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Negri Bossi Press Installation
Ferriot has completed the installation of an exciting addition to our press fleet: A new 2,250-ton Negri Bossi injection molding large press. Watch the time-lapse video showing the installation of the new press, from its delivery via five semi-trucks to operational testing of the KUKA multi-function robot’s automation capabilities.
The new press increases our production capacity, operates more efficiently, and accelerates delivery times for finished products. As a back-up to our next-largest press, it also helps assure our customers for larger plastic parts that we have the capacity to quickly turn around their orders.
Parts for the new press arrived in January, 2018 via a fleet of 18-wheeled trucks. There will be many steps involved in the assembly of the press and all its peripheral parts—robots, dryers, conveyors and magnetic platens.
April 6: Installation continued this week with the installation of a Machine Interface Unit (MIU) on the new press. This unit will enable the press to communicate wirelessly to our IQMS ERP software, transmitting data that can be viewed in real-time both on the production floor and in the offices regarding the state of jobs running on the press. Supervisors can monitor the press performance, and react to issues that arise, minimizing downtime and scrap.
March 29: We’re getting closer! With power connections to the press complete, we can soon begin the commissioning process. Here, we have a look at the control panel that press operators will use to program and control the jobs with.
March 23: The safety cage surrounding the robot has been installed, which protects operators from the movement of the robot as well as coming in contact with hot, freshly-molded parts.
Technicians are well on their way with configuring the robot and its control systems to the press. Installation and configuring will continue through next week.
March 16: With the base firmly bolted to the floor, the robot has been mounted to its base, ready to be connected to its control system. A technician from Italy will be here next week to begin connecting and configuring the robot to the press.
March 9: With the trench complete, electricians have run conduit in the trench to the press. Electrical wire will be run next week, and powering on the press and testing will begin soon!
The electricians have spent the week making all the necessary electrical connections, as shown here in one of the open electrical panels.
The robot has arrived and is awaiting installation.
The pedestal is in place that the robot will eventually be mounted to. Installation and connections should begin next week!
March 2: With the trench cut, the process of creating the box that the electrical conduit will go into continues.
Electrical wire sits at the ready to be connected to the press and new electrical service.
February 23: Electrical installation continued this week with the cutting of a trench in the concrete floor to accommodate the new electrical service to the press. We also learned that jackhammers are really loud.
With the excavation complete, reinforcing bar is added to the trench which will support a conduit box that will hold the cables, then get covered by an aluminum plate.
The copper wires have been run through the new ceiling conduit, ready to be connected to the press.
February 16: Installation continues with electricians running conduit up in the rafters to handle the new electrical service required to power the press. The press requires 480-volt, 1,000-Amp service, or enough power to run about 5-10 homes.
While our cars may only take five quarts of oil, injection molding machines take a little bit more. These two containers hold a total of 660 gallons of hydraulic oil. The press will take 650 of these 660 gallons in the initial filling of its tanks.
February 9: Assembly of the press is moving along! Up next: adding the robot and material handling equipment.
The injection unit mating with the fixed platen.
A view of the movable platen.
The hopper awaits hookup to the machine. Plastic pellets will load here for their journey to the injector.
A view through the eyes of plastic pellets as they would be entering the barrel.
January 31: Tie Rods for the new press are uncrated.
The first crate off the truck, weighing in at 48,000 pounds, is put into place.
The first of five semi trucks enters our plant and begins to unload its cargo.
January 30: The first trucks arrive on a snowy morning in Akron after an overnight trip from New Jersey.
November 30: The new concrete for the machine’s foundation was poured. It required 3 to 4 weeks to fully cure.
In order to install such a large press, special plant floor reinforcement and preparation was needed.
About the Negri Bossi BI-POWER VH2000-22500 Press
Robust design for proven, reliable performance
Clamping unit with generous tie bar spacing and clamping pistons on the moving platen for excellent reliability and faster dry cycle times
Long ejector strokes
Robust twin cylinder injection unit
Fully digital CanBus control
Electric screw drive for energy savings, and overlapping movements for faster cycle times
Powerful, user-friendly COLUMBIA user interface with full range of control parameters