistent in working on their production-side sustainability. From starting with 100% virgin raw material at startup time, they are now at nearly 100% recycled and compostable material.

When asked about concrete visions or dreams for the near future, the answer is rather down-to-earth: “Two days away from the company, but everything continues to run” – that’s a good vision. But of course they are well aware of the challenges ahead and want to face them. And who knows, “maybe we’ll become the smallest smart factory in Europe.”

Info box

Production profile of Emperor Mouldings:

• All Zeres machines run smoothly in 24/6mode;
• All machines are equipped with automation;
• During the day, the machines are serviced and processes optimized if necessary; at night, they produce unmanned;
• Only small parts with a high number of pieces are produced.