Largest ENGEL Injection Molding Machine Installed in U.S. Facility

ENGEL North America has completed installation of its largest injection molding machine in the U.S. – the first of two ENGEL duo 45050/4400 US machines to be placed in the Winchester, Kent., plant of Infiltrator® Systems, Inc. Between its two plants, this environmental onsite wastewater solutions company operates a large number of ENGEL injection molding machines.

Begin with special shipping containers and ground transport operations, and add modifications to the plant floor for a machine foundation, as well as an extensive installation with overhead cranes and large rigging equipment, and the result is the largest U.S. installation of an ENGEL injection molding machine in the U.S. ENGEL North America, a world leader in the design and manufacture of injection molding machines and part-handling automation systems, has completed installation of the first of two duo 45050/4400 US injection molding machines in the Winchester, Kent., plant of Infiltrator Systems, Inc. The second machine installation is under way.

“This installation required us to re-pour new foundations to accommodate the machine,” explained Ron Brochu, Infiltrator Systems general manager of manufacturing. “We have an extensive crane system, which greatly assists in the installation, but larger equipment to set the platens were required. The entire process takes over two weeks to accomplish, once the machine arrives at our facility

The machine, which is built in ENGEL’s St. Vallentin, Austria, facility, is transported by sea freight using a large number of custom pallets and containers, and then onto special oversized trucks, according to John Pirro, ENGEL manager of technical sales support. “It’s a very large operation, even when broken down into many pieces,” he said. ENGEL technical support is on hand throughout the installation process, and is especially critical to the start-up process. “We do a great deal of testing of the machine, and particularly how it’s integrated with the rest of the manufacturing operations,” Pirro said. “We also conduct extensive testing of the system, including the customer’s tooling, before we hand over operations.”

Maximize Production Capacity
“This installation is allowing us to replace the production output of three older large presses, and operate more efficiently with the use of two new ENGEL robotic systems,” said Jim Bransfield, Infiltrator Systems marketing manager of onside systems. “We have the capability to produce chambers for over 1/3 of the septic systems installed in the U.S. annually with these new duo machines.”

Infiltrator Systems is the world’s leading manufacturer of plastic leachfield drainage chambers for environmental onsite wastewater solutions. The company’s Quick4® chambers are a direct replacement for stone and pipe leachfields, and have revolutionized the septic industry for their cost-effective, efficient methods for handling residential and commercial wastewater.

ENGEL’s duo systems offer large-capacity injection molding with high clamping forces, and feature a two-platen design for flexibility and performance. The duo line includes 10 machine sizes, all with high-speed cylinders that help reduce cycle time, a stable platen control system and power-saving drive units. The result is improvements to the overall injection molding operation, including increased output and higher product quality.  These new duo injection molding machines are the largest addition to Infiltrator’s complete conversion to the ENGEL duo in 2005. Infiltrator currently operates several ENGEL duo machines in their Kentucky and Utah facilities, including 23050/1900 US, 7050/720 US and 23050/1250 US duo machines.

 “Continuous improvement has always been one of Infiltrator Systems’ core values, in product design and development as well as manufacturing processes,” said Roy Moore, Infiltrator Systems CEO. “Four years ago, a major initiative began and was undertaken to improve manufacturing efficiency through installation of faster, more efficient molding machines, along with a complete redesign of our molded parts. After reviewing nearly a dozen manufacturers of injection molding machines, ENGEL stood out as a high quality, technically advanced, well run organization offering a competitively priced machine with the features and benefits Infiltrator Systems required. Recently we have continued our manufacturing innovation, requiring significantly larger equipment and lead to the purchase of the two 4400T ENGEL machines.”
Bransfield said, “We’re pleased with the speed, reduced electric consumption and footprint efficiency of our duo machines. The intricate design of our chambers requires long flow lengths, meaning higher clamp tonnage. The duo accomplishes that for us. In addition, Infiltrator Systems is a top ranked environmental firm in North America. These duo machines have allowed us to maximize our efficiencies in using recycled content.”

Technical support was also a priority criteria when choosing ENGEL injection molding machines. Infiltrator Systems’ CEO Roy Moore said that when the company was evaluating injection molding machine providers, “ENGEL’s management and engineering teams worked closely with Infiltrator Systems throughout the bidding, specification and eventual construction processes, from their first presentation through installation and start-up of multiple machines in different manufacturing facilities.”