Precision & performance for innovative laboratory diagnostics products

Röchling Medical is an innovative development partner and contract manufacturer for leading global pharmaceutical, biotech and medical technology companies. For some time now, Röchling has been manufacturing special polystyrene contact trays with improved ergonomics and safety in its production facility for laboratory diagnostics at the German site in Waldachtal: thanks to a sophisticated three-point locking system instead of conventional threads, the lid can be fitted particularly quickly and easily and always remains firmly closed during transport of the samples.

For the production of the contact shells however, the filigree mechanism meant increased demands on precision and process consistency: even the smallest deviations in the geometry of the moving components would mean impaired functionality. At the same time, the shortest possible cycle time is necessary to ensure the cost-effectiveness of production - a must with a production volume of around 12 million units per year. To solve this balancing act, Röchling contacted ENGEL.

The specifications for this laboratory diagnostics application clearly identified ENGEL's all-electric high-performance e-motion series as the most suitable basic machine. Compared to hydraulic or hybrid drives, its powerful, servo-electric direct drives enable significantly faster machine movements with particularly high repeat accuracy - an advantage for the mass production of diagnostic products. In addition, the all-electric drive concept is particularly low in emissions - another relevant advantage for operation under cleanroom conditions.

To best meet Röchling's requirements, ENGEL equipped the 1,600 kN injection moulding machine with several option packages: A clean room package enables absolutely clean production up to class ISO 7 and particularly easy cleaning of all potential sources of contamination. In addition, the PREMIUM version of the electric injection unit delivers the performance required to reliably fill the thin-walled cavities shot after shot: Its servo-electric direct drive is not only particularly powerful, but also offers synchronised movements compared to a belt drive. In combination with the ENGEL smart shut non-return valve, maximum precision is also achieved on the injection side.

Daniel Tobien, Head of Production at Röchling Medical, summarises: "The precision of the all-electric machines is significantly better than that of hydraulic machines. The advantage is particularly evident with short cycle times: switching the electric motors is much easier and faster than with a hydraulic pump or a valve."

Another essential aspect of injection moulding for laboratory diagnostics is temperature control. Röchling relies on the ENGEL temperature control system to cool the parts in the mould cavities as quickly and evenly as possible. The interaction between the ENGEL e-temp temperature control units and the e-flomo automatic water distributor is precisely controlled by the intelligent iQ flow control assistance system. The ΔT control of iQ flow control permanently monitors the difference between the flow and return temperatures and automatically regulates the flow rate via the e-flomo units in the event of deviations. Ensuring the components are always cooled quickly and optimally while minimising water and energy consumption. Defective components due to temperature control errors are avoided by using iQ flow control. This process also protects the temperature control units and extends their service life.

The customer was not just impressed by the machine itself, but also by ENGEL's competent support throughout the entire process: ENGEL demonstrated a deep understanding of Röchling Medical's specific requirements right from the planning phase. In addition to the customised design of the machine, the logistics, commissioning and service from ENGEL ensured a rapid start of production and smooth operation.

 Daniel Tobien emphasises: "We are very satisfied with the machine. With the combination of the mould and the automation, high output rates have been achieved. So far, there has not been any machine-related downtime."