Optical precision from the cleanroom: 77 Elektronika manufactures diagnostic cuvettes using tie-bar-less ENGEL technology

At a cleanroom facility on the shores of Lake Balaton in Hungary, more than half a million products are manufactured every day for use in laboratories around the world - unassuming at first glance, yet essential in their function. The UriSed cuvettes produced by 77 Elektronika are specialised containers designed for the microscopic optical analysis of urine samples. What makes them unique is that, as components of in-vitro diagnostics, they are themselves highly precise products. They are manufactured under strict cleanroom conditions on 12 fully electric, tie-bar-less victory electric 80 injection moulding machines from ENGEL (designated “e-motion 80 TL” before 1 January 2025).

Since 1986, 77 Elektronika has been a leading supplier of diagnostic equipment. In addition to blood glucose meters, the company focuses on fully automated urine analysers, which are marketed worldwide under its own brands as well as OEM and ODM products. The cuvettes are a central component of these devices. Their production demands maximum process reliability, as even the slightest deviation in shape or surface quality can impair the optical analysis of samples.

“What we produce may be a small plastic part, but it is anything but ordinary,” explains Norbert Pozsgai, Plant Manager at 77 ING. “Our cuvettes, made of polycarbonate, are part of an optical analysis process. This means that every surface, every radius, and every wall thickness must be absolutely precise - and not just once, but reproducible millions of times.”

These requirements can only be met through a combination of highly precise machine technology, optimised mould design, and extensive experience. Each year, 77 Elektronika produces over 200 million cuvette halves, using family moulds with eight upper and eight lower parts each.

Fully electric machines are essential in this setting - if only due to cleanroom requirements. “A hydraulic machine is not an option for us, not because of its performance, but because we aim to minimise the amount of oil used in production. In addition, the tie-bar-less design results in fewer dust deposits,” explains Pozsgai.

The decision to use ENGEL’s tie-bar-less technology was made early on. Today, 77 Elektronika operates 12 victory electric machines with 800 kN clamping force. For Pozsgai, the benefits of the tie-bar-less design are clear:

1. Maximum use of space: “We can run large moulds on relatively compact machines, without tie-bars getting in the way.”

2. Simplified automation: With unrestricted access from three sides, robots, grippers, and conveyor systems can be integrated in a particularly compact and efficient manner - an important factor for the highly automated production cells at 77 Elektronika.

3. Precision on both the injection and clamping sides: The electric injection units respond extremely quickly and accurately during switchover points - ideal for short cycle times with consistently high quality. At the same time, even clamping force distribution across all cavities ensures dimensional accuracy, even with high-cavity moulds, in this case family tools with 2 × 8 parts, while also protecting the mould thanks to excellent platen parallelism.

A key element of production at 77 Elektronika is the complete automation of the manufacturing cells. Each machine is integrated into a precisely coordinated system: an ENGEL viper linear robot removes the moulded cuvette halves from the mould and transfers them to an assembly station. There, the parts are precisely aligned before a rotary unit places them onto a conveyor belt. From there, they proceed to quality inspection and packaging.

“This process chain is the result of years of collaboration with ENGEL,” says Pozsgai. “Together we tested, optimised, and gradually refined the system. Today, it runs with great stability and efficiency.” One major advantage: even minor faults - such as those affecting power supply or components - can be corrected during operation, without the need to call a technician. “Our operators can resolve most issues themselves, which significantly reduces downtime."

The automation is divided into two sections. The first part comes entirely from ENGEL, including the robot, conveyor, and assembly unit. The second part, for example, the packaging, was integrated into the system by another partner. The result is a production cell that meets all the requirements of modern medical technology manufacturing, from cleanliness to efficiency.

All victory electric machines at 77 Elektronika are equipped with ENGEL’s Medical Package. This includes:

• sealed drive systems with no leakage potential, such as encapsulated toggle levers,

• easy-to-clean surfaces,

• and cleanroom suitability in accordance with GMP requirements.

“For us, cleanliness in production is part of a lived manufacturing philosophy,” says Pozsgai. “The demands for cleanliness, traceability, and safety are constantly increasing - we see it as our responsibility to actively implement these standards or even exceed them.” The machines themselves make a major contribution to this: minimal hydraulics, no oil emissions, no unwanted influences, but instead reproducible quality across millions of cycles.

The collaboration between 77 Elektronika and ENGEL goes back many years. With each new production line, mutual understanding has deepened and the technology has been further refined. “Our projects with ENGEL run smoothly within a well-coordinated team,” says Pozsgai. “We haven’t just purchased machines - we’ve developed production solutions together that are tailored precisely to our needs.”

Short communication channels, direct contact with key personnel, and strong expertise in medical technology make ENGEL a strategic partner for 77 Elektronika. The next machine has already been ordered - once again a victory electric 80, once again for cleanroom use, and once again part of a highly automated line for a small product with a big impact.

In the production of medical consumables, precision, cleanliness, and efficiency are essential. 77 Elektronika demonstrates how these factors can be implemented on an industrial scale, with the help of fully electric, tie-bar-less injection moulding machines from ENGEL’s victory electric series. The combination of machine performance, the Medical Package, and well-conceived automation provides the foundation for the reliable manufacture of over 200 million diagnostic cuvettes per year.

What may appear routine is in fact the result of years of development, close collaboration, and an uncompromising focus on quality. And that is where the true strength of this system lies - not only in plastics, but in partnership.