04/22/2008

Efficient manufacturing solutions for the packaging industry

Demand for high-grade metal packaging is growing. In particular, sales of cans and bottles –  80 percent made of aluminum – have grown steadily over the past few years.  The requirements made of production technology have risen strongly, mainly as a result of high raw material and energy costs and overcapacities on the market. In order to succeed in such a market, manufacturers need high-quality and efficient manufacturing solutions. At the Metpack 2008 fair in Essen/Germany, Schuler is presenting two innovative press solutions which are ideally suited to these requirements. With its new DA 140 cupping press, Schuler has developed an efficient solution for the production of two-part beverage cans which offers considerable advantages over conventional presses. The new generation of impact extrusion presses with press forces of 150 to 1,200 t is ideally suited to the production of cans, tubes or other symmetrical bodies and offers high production reliability at 220 strokes per minute.

New cupping press guarantees high output and quality

With a press force of 140 t and maximum speed of up to 350 strokes per minute, the DA 140 cupping press generation is designed for maximum output. In everyday practice, users generally operate at speeds of 250 strokes – corresponding to an output of around 3,000 cans per minute. Thanks to its high performance rating, the Schuler press is also well equipped to meet future needs. Despite its high speed, a dynamic mass counterbalance means that the press can be mounted on dampening ocker elements directly on the press shop floor. This enables fast integration into existing manufacturing environments without major construction work.

Modern design guarantees high machine availability and part quality

For the design of the new machine generation, Schuler was able to draw on its know-how from the development and production of high-speed presses. This offers clear advantages in comparison to conventional cupping presses. For example, the slide of the new press type is mounted on maintenance-free roller bearings. Highly precise slide guiding ensures outstanding part quality, especially for thin-walled cans and complex manufacturing processes. Schuler’s experience also plays a key role when it comes to machine availability. The maintenance-free direct drive system with its fast hydraulic clutch/brake combination ensures that the press slide comes to a standstill within one crankshaft revolution. In this way, the press drive avoids die disruption and reduces wear and tear on the die. Reliable operation is also aided by the low-maintenance external hydraulic unit which supplies the press with lubricants.

Sales in cooperation with can specialists TG Can

Schuler is cooperating with can manufacturing experts TG Can with regard to sales, die equipping and press peripherals. The company has facilities in the UK, Europe’s largest market for beverage cans, and the USA, the world’s largest market with over 100 billion cans per year.

Schuler’s XS range of impact extrusion presses offer reliable production at 220 strokes per minute

Impact extrusion presses are ideally suited to the manufacturing of cans, tubes or other symmetrical bodies. Launched in 2006, Schuler’s XS range represents a new generation of impact extrusion presses with forces of 150 to 1,200 t. The decisive technical improvement is the modified knuckle-joint drive. In contrast to conventional presses, it boasts not three but four articulated joints and thus enables the press to reach higher stroking rates – up to 220 strokes per minute – while at the same time offering slower forming speeds. This results in a number of benefits with regard to production technology. The lower slide speed ensures a more gentle impact of the punch on the material and forms it with almost constant velocity. This allows the material to flow more smoothly and results in higher part quality. The reduced wear and tear on the die also prolongs its service life. However, as the forward speed of the slide is faster than on a conventional press, overall output is increased.

Increased nominal forming travel offers greater flexibility

The new drive also increases the nominal forming travel of the press. The forming travel of the XS 250S model, for example, is up to 20 mm and for aluminum is thus about three times that of a conventional press. This makes it possible to form thicker aluminum slugs and to manufacture a wider spectrum of parts. Depending on the machine set-up, nominal forming travels of up to 40 mm can be achieved. This means that parts with a maximum length of 465 mm and a maximum diameter of 150 mm can be manufactured. The machine’s increased flexibility is also aided by the part transfer system via three dial feed plates with NC servo drive. The dial feed plates can be adjusted along the slide direction and, like the shaft, are easy to exchange. Easily exchangeable pockets on the dial feed plates also facilitate changeovers and maintenance. Thanks to the machine’s hydraulic tool clamping feature, dies can be exchanged within minutes. Self-centering die holders provide automatic alignment.

Play-free slide guiding ensures absolute precision

As with part feeding and transport, Schuler also specially designed the slide guiding system of the XS range to handle the machine’s high stroking speeds. Slide guiding is mounted under the slide and equipped with maintenance-free 2 x 2 linear ball bearing units with ceramic balls. In addition to the new slide guiding system, a molybdenum-coated adjustment wedge ensures permanent and precise positioning of the punch. The design guarantees consistently high part quality.

Schuler will also be presenting both manufacturing solutions from April 22 to 26, 2008 at the Metpack fair in Essen/Germany, Hall 3, stands No. 324 and 347.